STANDARD OPERATION PROCEDURE

Cage Forming
1. Operator
A. Ensure that the machine can run properly
i.
Caging Machine (P400 and P600)
(1) Check:
(a) Control panel
(i) Ensure that all button can functional
(ii) If there is problem immediately inform the Production Supervisor

Make sure all button can be functional

(b) Copper bar
(i) Ensure that free from steel waste
Use grinder to grind away the steel waste
(ii) Change the position
(iii) Keep properly and do not lost it

Change the position

If exhausted, use the other copper bar

(c) Copper ring

(i) Ensure that free from steel waste
(ii) Change the position

Rotate the copper ring

Copper ring must free from steel waste

(d) Carbon brush
(i) Check the condition, if there is abnormal immediately inform the Production
Supervisor

Carbon brush

Check for abnormality

(e) Caging stand support

(i) Ensure that all stand support can be functional
(ii) Inform the Production Supervisor if there is problem immediately
(f) Plate guider

This hole always at 6 oclock position

B. Set the machine to perform the specified cage size

C. Loaded the PC bars to the machine and secure in position
i.
ii.
iii.

Check the length

If PC bars uneven length segregate the PC bars
Collect the shorter or longer PC bars until enough to produce a cage

How to check for uneven length

Can proceed

Segregate the bars

D. Use correct size of PC bars and spiral wire

i.

Follow the table below:

Pile size (mm)

No. PC bars x PC bars Dia.

Spiral Dia. (mm)

250

6 x 7.1 mm

3.8

300

7 x 7.1 mm

3.8

350

9 x 7.1 mm

3.8

400

8 x 9.0 mm

3.8

450

8 x 9.0 mm

3.8

500

10 x 9.0 mm

4.0

600

14 x 9.0 mm

4.5

E. Initiate the machine by selecting the representative cage size

i.

Select proper setting

(1) Size (mm) 250, 300, 350, 400, 450, 500, or 600
(2) A, B or C for forming type based on size
(3) Length (m) 6, 9, 12, or 15
(4) Adjust the control for welding
(a) Heat control
(b) Heat time

F. Inspect and verify the welding quality and pitch length as per specification
i.
All loose welding shall be tied with G.I wires where applicable
(1) Tied at minimum 4 points
4 points

Loose cage shall be tied with G.I wire

Rearrange the spiral wire and tied at minimum 4

points

ii.

Check pitch length

Tool for measure pitch length

How to use the tool
iii.

Check the uneven length of PC bars cage

How to check:
1.

2.

Can send the cage to the next section (assembly).

Loose the uneven length of bars, rearrange the bars

and tied back the bar with G.I wire. Do not easily
to destroy the cage.
G. Record all the number and sizes of cage formed in auto cage forming records
i.
Record based on actual hourly cage output
ii.
Reject cage must be recorded

2. Supervisor
A. Ensure that the operators wear proper personal safety equipment.
B. Monitor the cage forming process.
C. Check the welding quality and pitch length as per specification.
D. Ensure that the reject of cage must be clear at the end of the shift.
E. Ensure that the PC bars from reject cage and recycle spiral wire need to be used.
PERFORMANCE REQUIRED
Size

Length

Qty. in 1 hour

250

6
9
12

28
18
14

300

6
9
12

23
15
12

350

6
9
12

20
13
10

400

6
9
12

18
11
9

450

6
9
12

16
10
8

500

6
9
12

14
9
7

600

6
9
12

12
8
6