Appendix A:

Typical Process Flow in Metalworking Process

Typically, in a metalworking sector, the main processes in fabricating or manufacturing
metal parts are:
A. Receiving
B. Forming
C. Cutting
D. Treatment
E. Joining
F. Assembly & Testing
G. Packaging & Shipping

There are sub-processes in each of these main processes. For example, when we receive
raw materials, there will be sub-processes of forklift operations, overhead crane
operations, manual lifting, storage of materials, etc.

The following shows the typical process flow in the metalworking sector. For easy
reference, the main processes are tagged with an alphabet and sub-processes are tagged
with an alphabet-number, e.g. “Forming” (main process) is tagged with “B” and “Stamping”
(sub-process) is tagged with “B4”.

A. Receiving
A1. Forklift operation A3. Manual lifting A6. Quality checking
A2. Mechanical lifting using overhead/ A4. Weighing A7. Storage of materials
gantry/ lorry crane A5. Package opening A8. Sorting of materials

B. Forming
B1. Die casting B5. Raising B9. Sheet metal forming
B2. Forging B6. Bending B10. Manual lifting
B3. Extrusion B7. Drawing B11. Mechanical lifting using
B4. Stamping B8. Sintering overhead gantry/crane

Page 1 of 2 page(s)
 C. Cutting
C1. Cutting C4. Drilling C6. Filing
C2. Milling C5. Grinding C7. Broaching
C3. Turning (Lathe)

D. Treatment
D1. Degreasing D3. Plating D5. Grit blasting
D2. Heat treatment D4. Spray painting D6. Phosphate Coating

E. Joining
E1. Welding E2. Brazing E3. Soldering

F. Assembly & Testing

F1. Preparation and validation F3. Using bench test F5. Pressure testing
e.g. using marking tools equipments F6. Load testing
F2. Using pneumatic tools F4. Using hydraulic test rigs F7. Performance trials

G. Packaging & Shipping

G1. Forklift operation G3. Manual lifting G5. Package opening
G2. Mechanical lifting G4. Crating G6. Storage of materials

Apart from the main processes, other activities are to be identified. These activities are
mainly those supporting the main processes, e.g. maintenance of production equipment,
operation of facilities equipment, etc. The following are the typical supporting activities in
the metalworking sector. Similarly, for easy reference, the supporting activities are tagged
with an alphabet and sub-processes are tagged with an alphabet-number.

H. Supporting Activities
H1. Equipment maintenance H3. Facilities equipment operation and
H2. Factory maintenance maintenance
H4. Construction (M&E works during plant
expansion)

Page 2 of 2 page(s)