| STEP |
WHO |
WHEN |
INFO TO
USE |
WHAT TO
DO |
RESULTS |
| 1 |
Die sinker or Die Shop
Lead Man |
Upon receiving a newly
(re) sunk or questionable die |
Die number on die; own
observations |
Make one cast of each
flash forming impression for any (re)sink, plus a
second for new or modified dies (or if after cast(s)
set, mark with die number, date, impression number,
die sinker and shim thickness (if any); forward one
cast of each impression to CMM Programmer/Operator;
if a second has been made, store it per step
13. |
Cast ready for inspection;
second cast, if any, stored |
| 2 |
CMM
Programmer/Operator |
Within 2 days of receiving
cast |
Forging print with
Engineering notes on die sink tolerances and/or
pattern; 3D Die Design
Checksheet |
Thoroughly inspect
dimensions of cast (typically using CMM) or (scan
dies with Inspection Arm and compare to 3D
Model); for new or
modified die also measure volume and calculate
forging net weight from water displacement (if
required), pass new weight on to appropriate
Engineer. Give 3D Die Design
Checksheet to Engineer per TOP-SOLID. |
CMM Programmer/Operator
report, with any out-of-tolerance
readings high-lighted, returned with cast and new net
weight (if applicable) to Engineer. 3D Die Design Checksheet to
Engineer |
| 3 |
Engineer* |
IF CAST IS DISAPPROVED
INTERNALLY |
CMM
Programmer/Operator's report, forging print,
pattern or previous cast |
Determine degree of
changes needed to die impression, notify Production
Scheduler and team members listed on Internal Cast Status via e-mail;
report to VP-Quality & Engineering for die
repair; temporarily hold CMM Programmer/Operator
report unless in own judgment die repair is too minor
to justify another cast; destroy disapproved cast and
after die is corrected go back to step
1. |
Decision made and executed
regarding repairs; Production Scheduler and team
members notified |
| 4 |
Engineer* |
IF CAST IS APPROVED
INTERNALLY |
CMM Programmer/Operator
report; 3D Die Design Checksheet |
Notify Production
Scheduler and team members listed on Internal Cast Status via e-mail (be
sure to notify A/R); verify that Tooling program in
M2M has been updated with new net weight, gross
weight and material size, if required. Give 3D Die Design
Checksheet to Engineer per
TOP-SOLID. |
CMM Programmer/Operator
report in Engineering file and material size
forwarded Materials Manager via computer; Production
Scheduler notified. 3D Die
Design Checksheet to
Engineer |
| 5 |
Engineer |
Upon receipt of material
size and weight via computer
notification |
Water weight & stock
size |
Enter material size, net
weight and gross weight in Tooling
program. |
Material size, net weight
and gross weight entered in Tooling
program. |
|
6 |
CMM
Programmer/Operator |
Cast is approved
internally |
Personal
knowledge |
Notify all Engineering
Team Members and Sales Assistant that cast is
approved. |
Notification sent that
cast is approved |
| 7 |
Engineering
Assistant |
After receiving
notification that cast is approved |
Approval notification from
CMM Programmer/Operator |
Get Die Impression Cast Approval
Letter ready; Send cast and cast
approval cover letter to customer; file copy of cover
letter in Cast Follow-up file. |
Cast cover letter sent
out; Cast and Die Impression Cast Approval letter to
customer; copy of Die Impression Cast Approval Letter to Cast-
Follow-Up File; Approval slip to CMM
Programmer/Operator |
| 8 |
Engineering
Assistant |
Bi-weekly |
List of outstanding cast
approvals; engineering files |
Check engineering files to
be sure approval has not been received: record notes
on list. Call customers who have not returned
Die Impression Cast Approval
Letter for 2 weeks (if approval is further
delayed, notify sales person who services that
customer's account). |
Cast approval list
updated. Casts not lost at
customer |
| 9 |
Engineering
Assistant |
Upon receiving
Die Impression Cast Approval Letter back |
Die Impression Cast Approval
Letter back from customer; Cast Follow-Up
File; Die Billing File |
E-mail customer's
approval/ disapproval; Die
Impression Cast Approval Letter to
Engineer; check die billing file and forward E-mail
notification to A/R Clerk, or set up cost
amortization in Dies info. |
E-mail notification;
Die Impression Cast Approval
Letter back to Engineer; tooling billing
set up either by E-mail notification to A/R for
pay-in-full or in Dies info for
price-per-part |
| 10 |
Engineer |
Upon receiving
Die Impression Cast Approval Letter back |
Die Impression Cast Approval
Letter back from customer |
Review and file cover
letter; determine next step. IF DISAPPROVED GO BACK
TO STEP 3. |
Die Impression Cast Approval
Letter to Engineering
File |
| 11 |
Engineer |
Once cast fully
approved |
Prints, Die Impression Cast
Approval Letter, verbal communication |
Turn cast (if any) over to
Die Shop Leadman. |
Approved cast ready for
storage (unless kept by customer) |
| 12 |
Die Shop Lead
Man |
Upon receiving cast to
store |
Cast |
Verify cast marked with
die number (and impression), date and die sinker;
store cast in cast cabinet after discarding or
marking "OLD SINK" any casts of the
impression already in the cabinet. |
New cast in
cabinet |
