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TOP-CASTS...Die Impression Casts

REV: 06/07/07

Scope: This procedure covers the inspection and storage of casts (dimensional representations of an impression of a forging die taken by pouring plaster or other material directly into the impression).

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 Metrologist; if a second has been made, store it per step 13. Cast ready for inspection; second cast, if any, stored
2 Metrologist 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); for new or modified die also measure volume and calculate forging net weight from water displacement (if req'd), pass new weight on to appropriate Engineer. Give 3D Die Design Checksheet to Engineer per TOP-SOLID. Metrologist 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 Metrologist'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 Metrologist 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 Metrologist 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 req'd. Give 3D Die Design Checksheet to Engineer per TOP-SOLID. Metrologist 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.
IF CUSTOMER APPROVAL NOT NECESSARY, SKIP TO STEP 12
6 Metrologist 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 Metrologist 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 Metrologist
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 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, cast approval letters, 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

"Engineer" refers to the member of the Engineering Department assigned the die in question. If there is any question as to which Engineer is assigned a particular die, the VP-Quality & Engineering decides.

 

 

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