|
STEP |
WHO |
WHEN |
INFO
TO USE |
WHAT
TO DO |
RESULTS |
| 1 |
Steelyard
Supervisor or
Specialist |
As production needs and
shear/saw time dictate |
Steelyard Traveler; Steel info on computer; bundle
tags; BOM (bill of material) |
Review Steelyard Traveler
and BOM. If a specific heat code or codes are specified for a Job,
this information will print out on the Steelyard Traveler; if a note appears
on the Steelyard Traveler to get approval before cutting, contact Materials
Manager for approval; determine which bundle (or
maybe just heat code) to cut, mark it on the
Steelyard Traveler and give it to
the Steelyard Helper;
assign heat codes, print and put on Steelyard clipboard. |
Steelyard Traveler
and BOM reviewed; ticket issued to cut; heat codes assigned; contact made with Materials
Manager for approval (if
required) |
| 2 |
Steelyard Helper |
Upon starting Steelyard Traveler or new heat code for same ticket |
Steelyard Traveler;
bundle tags; billet job order pick list |
Select
the proper bundle of steel to cut from and pull the steel up to the
shear/saw; write the bundle ID and verify heat code on the
Steelyard Traveler;
have Supervisor or Specialist double check bundle I.D., heat code and material
container tags; measure the bars and write the bar length on the Steelyard Cutting Sheet; separate out the bars to be
cut and set the shear/saw for the right cut length;
check for mill seams and note yes or no on Steelyard Cutting Sheet;
If "yes" get a Supervisor's approval; do not take cut steel with seams to
hammer; make the first steel
buggy/tub tag; adjust the shear/saw to give a clean cut; IF THERE ARE ANY
PROBLEMS OR QUESTIONS TELL THE SUPERVISOR OR FOREMAN; note on Steelyard Traveler if job is an "upset job" and
measure billet weights for upset jobs. |
Steel
pulled; "upset job" noted on the Steelyard Traveler; steel bundle I.D., heat
code and tags verified: steel checked for mill seams; buggy/tub tags made;
adjustments made to give clear shear/saw a clean cut; Supervisor or Foreman
advised of any problems |
| 3 |
Steelyard Supervisor,
Specialist or Helper |
Before cutting (or, if
unable to use computer, as soon as possible) |
Steelyard Traveler;
Steel info on computer |
Enter the Steelyard Traveler line into the Steel program to validate that the bundle chosen is correct for the
job; IF THE COMPUTER GIVES ANY WARNING OR
ERROR MESSAGE, HAVE THE SITUATION RESOLVED BY THE PURCHASING MANAGER, PRODUCTION FOREMAN,
PRODUCTION SCHEDULER OR NIGHT FOREMAN BEFORE CONTINUING; if an urgent need necessitates
cutting before all info is available, issue an Urgent
Release form per
TOP-URGNT
; initial "entered" column on cutting ticket. |
Approval to continue
(or cutting stopped); inventory updated; Urgent Release form if needed |
| 4 |
Steelyard Helper |
As cut steel |
Steelyard Traveler;
bundle and buggy/tub tags |
Cut steel
per
Steelyard Traveler
into empty buggy or tub
(container must be completely empty); if the Steelyard Traveler
notes it is an "upset job", weigh the bar ends to see if it's useable (over
billet weight is useable, under billet weight is not useable); if it is
useable, saw to the billet weigh; make sure buggy/tub is kept tagged
correctly; stack bar ends to side and keep an ongoing count of bars cut and
be sure
Steelyard Traveler is right;
when buggy/tub is full, count parts either by hand or weight counting and
enter count on buggy/tub tag and Steelyard Traveler; occasionally check bundle tag against buggy/tub tag and
Steelyard
Traveler; watch for seams and
cracks in bars being cut; frequently check cut length; dispose of bar ends
and any nonconforming material in containers marked for scrap; REPORT ANY
PROBLEMS OR QUESTIONS TO THE STEELYARD SUPERVISOR, PRODUCTION COORDINATOR OR
PRODUCTION FOREMAN. |
Steel cut in controlled
manner; billet count is accurate |
| 5 |
Steelyard Supervisor or
Specialist |
At least twice per
shift |
Steelyard Traveler;
bundle and buggy/tub tags; job pick list |
Double-check the person
cutting the steel by performing the same checks listed in step 4. |
Second set of eyes
watching the steel |
| 6 |
Steelyard Helper |
As buggy/tub filled up |
Steelyard Traveler;
buggy/tub tags; job pick list |
Be sure buggy/tub is
tagged correctly; move filled container to hammer staging area (or to hammer if rush) or
stud welding staging area; unless through with bundle, tag next buggy/tub including a letter (A, B, C) showing which container this is for this heat code and
make sure tub/container is empty (no bar ends). |
Containers tagged
correctly, steel ready for next step |
| 7 |
Steelyard Helper |
Whenever new bundle of
steel will be of different heat code from last |
Steelyard Traveler;
bundle and buggy/tub tags; job pick list |
Mark new buggy/tub tag with "CODE CHANGE"; be sure Steelyard
Leadman or
Specialist knows about code change. |
Containers marked to help hammer crews; Leadman or Specialist notified of code change |
| 8 |
Steelyard Supervisor or
Specialist |
As steel of a new heat
code is cut for a job |
Steelyard Traveler;
steel info on computer; job pick list |
Ensure
new code is approved for job; if job has heat code stamped in die; retain
Steelyard Traveler in Steelyard office until needed
for production. |
Heat code information
provided and updated |
| 9 |
Stud welder |
As receive buggies/tubs
to stud |
Buggy/tub tags |
Weld on studs; Be sure
buggy/tub is tagged correctly; move container to hammer staging area (or to hammer if
rush). |
Containers of studded
billets tagged correctly and ready for forging |
| 10 |
Steelyard Supervisor or
Specialist |
As requested by
Production Foreman, typically every other hour |
Own observation |
Be sure all hammers
have enough steel; move steel from staging area to hammer as needed; think ahead and be
sure appropriate jobs are being cut so that bottlenecks are avoided; tell Steelyard
Helpers of rush situations; be sure all empty containers have old tags removed and remove any type billets or drop offs. Container
must be empty. |
Hammers not waiting on
steel |
| 11 |
Steelyard Helper |
Upon
completing Steelyard Traveler |
Material Grade
Report; Forging Materials Reference List |
Retag any partially-cut bundle and return to bin; repaint bar ends as
needed; double-check Steelyard Traveler to be sure everything is
finished; return Steelyard Traveler to Supervisor. |
Partially cut bundles are retagged and returned to
bin; cutting job finished; Steelyard Traveler
returned to Supervisor |
| 12 |
Steelyard Supervisor |
Upon
receiving completed Steelyard Traveler |
Steelyard Traveler;
steel info on computer; job pick list |
Be sure
all steel needed has been cut, Steelyard Cutting Sheet
has been properly filled out and all computer entries made; return
Steelyard Traveler to Steelyard office. |
All steel needed
has been cut; Steelyard
Cutting Sheet properly filled out; computer entries made; Traveler
returned to the in box in the Steelyard office |
| 13 |
Steelyard Supervisor |
Weekly (more or less) |
Steelyard Traveler |
Keep Steelyard Cutting Sheet in the Steelyard in box
until job is complete and no likelihood that more steel will need to be cut
(if more is needed same ticket can be sent back out to steelyard) Forward Steelyard Traveler,
Cutting Sheet and Pick List
to Accounting Clerk when completed. |
Steelyard
Traveler, Pick List and Cutting Sheet available until job is complete;
forwarded to Accounting Clerk for filing when
completed |
|
14 |
Accounting Clerk |
Weekly (more or less) |
As receive steelyard records from
Steelyard Supervisor |
File Steelyard
Traveler, Pick List and Cutting Sheet in numeric order in closed Steelyard
Traveler File. |
Steelyard Traveler,
Pick List and Cutting Sheet filed |
