| 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 |
