| STEP |
WHO |
WHEN |
INFO TO USE |
WHAT TO DO |
RESULTS |
| 1 |
Production Supervisor or Leadman
("Foreman") |
When determines that it is time to
set up job after completing TOP-JSTRT and having initial
steel cut per TOP-CUTIT
and when determining need to
change process |
Production schedule and personal
knowledge of shop activities; Steelyard Traveler; Inspection print |
Check to be sure all
preliminaries are ready to begin setup; assign team members as Hammerman and other
positions needed for the job and equipment; tell Hammerman any special instructions
regarding job based on experience from last run; if
needed, notify Die Prep to set up trim/punch tooling; notify QC Specialist if this job is
to run on a previously idle hammer; notify Maintenance if special equipment is needed. If process changes notify QC Supervisor or QC Specialist (via e-mail) of
need to modify (step-up) inspection; verify and approve the Hotcell. |
Job assignments made. QC Supervisor and/or QC Specialist notified when
process changed. |
| 2 |
Hammerman (and others involved in
set up) |
As assigned by Foreman |
Instructions from
Foreman;
Hotcell; Inspection print |
Verify die number
on Traveler, match tooling and tub/buggy tag; as soon as setup is
complete, forge first parts and inspect for mismatch and heat code
letters and part numbers, get first steel heating ; unless the job has already
been partially run, and
the tub/buggy tag should show this to be the first container for the heat code; start a
new line for the job on the hammerlog
showing at least the die number and the heat code ("code letter") on the part,
on the tub/buggy tag and on the Production Floor Traveler; adjust hammer and make test forgings until
match looks good; as soon as possible trim (and punch, hot pad, bend or whatever as
required) to produce test pieces and make adjustments until you and QC Inspector,
Production Leadman or Production Supervisor agree that part looks good; scrap all defective parts and record them in the
Hammer Scrap Log; if test bar is
required by the Production Floor Traveler, work with Foreman to ensure that one is produced and marked
with Job Order number and heat code; unless specifically
ordered by Foreman or QC, do not hold up job waiting for full first-part inspection (the
risk of scrap is just not worth the lost production time); Document any changes that deviate from the Hotcell and
forward to the Production Supervisor. |
Job is set up; production setup
aids updated as deemed appropriate; hammer log maintained; test bar produced as needed; changes in production are documented on the Hotcell |
| 3 |
Production Leadman |
At
start-up when first set of production parts are forged |
Production Floor Traveler, Hot Cell, and QC Print |
Validate first forged parts; disposition any parts that are flawed or
questionable; contact a QC team member when further assistance is required concerning flawed
or questionable parts |
Set-up, flawed and questionable parts inspected and separated from production
parts |
| 4 |
Die Prep and Maintenance (as
needed) |
As Foreman reports new job being
set up needing their services |
Foreman request |
Perform task as quickly as
possible, calling on hammer crew for help as needed; if there is any holdup or reason to
think the quality of parts produced might be questionable, report to the Foreman
immediately |
Trimmers, special benders and the
like set up in concert with production needs |
| 5 |
Hammerman (and hammer crew under
his leadership) |
After job is set up |
Personal observation; advice from
QC Inspector or others; tub/buggy tags, parts buggy tags; furnace
controls; Inspection print ; Production Floor Traveler |
Run job as productively as
possible; keep hammerlogs; Hammerman, Reliefman and Trimmer
operator continually watch each hot part for forging defects; periodically check parts against
Inspection print to assure compliance; Heater Operator (or Induction Heater Operator), Hammerman
and Reliefman continually watch color of steel to prevent over-heats or
under- heats; at least once each hour compare heat codes on tub/buggy, Production Floor Traveler and parts buggy;
discard flashings into scrap tub, which is to be dumped into
scrap bins as soon as full; put a tag on all containers of questionable parts telling job number and heat code;
(this step includes parts or billets awaiting reheating);
Make sure no parts are left behind the hammer and no
billets are left around the furnace; IF THERE IS ANY QUESTION THAT
BAD PARTS ARE BEING PRODUCED (OTHER THAN A FEW FROM SIMPLE FORGING ERRORS) STOP FORGING,
INFORM QC INSPECTOR AND OTHER CREW MEMBERS, AND HAMMERMAN REPORT TO THE FOREMAN |
Parts running under crew control
unless possible bad parts; hammerlogs |
| 5a |
Production Supervisor or Steelyard Leadman |
When a job is
pulled, but the order is not completed |
Production Scheduling, Hammer Logs; Production Floor Traveler |
Note on Production Floor Traveler the quantity of parts produced at the time the job was
pulled; let the Production Control Manager know what buggy letter was
pulled, so note can be added to the three day schedule, put the box of steel
that was pulled in the steel yard holding area, see Steelyard Leadman |
Steel box or buggy
pulled from production and put into steel yard holding area so we can start with the
letter of steel that was pulled and we don't have any shortages or miss
any boxes or buggy's of cut steel |
| 6a |
Hammerman and hammer crew |
At end of shift |
Hammerlogs |
Hammerman submits hammerlogs with
the correct die number and die configuration; if test bar is required by Production Floor Traveler, work with Foreman to ensure that one is
produced and marked with job number and heat code. |
Hammerlogs to Foreman (for use by Foreman; test bar produced as needed |
| 6b |
Hammerman and hammer crew
|
At the end of each job or at end of shift |
Production Floor Traveler; hammerlogs |
All scrap parts are
to be placed in the designated scrap barrel or table at each hammer. The
trimmer man is responsible for placing the scrap in the barrel and the
hammer man is responsible for obtaining the scrap count from the barrel and
recording it on the Hammer Scrap Log and
scanning into M2M. If the Production count does not equal the Steel
Yard count, the problem must be resolved at the end of each job. Make sure
no parts are left behind the hammer and no billets are left around the
furnace. |
Part
count is double checked; scrap is placed in appropriate location and scanned
into M2M; No parts left behind hammer and no billets are left around the
furnace |
| 7 |
Hammerman |
At end of job (or if down) |
None |
Report to Foreman for
reassignment; On all jobs, at the end of a job take the flash and part from the last piece
trimmed to the Production Supervisor, tag with job
number;
Make sure no parts are left behind the hammer and all
billets have been
forged. |
Foreman can reassign crew,
last
flash and part from job saved; No parts left behind
hammer. No billets left over before next
job. |
| 8 |
Production Supervisor or Production Control Manager |
At end of shift |
Hammerlogs |
Review all hammerlogs
and Hotcell
submitted for the shift and resolve any questions or irregularities; Review any last piece flash from upset jobs. |
Hammerlogs verified; Correct
billet weight verified |
| 9 |
Production Control Manager |
Typically daily |
Hammerlogs
and Hammer Scrap Log |
Collect hammerlogs
and Hammer Scrap Log
and forward to Materials Clerk to enter info into computer. |
Hammerlog and Hammer Scrap Log info forwarded
to Materials Clerk |
|
10 |
Materials Clerk |
Hammerlogs and Hammer
Scrap Log received |
Hammerlogs and Hammer
Scrap Log |
Enter Hammerlog and Hammer
Scrap Log data into M2M. |
Hammerlog and Hammer Scrap
Log data entered |
| 11 |
All Supervisors |
At end of pay week (review may be
more frequent) |
Time cards for own department |
Review all time cards, resolve
any questions or irregularities; review and approve hours and positions; submit time cards
to the Payroll Clerk. |
Time cards verified |