| 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
perTOP-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; place die warmer on trim 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 |
| 6 |
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 |
| 7 |
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 |
| 8 |
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 |
| 9 |
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. |
| 10 |
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 |
| 11 |
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 |
| 12 |
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 |
| 13 |
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 |
