SCOPE: This procedure covers the forging of parts, including setup of the equipment. This procedure alone by no means covers the entire control of the forging process. (See also TOP-TRECS, TOP-JSTRT, TOP-CUTIT, TOP-CDCHG, TOP-AFTFG, TOP-FTEMP,  TOP-IMPTL, TOP-BKDWN & TOP-QCTRL.)

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