| STEP |
WHO |
WHEN |
INFO TO USE |
WHAT TO DO |
RESULTS |
| 1 |
All production workers |
Constantly |
Personal observation |
Watch
color and behavior of steel to be sure not overheated (not white, no sparks
or bubbling in still air); if there is any reason to suspect that the
induction heaters' pyrometers are not operating properly, immediately report
to Forging Production Supervisor or Leadman; If need to make adjustments on
furnace temp controls, report to Forging Production Supervisor or Leadman; IF
OVERHEAT, STOP PRODUCTION AND REPORT IMMEDIATELY TO FORGING PRODUCTION
SUPERVISOR OR LEADMAN TO INITIATE STEP 7. |
Constant visual observation |
| 2 |
Engineer |
Whenever changes are needed to Forging Material Reference List (Steel Info) in
tooling program |
Customer purchase order; raw
material supplier; Material Grade Report
|
Enter
new grade and forging temperature into tooling program; notify QA Clerk, supplying forging temperature, temperature tolerance, and
emissivity. |
Forging Material Reference List
(Steel Info) kept updated |
|
3 |
QA Clerk |
When receive notice of changes
to Forging Material Reference List |
Forging temperature, temperature tolerance, and emissivity of new grade
specified by Engineer |
Make changes to Forging Material Reference List
as required. |
Forging Material Reference List
updated |
| *For
steps 4 and 5, it is mandatory that anyone using a pyrometer must sign it out, and back in
on the Sign Out Sheet for Pyrometers in the QC Supervisor's office |
| 4 |
QC Specialist or QC
Inspector |
As new jobs are
started (or early each shift for continuing jobs) |
Own readings; forging temperature
guidelines from Tooling Info; Jobs info (if includes forging temperature) |
With the emissivity set
per Forging Material
Reference List (if not noted the setting should be 0.85) use hand-held pyrometer* to measure
temperature of forging billet between furnace and hammer; record reading per TOP-PROQC; if reading outside of forging temperature guidelines (or Jobs
info), report immediately to Forging Production Supervisor (if not available, to
Production Leadman, QC Supervisor or QA Manager). |
Regular review of temperatures |
| 5 |
Maintenance Man |
Once a
day and as requested by Forging Production Supervisor or Production Leadman |
Own readings |
For each hammer in operation:
make sure reject gates are mechanically functional; use hand-held optical pyrometer* with the
emissivity per Forging
Material Reference List (if not noted the setting should be 0.85) to check the
consistency of gas furnace hearth temperatures (at least 3 spots across hearth, all within
75° F of each other) and to check the accuracy of induction heater pyrometers (readings
within 50°F of the hand-held pyrometer); record results on Furnace
Temperature Log; if results fall outside these ranges, report immediately
per TOP-BRKDN
; and to Forging Production Supervisor, QC Supervisor, and/or QA Manager; if
have any reason to suspect the possibility of overheating, report
immediately to Production Supervisor, QC Supervisor, and/or QA
Manager. If adjustments need to be made to furnace temp controls,
make adjustments and lock (possibly locked with passwords); forward Furnace
Temperature Log to Maintenance Supervisor. |
Furnace controls monitored;
Furnace Temperature Log to Maintenance Supervisor;
furnace temp controls safeguarded from unauthorized |
| 6 |
Maintenance Supervisor |
Each production day |
Furnace Temperature
Log |
Review day's Furnace Temperature
Log; if Furnace Temperature Log is not
turned in, instruct Maintenance Man to proceed immediately per step 5 of this TOP and
consider invoking TOP-ENFRC. |
Furnace
Temperature Log to file; daily update of
Temperature Log assured; compliance with TOP assured |
| 7 |
Forging Production Supervisor
or Leadman |
Randomly, or as requested |
Personal observation; any
observations or data from above steps; Forging Material Reference List (Steel Info) |
Review any measurements
presented; visually check color and behavior of steel (not white, no sparks or bubbling in
still air); Make sure pyrometer is properly aimed at
the billet; report any malfunctioning induction heater pyrometers per TOP-BRKDN;
and to QC Supervisor or QA Manager; IF need to make adjustment on Furnace temp controls, report to Maintenance Department; If quality forgings cannot be produced at recommended
maximum forging temperature production calls:
Manufacturing Manager or QC Supervisor, and a representative from the
engineering department to determine the next step. Compare furnace pyrometer reading
with the QC hand-held pyrometer. Proper settings on the hand-held pyrometer
are verified (measuring distance & emissivity) IF OVERHEAT, STOP PRODUCTION, NOTIFY QC SUPERVISOR, SEPARATE OUT ANY FORGINGS WHICH MAY
HAVE BEEN OVERHEATED, IDENTIFY THOSE WHICH ARE KNOWN OVERHEATS. |
Random review of temperatures;
follow-up of reports of overheating; control of overheats; Maintenance
informed of needed adjustments on Furnace temp controls |
| 8 |
QA Manager |
If possible overheats
reported |
Discussions; personal
investigation |
Determine scope of problem and
scrap all questionable parts if cost of testing not justified; if justified, have samples
heat treated if required by Job Order, then send
samples out for destructive testing to determine if internal damage (excessive grain
growth or grain boundary precipitates) may have occurred; if so, scrap all questionable
parts and submit findings as a Corrective Action Report (see (TOP-CARRR); if testing results okay, return parts to normal process and notify
Materials
Manager with approval to use elevated temperatures on future orders. |
No parts suspected of possible
overheat damage accepted without representative testing; any lab results to QC files;
Materials
Manager notified |
| 9 |
Engineer |
Upon notification that the forging temperature needs to be changed for a particular grade
of material |
Notification |
Update Trinity
Forge material information. |
Trinity Forge
material information kept updated |
