| 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 Assistant supplying
forging temperature, temperature tolerance, and
emissivity. |
Forging Material Reference List (Steel Info) kept
updated |
| 3 |
QA Assistant |
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 invokingTOP-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 |
