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TOP-GLOSS: GLOSSARY

REV:10/06/06

Approved Supplier - A vendor or subcontractor who is currently approved by the Quality Assurance Manager to do business with Trinity Forge and is listed on the Approved Supplier List.

ASTM E 1444 - ASTM is an acronym for the American Society for Testing and Materials. E 1444 is the designation pertaining to the standard practice for magnetic particle examination.

AS9100A - Quality Systems - Aerospace - Model for Quality Assurance in Design, Development, Production, Installation and Servicing. AS9100A is an SAE (Society of Automotive Engineers) specification.

Audit Committee- A group composed of two or more members (the Audit Manager plus ever-changing additional members) which over the course of year audits each procedure in the TOPs manual, ensuring that it addresses its purpose and that it is being followed.

BHN - Brinell Hardness Number, a unit of measurement.

Blasting - A process of pelting parts with small pieces of steel under high pressure to remove scale and other unwanted coatings.

Blocker - An intermediate impression in a forging die which is dimensionally similar to the finisher impression. Its purpose is to alleviate certain defects and to maximize the life of the finisher.

Bluebonnet Plant - A second plant purchased and briefly run in the early 1980s.

Brinell Hardness Testing - A means of determining the hardness of steel parts in the lower end of the hardness range of steel forgings. See Rockwell testing for the higher ranges.

CA - Computer-aided design (engineering computer system).

Calibration Control System (glossary) - The method by which Trinity Forge regularly reviews and ensures the precision of all precision measuring equipment.

CAM - Computer-aided design (machining computer system).

(CAR) Corrective Action Report - A report submitted whenever there is a major problem or a series of problems which may indicate that changes are needed to the quality system, procedures or suppliers.

Celltech - A method of in-process inspection, including hot inspection and material handling, which the Forging Division utilized in the early 1990's.

Certification (or Certificate of Material) - A document provided to a customer telling what material products were made from, what heat treat has been done, and what the results were of testing. The exact requirements for certification is established by customer requirements

Charpy Impact Test - A test where a special test sample or a sample taken from a forging is machined to a prescribed shape, chilled to a prescribed temperature and broken at a calibrated impact force. The results of such testing are sometimes provided as part of Trinity Forge's certificate of material.

Chop - A defect of a forging, similar to a cold shut, where the top die moves material down the side wall of a forging causing it to lap over itself. Most commonly seen in stainless steel forgings.

Coining - A method whereby a part is slightly deformed between two dies in a press to straighten the part or to tightly control a dimension.

Controlled Document - Any written document or computer record which pertains to design, purchasing, production, quality standards, inspection, or procedures. It must be generated and maintained according to TOPs and typically must be signed and dated.

Crack - A defect in a forging typically caused by a raw material defect or by poor temperature control.

Crib - Machining Division storage area for tools and fixturing.

Cycle Counting (glossary) - The method of inventory counting used by Trinity Forge whereby a semi-random sampling of the inventory is checked each week or so and over the course of six months all inventory has been counted.

Die - A heavy piece of steel containing an impression of the part being forged (or coined). The die may have several impressions to allow a part to progress in forging from a rough to a finished state. This is the primary unit of sales for Trinity Forge, and all production records can be traced to the die.

Die Impression - A single station sunk into a forging die to allow one part at a time to be forged one step in its process. Some dies have several impressions to step the forging through, say, a roll, block and finished stage, and some dies have impressions to forge multiple parts at a time.

Die Sinker - A subcontractor who machines impressions into die blocks and who typically produce other tooling as well.

Downsize - The dimensions of a forging perpendicular to the faces of the dies. With each blow of the hammer the dies come closer and closer together reducing the downsize of the forging. The dies' touching is referred to as "coming die-to-die".

*DSN - "Die Sequence Number", the job identifier for the sequence number of the particular order off a particular die. Example: 1234-005 is the fifth order of parts off die 1234.

Finisher - The final impression of a forge die that imparts the final dimensions and lettering. That is the impression that prints, patterns and models typically address.

First-Part Buy-Off - An approval provided by a Quality Control Inspector of the first good part in an operation, thereby authorizing full production to begin.

Flash Extension - The small rib of flash remaining on a part after trimming.

Flash Land - The area around the forging impression used to control die pressures so as to maintain maximum die life along with maximum filling conditions.

Flash Ratio - The width-to-thickness ratio of a die's flash land, which provides a measure of die pressure. Typically this ratio is between 3:1 and 6:1.

Forging (glossary) - The process of heating metal up to the "forging temperature" (typically over 2000F for steel) then deforming it between dies in a hammer and trimming it. Term also refers to a part made by the forging process.

Forging Division - The hot forging part of Trinity Forge, Inc. This is the original component of the company. See "Machining Division Furnace - A device for taking material up to a controlled forging temperature. At Trinity Forge, this term includes slot pre-heat and forging furnaces which operate off of natural gas and propane as well as electric induction heaters.

Gutter - The recessed area outside of a die's flash land for capturing excess material.

Hammer - The primary unit of production equipment used at Trinity Forge. A hammer holds the forging dies then by using any of several methods lifts the top die and drops it down against hot material placed on the bottom die to deform the material into the desired part shape.

Hammerman - The head of a production crew and the primary operator of a hammer. Also may relieve other members of the crew. The central position in the company.

Hatch Team - A group of Trinity Team members assigned the task of supplying the customer quality parts, in the time allotted, from a new die.

Heat - Term used by metals suppliers to refer to a single production lot of material. Typically all certification of material, such as chemistry, is traceable to the heat.

Heat Code (sometimes called "code letter") A 3- or 4- character code used to identify the supplier and heat of material, and where needed even the specific run of the die.

Heat Treat (including annealing, normalizing, tempering, etc.) Any time- and temperature-controlled method of using heat to refine the properties of metals. At Trinity Forge, roughly one-half of the forgings are sent out to subcontractors for one type of heat treat or another.

Heater - the person in a hammer crew responsible for heating material and getting it to the hammer;

Hewlett-Packard Computer - Data processing system used by Trinity Forge from October 1978 to April 1997, including an HP-1000 minicomputer which served as the Company's central computer and the terminals attached to it. Personal computers often doubled in the roles of these terminals.

IDEAS - The Company's program for soliciting ideas for improvement from all team members. Induction Heater - A device which heats metal by passing it through electrical induction coils that change the magnetic field around the material several hundred times a second thus inducing an internal "friction" in the metal through "eddy currents".

Inspector Stamp - A small pre-inked rubber stamp with a Trinity Forge trademark and a team member's employee number. Used by Quality Control Inspectors and others as a shortcut to having to hand-sign or initial documents.

Imaging System - Any product that can be used to view Trinity Forge online prints.

ISO-9000 (or ISO-9002) - An international quality system standard which Trinity Forge's own quality system is intended to meet. "ISO" refers to the International Standards Organization, 9000 is a series of standards and 9002 is the specific standard which applies to Trinity Forge. The quality system must be audited twice each year by an outside registrar for Trinity Forge to achieve and hold ISO-9002 certification.

Job - An ambiguous term which must be taken in context. May refer to a die, the process of running that die, or a particular run of parts from the die (a DSN), or particular process at Machining Division. Also may refer to a team member's employment with Trinity Forge.

Kanban - Japanese for "card." A pull inventory method whereby a card or other document indicates that a predetermined small quantity of inventory has been used and needs to be replaced. (Pronounced "cahn-bahn").

Kit Tooling and fixturing for a specific job at the Machining Division.

Lathe - A machine in which work is rotated about a horizontal axis and shaped by a fixed tool. (Advanced ones called "turning centers".)

Machining Division - The division of Trinity Forge located at 940 Trinity Drive where machining and certain other services are provided, primarily to provide a more finished product to the customer. It acts as a subcontractor to the Forging Division. Its previous name was "Target Machine."

Magnaflux (glossary item) - The manufacturer's name for the most common brand of magnetic particle inspection equipment. Magnetic particle inspection is often referred to simply as "magnafluxing".

Magnaflux QC File - Folder containing Technique Sheets, Magnetic Particle Inspection Logs, QC of the Magnetic Particle Inspection System forms and other items pertinent to magnetic particle examination. File kept in QC Department.

Magnetic Particle Certification - The certified results of the magnetic particle examination of forgings with the pertinent information required by the customer.

Magnetic Particle Inspection - A method for the detection of surface or slightly subsurface discontinuities in ferromagnetic material. Magnetic Particle

*Inspection Log - A record of the date, DSN, heat code, part name, inspector, quantity examined by magnetic particle inspection and the results. Filed in QC files.

Management Review Committee (glossary) - A group of managers from various areas affecting quality. It meets to annually review the quality system to ensure that it is continuing to be suitable, effective and self-improving. It produces a report to the President with its observations and recommendations.

Material Review Board - A standing committee in each division to review nonconforming or questionable parts on a daily basis.

Material Safety Data Sheet - Documents provided by the suppliers of industrial materials describing the potential hazards related to the use of their products.

Mill - Machine for removing material by relative motion between a workpiece and a rotating cutter.

Mismatch - A process irregularity in which the top and bottom forging dies are misaligned with one another. "Side match" is the right-to-left alignment and "end match" is the front-to-back alignment. "Mismatch" is also the term used for the type of forging defect caused by mismatched dies.

Model (glossary) - Dimensional exact model of forging die at production temperature made of epoxy or other material.

NC Program - Numerical control program to operate mills and lathes.

NCA-3800 - ASME Nuclear Survey Teams Survey of Applicants Quality System

NDT - Acronym for nondestructive testing. This is part of 3 team positions having to do with magnetic particle examination.

Neon - Very bright colored index card used for time critical communication. For example, used as a note to tell a material handler that raw material will soon be needed for a new job.

Nonconformance - A quality problem. Specifically something (raw material, product, paperwork or someone's action) that does not meet the specifications it is supposed to meet.

Non-fill - A defect of a forging where the entire die cavity has not been filled with material, typically seen in tight radius areas.

NQA-1 -

Pad -A hot coining operation.

PQR - "Parts Qualification Report", a now-obsolete form that was the primary means that the Quality Control Supervisor communicated problems with completed jobs so that improvements could be made before next run. Replaced by the Corrective Action Report.

Pattern - Dimensionally exact model of forgings at production temperature made of wood or other material.

Physical Analysis - A test where a special test sample or a sample taken from a forging is machined to a prescribed shape and pulled with a calibrated force until the sample stretches and breaks. The results of such testing are frequently provided as part of Trinity Forge's certificate of material.

Pick List - List of all tooling and fixturing to put in kit for Machining Division jobs.

Post-Forge Department - The department responsible for moving forgings away from the hammer cell, cleaning them and performing any in-house cold working other than machining.

Press - A device which mashes two pieces of tooling together to do work to a workpiece. At Trinity Forge, presses are used at the hammer to trim the flash off of a part just forged, to punch a hole through it or to hot pad it. Presses may also be used to cold coin parts.

Preventive Maintenance (glossary) - A program of checking equipment regularly and replacing parts as they become worn to avoid unexpected breakdowns.

Production Department (or "Forge Shop") - The department responsible for heating, forging and trimming parts. The central department of the company.

Pull test - Physical analysis.

Purchase Order - Verbal, written, faxed or electronic (e-mail) instructions to provide goods or services for a customer or prospect.

QC of the Magnetic Particle Inspection System - The record of the results found during the checking of certain quality control items involving the magnetic particle inspection equipment.

Quality - Conformance to customer expectations.

Quality Assurance - The department responsible for the quality system and for ensuring that it is observed. Also responsible for coordinating customer quality audits.

Quality Control - The department responsible for monitoring and inspecting products to ensure that they meet the requirements of the customer.

Quality Record - Completed paperwork or computer record which provides historical data about the operation of our quality system. Filing cabinets are often full of such records.

Reference Gage - A device used to help judge the functionality of a part which may not reflect any specific, measurable dimension. Often a customer-provided mating part.

Reference Specification/Standard - A document provided by a standardization body which provides universally recognized standards (e.g., AISI material specifications)

Reliefman (or "Utility Hammerman") A second hammer operator on a production crew who relieves any other member of the crew including the hammerman.

Resink - To cut new impressions in a die, typically after the die becomes worn with use.

Restrike - The use of a forging hammer and dies to hit a part again after it has been forged and trimmed to get the part closer to the prescribed downsize. Restriking may occur as part of the initial forging process or at a later time, either with the part heated (hot restrike) or not (cold restrike).

Rockwell "B" and "C" - Units of hardness measurement.

Rockwell Testing - A means of determining the hardness of steel parts in the mid- ("B") to high-end ("C") of the hardness range of steel forgings. See Brinell hardness testing for the lower ranges.

Roll - A simple die impression commonly used to break the scale off of the billet and to begin redistribution of the volume of the steel to more closely approximate the part.

Scale - An oxide coating quickly developed on steel at temperatures over about 1600F that must be substantially removed in forging to preserve the surface finish. Identified by the Forging Industry Association as the biggest single problem of forgers.

Seam - The most common raw material defect, consisting of a long rolled-in surface defect very similar to a cold shut in a forging.

Self-analysis - The annual process through which everyone at Trinity Forge is involved with reviewing and proposing improvements for all aspects of the business.

Shipping Department - The department responsible for handling shipping to and from subcontractors, carrying the finished goods inventory, packaging and finally shipping products. Previously combined with Post-Forge as the "Traffic Department".

Sink - To cut the impressions in a die. Trinity Forge usually has this performed by outside die sinkers.

Statistical Process Control - The use of numerical techniques to monitor and evaluate industrial processes.

Steel - The principal raw material of Trinity Forge, and sometimes used in the generic sense to refer to any raw material.

Steelyard - The area of Trinity Forge responsible for receiving, warehousing, cutting and delivering raw material.

Suggest-a-Share---obsolete name---see IDEAS---The Company's program for soliciting ideas for improvement from all team members.

Supplier - See Approved Supplier

Target Machine - The previous name of the Machining Division of Trinity Forge, Inc. Until 1992 it was an independent company, "Target Machine, Inc." and even earlier, "Target Manufacturing, Inc."

Team Member - An individual employee of Trinity Forge, whether Trimmer, President, Engineering Assistant or Shop Superintendent.

Technique Sheet - Instructions on how to perform magnetic particle inspection for a specific part.

TMTR - Team member training requirement. The basic Trinity Forge Training Module required of all employees, regardless of team position.

Tooling - The dies, trimmers and other equipment especially made for a single die to produce parts. The term "tooling" is often used in the vernacular to mean tooling other than the forging die itself. For Machining Division, it refers to (small) equipment for running a specific job at the Machining Division.

Trinity Change - See self-analysis

Tracing Model - See Model

Traffic Department - Now called "Shipping Department". The department responsible for handling shipping to and from subcontractors, carrying the finished goods inventory, packaging and finally shipping products. Previously combined with Post-Forge.

Trinity Forge Team - All of the employees of the company, and to some extent the suppliers as well. The team is expected to act together to serve the customer, to continually improve Trinity Forge and to further the prosperity of all.

Trimmer - The tooling which is set up in a press (the "trim press") and is used to trim the flash off a forging. The tooling consists of a trimmer punch which passes through the trimmer plate, together acting somewhat like scissors. The term "trimmer" is also used for the person who operates the trim press.

TFQM - "Trinity Forge Quality Manual", the Company policies on all aspects of the Company's operation that affects the quality of products or customer service.

TFTM - "Trinity Forge Training Modules", the documents concerning the objectives and syllabus of each element of the Company training program.

TFTP - "Trinity Forge Team Positions", the documents which detail the role, responsibilities and requirements of each position on the Trinity Forge Team.

TOPs (glossary) - "Trinity Operating Procedures", the manual of operating procedures that fulfill the requirements of the Trinity Forge Quality Manual and other Company policies.

TPS - "Trinity Procedure Specifications", the set of run procedures which translate the customers' requirements into standardized production, heat treat and certification instructions. TPS formally refers to the generic templates which can be used to set up new orders, but informally also refers to the process steps of particular orders. Historically, a TPS was a less encompassing document with procedures identified by "TPS number".

NDT Level I - Performs specific calibrations and magnetic particle examination.

NDT Level II - Sets up and calibrates equipment, and interprets and evaluates results. Coaches Level I.

NDT Level III - Capable of establishing techniques and procedures, interpreting codes, standards, specifications and procedures. Coaches Level I and II. Must be certified by the ASNT (American Society for Nondestructive Testing, Inc.)

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