Trinity Operating Procedures (TOPs)
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Step 2 WHO removed QC Inspector II |
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Step 2 WHAT TO DO removed Traffic to added when removing parts from inventory, do an inventory transfer (M2M) to move parts to the designated area; take parts to the appropriate area; when removing parts from the racks spray paint over the piece count and gross weight; (only Traffic can remove parts from the racks) added After inspection or re-work is completed re-weigh each container placing the correct information on the container; added the memo must reflect changes when parts have been added to or taken out of a container; do another inventory transfer putting the parts back into finished goods. added put the parts back in the designated bin on the racks.
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Revisions made as of October 8, 2008
TOP-FORGE
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Step 6b WHAT TO DO added or table and the Hammer Scrap Log |
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Step 9 INFO TO USE added Hammer Scrap Log |
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Step 9 WHAT TO DO added Hammer Scrap Log |
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Step 9 RESULTS added Hammer Scrap Log |
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Step 10 WHEN added Hammer Scrap Log |
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Step 10 INFO TO USE added Hammer Scrap Log |
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Step 10 WHAT TO DO added Hammer Scrap Log |
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Step 10 RESULTS added Hammer Scrap Log |
TOP-CADFL has been made obsolete
TOP-POSQC
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Step 4 INFO TO USE removed AQL Inspection Sheet |
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Step 4 WHAT TO DO replaced AQL Inspection with random inspection |
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Step 5 INFO TO USE removed AQL Inspection Sheet |
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Step 5 WHAT TO DO replaced AQL Inspection with random inspection |
Revisions made as of October 3, 2008
TOP-QDATA
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Changed SCOPE to This procedure covers reviewing, reporting and analyzing of scrap. |
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Step 1 WHEN changed to Daily |
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Step 1 INFO TO USE changed to Scrap Reporting Spreadsheet |
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Step 1 WHAT TO DO changed to Update Scrap Report in M2M on personal computer; run query of scrap using the Scrap Reporting Spreadsheet; generate reports for scrap tracking and analysis from the Scrap Reporting Spreadsheet, and route the reports as specified in the spreadsheet. |
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Step 1 RESULTS changed to Data entered for scrap in M2M; reports generated |
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Step 2 WHEN changed to Monthly and Quarterly |
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Step 2 INFO TO USE changed to Scrap reports queried from Scrap Reporting Spreadsheet |
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Step 2 WHAT TO DO changed to Review reported scrap data on quantity of parts scrapped and scrap causes; perform cost analysis monthly and quarterly; use reported data to determine a plan to decrease scrap. |
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Step 2 RESULTS changed to High-level analysis of cost from scrap tracking data |
Revisions made as of October 2, 2008
TOP-BENFT
Correction
Education Benefits
Any full-time employee, after they have been continuously employed by Trinity Forge for more than ninety (90) days, can be reimbursed 80% of the amount that they pay for books, tuition and required fees if they complete a semester of a college course or courses with a passing grade.
The classes that an employee completes must be courses that can be applied to the employee's present or future team position at Trinity Forge and they must be pre-approved by the employee's supervisor or manager. The employee must submit receipts and passing grades with the request for reimbursement.
The company will not reimburse an employee for transportation, parking fees, or other fees that are not required.
Revisions made as of October 1, 2008
TOP-BENFT
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Added: |
Education Benefits
Any full-time employee, after they have been continuously employed by Trinity Forge for more than ninety (90) days can be reimbursed 80% of the amount that they pay for books, tuition, and required fees if they complete a semester of a college course or courses with a passing grade.
The classes that an employee completes must be courses that can be applied to the employee's present or future team position at Trinity Forge and they must be approved by the employee's supervisor or manager. The employee must submit receipts and passing grades with the request for reimbursement.
The company will not reimburse an employee for transportation, parking fees, or other fees that are not required.
This will include Continuing Education Classes.
Revisions made as of September 30, 2008
TOP-WASTE
Added NOTE: IN THE CASE OF A SPILL, SEE TOP-EMERP.
Revisions made as of August 30, 2008
TOP-TPSMM
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Step 4 INFO TO USE added BOM, Router and Item Master Checklist |
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Step 4 WHAT TO DO added 2 places BOM, Router and Item Master Checklist |
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Step 4 RESULTS added reviewed using BOM, Router and Item Master Checklist |
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Step 5 INFO TO USE added BOM, Router and Item Master Checklist |
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Step 5 WHAT TO DO added BOM, Router and Item Master Checklist |
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Step 5 RESULTS added per BOM, Router and Item Master Checklist |
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Removed Step 6 and renumbered rest of the steps |
Revisions made as of August 14, 2008
TOP-RECHK
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Replaced Metrologist with Metrologist Clerk throughout the TOP |
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Step 1 WHAT TO DO changed to Report situation to the Metrologist Clerk. |
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Step 5 WHAT TO DO added forward copy to QA Manager |
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Step 5 RESULTS added copy to QA Manager |
TOP-MWELD
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Step 4a INFO TO USE added Weld Log |
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Step 4a WHAT TO DO added Weld Log |
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Step 4a RESULTS added Weld Log |
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Step 5 INFO TO USE added Weld Log |
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Step 7 INFO TO USE added Weld Log |
Revisions made as of August 14, 2008
TOP-PATRN
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Step 1 WHAT TO DO added Job Order request changed go to Step 13 to go to Step 14 |
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Added a new Step 2 renumbered remaining steps |
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Step 9 INFO TO USE added email |
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Step 9 WHAT TO DO changed add approval information to customer file to add approval information to email and send to Engineer |
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Added a new Step 11a |
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Step 13 WHAT TO DO added close out Job Order |
Revisions made as of July 31, 2008
TOP-AFTSH
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Step 2 WHAT TO DO added when manual certifications are needed, email the QA Clerk; forward the Traveler, Shipping Memo, and other information about the order |
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Step 2 RESULTS changed to Manual certs info forwarded to QA Clerk; QA Manager notified review is required |
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Added a new Step 3 |
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Renumbered remaining Steps |
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Step 4 WHEN changed to Upon being notified that a job requiring manual certifications is being readied for shipment |
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Step 4 INFO TO USE changed to Information provided with manual certifications; Job Order |
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Step 4 WHAT TO DO added and manual certifications |
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Step 4 RESULTS changed to Jobs requiring manual certifications are released for shipment; certs and invoice are printed; reviewed and signed by QA Manager |
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Step 5 INFO TO USE changed to Traveler; Sales Orders |
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Step 5 WHAT TO DO changed If Billing Notes reflect a special review to If Traveler or the Sales Order reflects a special review |
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Step 5 RESULTS added certifications and shipping documents prepared |
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Step 6 INFO TO USE changed to Sales Orders; Shipper numbers |
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Step 6 WHAT TO DO changed to Sign certifications; place Bill of Lading in the Sales Department box for filing; send a copy of the Bill of Lading, invoice, and certifications to the customer |
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Step 6 RESULTS changed to Paperwork is sent to customer; billing is completed for job |
Revisions made as of July 12, 2008
TOP-DSCON
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Step 2 INFO TO USE changed to Notification from Die Shop Helper die material is needed |
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Step 2 WHAT TO DO removed E-mail Materials Manager of need for die steel added E-mail Engineering Assistant to order die material |
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Step 2 RESULTS removed Materials Manager added Engineering Assistant changed die steel to die material |
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Step 3 WHO changed Materials Manager to Engineering Assistant |
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Step 3 WHEN changed die steel to die material |
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Step 3 INFO TO USE changed die steel to die material |
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Step 3 WHAT TO DO changed die steel to die material |
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Step 3 RESULTS changed die steel to die material |
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Step 4 WHEN changed die steel to die material |
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Step 4 WHAT TO DO changed Materials Manager to Engineering Assistant |
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Step 4 RESULTS to changed Materials Manager to Engineering Assistant changed die steel to die material |
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Step 5 WHEN changed die steel to die material |
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Step 7 WHO changed Materials Manager to Engineering Assistant |
TOP-MNTRM
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Step 1 WHAT TO DO added contact Materials Manager via email for approval to use; if approved to use added NOTE: The Materials Manager needs to give approval to use any material in the Steelyard. Due to the cost of material only the required amount for a job may have been purchased. |
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Step 1 RESULTS added Approval or disapproval to use material received |
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Added a new Step 2 |
Revisions made as of June 28, 2008
TOP-CHNGE
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Step 2 WHAT TO DO removed use e-mail telephone (intercom) or face to face meeting if required to notify other departments of imminent change to order in process; place notes as deemed necessary in Sales Orders and Job Orders replaced with notify via e-mail to the Production Control Manager, Materials Manager, Sales Operations Manager, QA Manager, QC Supervisors, Machining Manager (if required), and Engineer assigned to customer to take immediate action; place notes as deemed necessary in Sales Orders and Job Orders and place on hold. |
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Step 2 RESULTS changed to Concession/Change Order information distributed; copy filed in Customer PO file; notifications made to key personnel of changes; Sales Orders and Job Orders and place on hold |
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Step 3 WHO changed to Production Control Manager |
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Step 3 INFO TO USE changed to Customer Concession/Change Order notification |
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Step 5 INFO TO USE changed to Verbal (or e-mail) |
TOP-URGNT
Changed Materials Buyer to Materials Manager throughout
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Step 1a WHAT TO DO removed discuss with Materials Buyer, Production Coordinator or Night Foreman replaced with discuss with Materials Manager and Production Control Manger removed fill out an Urgent Release Form giving the bundle ID, heat code, DSN replaced with initiate an email giving the bundle ID, heat code, Job Order |
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Step 1a RESULTS removed Urgent Release Form to Materials Buyer replaced with Email to Materials Manager |
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Step 1b WHAT TO DO removed fill out an Urgent Release Form giving the identity, location, DSN replaced with initiate an email giving the identity, location, Job Order |
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Step 1b RESULTS removed Urgent Release Form to Materials Buyer replaced with Email to Materials Manager |
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Step 2 WHEN removed Urgent Release Form replaced with email |
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Step 2 INFO TO USE removed Urgent Release Form replaced with email |
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Step 2 WHAT TO DO removed DSN replaced with Job Order removed Urgent Release Form replaced with email |
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Step 2 RESULTS replaced with Notifications made; disposition noted |
TOP-PROQC
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Step 1 WHO added QC Inspector II |
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Step 1 WHEN added QC Inspector II |
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Step 1 WHAT TO DO removed hammer log replaced with Hammer Scrap Log |
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Step 3 WHAT TO DO removed initial hammer log added record scrap on Hammer Scrap Log |
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Step 3 RESULTS added scrap recorded on Hammer Scrap Log |
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Step 4 WHO changed to QC Inspector II |
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Step 5 WHO changed to QC Inspector II |
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Step 5 WHAT TO DO added ensure parts scrapped at the hammer are recorded by the hammerman on the Hammer Scrap Log per TOP-SCRAP |
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Step 5 RESULTS added scrap at the hammer recorded on Hammer Scrap Log |
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Step 7 WHAT TO DO added and recorded on the Post Forge Scrap Log |
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Step 7 RESULTS added scrap recorded on the Post Forge Scrap Log |
TOP-MOPQC
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Step 5 WHAT TO DO removed or exceeding 2% added scrap requirements per TOP-SCRAP |
TOP-NOCON
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Step 3 WHAT TO DO added for scrap requirements per TOP-SCRAP |
Revisions made as of June 2, 2008
TOP-HAZCM
Was “LIST OF HAZARDOUS CHEMICALS”
Now “HAZARDOUS CHEMICALS”
Was “In this organization the Environmental Coordinator maintains a master list of all hazardous chemicals used. Called the Master Chemical List, this hazardous chemical list is updated whenever new chemicals are received at the facility. This Master Chemical List is maintained in the shop warehouse, the Machining Division and the office of the Environmental Coordinator. It is available for inspection upon request. In some situations, particular work areas that use hazardous chemicals find it helpful to keep a chemical list nearby, In such cases, employees are told about this option and where this information may be found. No new hazardous chemical substances may be purchased or brought into this facility unless the Environmental Coordinator is informed in advance.”
Now “No new hazardous chemical substances may be purchased or brought into this facility unless the Environmental Coordinator is informed in advance.”
Revisions made as of May 12, 2008
TOP-FINIS
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Capitalized Shipping Memo throughout the TOP |
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Step 3 WHAT TO DO added place green dot on container with employee stamp |
TOP-PREQC
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Step 2 INFO TO USE added Job Order |
Revisions made as of April 15, 2008
TOP-ORDUE
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Step 1 WHAT TO DO replaced Print copy of Orders Due List with Review SOsOnOrder.xls |
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Step 2 WHO changed to Customer Service Representative |
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Step 2 WHAT TO DO replaced note with email |
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Step 2 RESULTS changed to Updated Jobs Info; shipping notified |
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Step 3 INFO TO USE removed Order's Due List added 13 Week Outlook |
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Step 3 WHAT TO DO removed Orders Due List added SOsOnOrder.xls |
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Step 4 WHO replaced Sales Assistant with Customer Service Representative |
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Step 4 INFO TO USE replaced FG_Racks spreadsheet with SOsOnOrder.xls |
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Step 4 WHAT TO DO replaced FG_Racks spreadsheet with SOsOnOrder.xls |
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Step 4 RESULTS replaced Sales Assistant with Customer Service Representative |
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Step 5 WHO changed Customer Service Representative to Sales Operations Manager |
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Step 5 INFO TO USE replaced Order's Due List with 13 Week Outlook; Sales Orders; SOsOnOrder.xls |
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Step 5 WHAT TO DO replaced Orders Due List with SOsOnOrder.xls replaced noting on Orders Due List and notifying Sales Assistant with noting on SOsOnOrder.xls and notifying Customer Service Representative. |
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Step 6 WHO changed to Customer Service Representative |
Revisions made as of April 11, 2008
TOP-SCRAP
Scrap Reporting
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Added allowable scrap miscount and Any lower threshold may be directed by specific customer requirements as recorded on the Router per TOP-TPSMM. |
TOP-TPSMM
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Changed the description from TPS Maintenance & Control to Maintenance & Control of BOMS & Routers |
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Step 4 INFO TO USE added Customer Window |
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Step 4 WHAT TO DO added the Customer Window and appropriate router steps |
Revisions made as of April 11, 2008
TOP-ORGCH: Organizational Structure has been updated
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Added Production Scheduler (Dean Colvin) |
TOP-SYSTEM
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| Changed IS=Information System to IT=Information Technology |
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| Moved the two sentences "The IT Manager is responsible for maintaining instructions for what to do and who to contact in the case of likely failures, posting the list in the main server area, and providing a copy of the list to the President for offsite back-up. The Controller is responsible for review, approval and maintaining of the list" to end of “Documentation” section |
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| Added a new sentence to end of last section " If there is a loss of computerized data, even if most can be restored from backup tapes, the IT Manager is responsible for explaining the scope of the problem to all affected user-department managers, and those managers are in turn responsible ensuring that all lost data has been successfully restored or re-created. In such a case, each manager is responsible for involving all computer users in the department in reviewing the data since many files may have been updated without the manager’s awareness. |
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Removed #4 from “Back-up Strategy and Rotation”
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Revisions made as of April 11, 2008
Added a new TOP
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TOP-SCRAP : Scrap Control |
Revisions made as of April 10, 2008
TOP-MORDR
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Step 1 WHEN changed to Upon review of daily schedule showing newly released Job Orders |
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Step 1 INFO TO USE changed to Shop Schedule (Machining) |
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Step 1 WHAT TO DO removed Review PO added Review Job Order removed Order Status added Router |
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Step 1 RESULTS changed to Job Order and Schedule reviewed |
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Step 2 WHEN changed to On receipt of Job Order |
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Step 2 INFO TO USE changed PO to Job Order |
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Step 2 WHAT TO DO changed PO to Job Order removed if there is any question that an NC program change is needed, forward an MPS Change Notice to the Programmer changed pull print from Trinity Apps program to pull print from Print Viewer |
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Step 3 WHEN changed to Upon review of Machining Department Schedule for jobs scheduled to start within two weeks |
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Step 3 WHAT TO DO added Welder |
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Step 4 WHAT TO DO added for revision level |
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Step 4 RESULTS added revision levels |
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Step 5 INFO TO USE changed Machining Work Orders and Packing Slips from Shipping to Shop Floor Travelers; product received from traffic |
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Step 5 WHAT TO DO added or to Material Storage racks as required |
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Step 6 INFO TO USE changed Current Machine Job list to Current Machine Shop Schedule |
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Step 6 WHAT TO DO removed Crib Attendant added QC Inspector |
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Removed Step 7 |
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Renumbered remaining Steps |
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Step 7 WHAT TO DO removed or other tools; add Job Cards and photos (if any) to job packet; coordinate with Crib Attendant to be sure all inspection equipment is ready for the job; if resources are not available or may impact the scheduling of the job, notify the Manager; added secure Shop Floor Traveler for tooling work from Machining Department Manager or Supervisor |
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Step 8 WHO removed Leadman added Supervisor |
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Step 8 WHAT TO DO removed the machine choices added Shop Floor Traveler |
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Step 9 WHEN changed Leadman's notification to Supervisor's notification |
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Step 9 INFO TO USE changed Leadman's vebal notification to Supervisor's verbal notification |
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Step 9 WHAT TO DO removed job packet from Pending Assignments file added job packet and kit from Tool Crib added Notify NC Programmer need for program download. |
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Step 9 RESULTS changed Material Handler and NC Programmer alerted to NC Programmer notified |
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Step 10 INFO TO USE changed Machine Department Schedule & Leadman to Machine Department Schedule; Supervisor's instructions |
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Step 11 INFO TO USE changed Leadman's verbal notification to Supervisor's verbal notification |
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Step 11 WHAT TO DO changed Leadman to Supervisor added check job packet with last machined part from QC |
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Moved Step 15 to Step 12 |
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Step 12 INFO TO USE added Shop Floor Traveler |
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Step 12 WHAT TO DO added review counts for accuracy; review materials issued to job removed discard duplicate print copies; file all marked-up document (example: Inspection Records) in the Machining Job File replaced with forward completed packet to Machining Department Clerk. |
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New Step 13 |
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Step 14 was Step 16 |
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Step 14 INFO TO USE changed to Shop Floor Traveler; Operation Order |
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Step 14 WHAT TO DO removed Get "final" job packet for job and fulfill requirements of Operation Order; work with Set-up Person to fulfill requirements of Inspection Order |
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Step 15 was Step 17 |
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Step 16 was Step 18 |
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Step 16 WHO changed to Machining QC Inspector |
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Step 16 INFO TO USE added Shop Floor Traveler |
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Step 16 WHAT TO DO added Operator or Material Handler to resolve any problem or question, bringing Supervisor |
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Step 17 was Step 19 |
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Step 17 WHO added Machining QC Inspector |
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Step 17 WHEN changed to As jobs are ready to ship or return to Traffic for additional processing |
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Step 17 INFO TO USE changed to Shop Floor Traveler; rest of job packet |
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Step 17 WHAT TO DO added Shop Floor Traveler and to Machining Manager for final review. |
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Step 17 RESULTS replaced Machining Department Clerk with Machining Manager |
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Step 18 was Step 20 |
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Step 18 INFO TO USE added Shop Floor Traveler |
TOP-SOLID
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Step 5 WHAT TO DO changed to Place a copy of the 3D Die Design Checksheet in PROE parts directory. |
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Step 5 RESULTS changed to 3D Die Design Checksheet in PROE parts directory |
TOP-EMERP
INCLEMENT WEATHER
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Number 1. e. changed kit is kept in the kitchen to kit is kept in the Training Room |
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Number 2. d. changed kit is kept in the kitchen to kit is kept in the Training Room |
CHEMICAL LEAKS OR SPILLS
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Number 1. a. changed Manufacturing Manager, Maintenance Manager to Maintenance Manager, Maintenance Supervisor |
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Number1. b. changed Manufacturing Manager or the Maintenance Manager to Maintenance Manager or the Maintenance Supervisor |
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Number 2. a. changed Manufacturing Manager, Maintenance Manager to Maintenance Manager, Maintenance Supervisor |
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Number 2 . b. changed Manufacturing Manager or the Maintenance Manager to Maintenance Manager or the Maintenance Supervisor |
HAZARDOUS WASTE LEAKS AND SPILLS
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Number b. 1. changed Manufacturing Manager to Maintenance Manager |
FIRE AND EXPLOSION
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f. changed kit is kept in the kitchen to kit is kept in the Training Room |
TOP-MOPPP
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Step 5 WHAT TO DO replaced have Operator verify with have QC Inspector verify |
TOP-PROQC
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Step 1 WHAT TO DO added and on the Traveler added |
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Step 1 RESULTS added Engineer notified via e-mail of any changes |
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Step 2 RESULTS changed to At hammer QC duties performed |
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Step 4 WHAT TO DO added verify Hotcell and Traveler |
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Step 5 WHAT TO DO added sample parts added QC SUPERVISOR added per step 6 |
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Step 7 WHAT TO DO added When dies or tooling exhibit excessive wear, visual or dimensional problems fill out an Internal Process Review Form; forward to QC Supervisor. |
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Step 7 RESULTS added Internal Process Review Form forwarded to QC Supervisor. |
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Step 8 is a new step |
Revisions made as of April 4, 2008
TOP-POSUP
Additionally, raw material suppliers must also:
Added a new line 9
9. All Mill Chemical Reports must be legible and be able to be reproduced by photocopying.
Renumbered original 9,10, and 11 to 10, 11, and 12
TOP-MFLUX
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Step 2 WHAT TO DO added ensure there is a Technique Sheet for the job. |
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Step 2 RESULTS added Technique Sheet made for the job |
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Step 3 WHAT TO DO added submit Technique Sheet to NDT Level III |
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Step 3 RESULTS changed to Determination on whether to inspect parts; requestor notified; Technique Sheet assigned; inspection scheduled and noted on Production Floor Traveler |
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A new Step 4 was added |
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Steps 4, 5, and 6 renumbered to 5, 6, and 7 |
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Step 6 WHAT TO DO changed to Review results, sign when approved and return to QA Manager |
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Step 6 RESULTS changed to NDT Certification reviewed and approved; forwarded to QA Manager |
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Step 7 WHAT TO DO added copy on server |
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Step 7 RESULTS added copy on server |
Revisions made as of March 31, 2008
TOP-POSQC
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Step 1 RESULTS added Production Floor Traveler updated |
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Step 2 WHAT TO DO added NOTE: For any grinding use the Grinding Verification Log to state a visual inspection was performed on the work in process. |
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Step 5 WHO changed to QC Inspector III |
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Step 5 WHAT TO DO added use a Part Inspection Sheet for inspection data |
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Step 6 WHO changed to QC Inspector III |
TOP-DOCUM
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Added Step b4 |
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Step b5 WHAT TO DO added record vendor ratings in vendor's online file |
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Step b5 RESULTS added vendor ratings recorded |
Revisions made as of March 28, 2008
TOP-PURCH
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Step 2 INFO TO USE added Material Availability Report |
TOP-HARDT
Section I
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Added Step 4 |
Section II
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