SCOPE: This procedure covers the production steps to determine that a
forging job needs to be run and the steps to get it started.
| STEP |
WHO |
WHEN |
INFO TO USE |
WHAT TO DO |
RESULTS |
| 1 |
Forging
Production Supervisor |
As soon as
possible as
production needs change |
Production schedule; Traveler*, personal knowledge of
production resources |
Decide to
start preparation for a forging job (sometimes based on what is currently
stamped in die from Traveler* and/or print); prepare Hotcell Sheet and
forward to the Hammerman to be posted at the hammer. |
Decision as to what
job, on which hammer in what sequence; Hotcell Sheet prepared, forwarded for
posting at hammer |
| 2 |
Production
Control Manager |
Upon
deciding to start preparation of a job |
Production schedule; check BOM, die, steel, heat code in M2M. |
Determine
which job orders need released, quantity and any special restrictions and
edit BOM**; notify Steelyard and Die Prep if "rush job" |
Print pick list in the Steelyard; Traveler* is kept in the steel yard and
Die Prep picks up Traveler* when needed |
| 3 |
Steelyard
Supervisor or Specialist |
Upon
receiving BOM** |
Traveler*; Steel info on computer |
Carefully
verify the BOM**, report any problems or questions back to Engineering or
Production Scheduler; if chemical check analysis is required, initiate
TOP-CHEMC; determine
first bundle to cut for the job; pull the bundle up to the shear or saw;
write the bundle ID and heat code on the Traveler* in large black letters
and initial it; add heat code to Traveler* in computer; Print Traveler* in
steelyard's office; begin cutting steel (TOP-CUTIT) |
BOM** verified and started. Traveler* printed |
| 4a |
Die Prep
Helper |
As
determine that a die needs to be prepared (may be because of Traveler*, call
from Forging Production Supervisor or simply shop schedule) |
Shop
schedule; print or notes from computer or hard copy; Traveler*;
Trinity Forge Material information; QC Print |
Pull the
die from the racks (or from die shop) and open them up; clean up and polish
dies and other tooling and repair any minor damage that you can; notify
Forging Production Supervisor, VP-Quality & Engineering, Production Control
Manager or Die Shop Supervisor if there are problems you cannot quickly fix;
take QC print and Traveler* to the hammer; (DO NOT IGNORE ANY DIE OR
TOOLING PROBLEM AND LET IT GET TO THE HAMMER); determine the correct
lettering and stamp it in the die or use clay to read numbers and letters to
avoid seeing a mirror image; if tooling for hot stamping is needed, send
Traveler* to Die Shop Die Man for assembly and check (see steps 4b thru 4e);
insert the stencils (IF YOU HAVE QUESTIONS, ASK!); get Traveler* from
Steelyard office; sign the Traveler*; call the Die
Prep Leadman or another Die Prep Helper to verify the
die and lettering and be sure they co-sign the ticket;
scan stamping approval into M2M; take the die,
Traveler* and other tooling to the hammer and put a warmer on the die if
production is expected to start within 2 hours; if "rush job" notify
Supervisor that dies are ready. |
Die
prepared, verified and ready; Traveler* taken to hammer; stamping approval scanned into M2M |
|
Steps 4b thru 4e are only performed when hot stamping is needed. |
|
4b |
Forging Production Supervisor or
Leadman |
At heat code change (when hot stamping
is used) |
Production Schedule; Traveler* |
Call die shop and inform Die Shop
Worker of need for heat code change. Determine if change can be done at the
press or if the tooling needs to be taken to the die shop. If tooling needs
to be taken to die shop provide them with the Traveler. |
Die shop notified of need for heat
code change; Traveler provided |
| 4c |
Die Shop
Die Man |
Upon
receiving Traveler* on a hot stamping job. Do not continue unless Traveler*
is available |
Traveler*; QC Print |
Assemble
heat code for hot stamping. If forge die is not in Die Shop, notify Die Prep
Helper that hot stamping tooling is ready. If forge die is in Die Shop;
notify QC Inspector to check tooling; notify Die Prep Helper to pick up die |
Tooling
is prepared for hot stamping |
| 4d |
Die Prep
Helper |
Upon
notification that tooling for a hot stamping job has been prepared |
Traveler* |
If forge
die is in Die Prep, retrieve hot stamping tooling from Die Shop, notify QC
Inspector that tooling is ready to be checked. If both die and tooling were
in Die Shop, retrieve assembled and checked die from Die Shop. |
Tooling
is retrieved for hot stamping |
| 4e |
QC
Inspector/QC Specialist |
Upon
notification that tooling for a hot stamping job has been prepared |
Traveler* |
Verify
that hot stamping tooling has been assembled correctly; initial or stamp
Traveler. Return Traveler* to Die Shop Die Man or Die Prep Helper
(whichever is appropriate). |
Hot
stamping tooling correctness is verified |
| 4f |
Die Shop
Die Man/Die Prep Helper |
When
Traveler* is returned from QC Inspector/QC Specialist |
Traveler* |
If hot
stamp punch was assembled and checked in Die Shop, notify Die Prep Helper to
pick up hot stamp tooling |
Hot
stamping tooling delivered to Die Prep Helper; Traveler* returned to hammer |
| 5 |
Forging
Production Supervisor |
Upon
determining the need to change the planned production sequence of heat codes
for a die after the Traveler* has been initiated
|
Own
judgment; Traveler*; tub/buggy tags |
Match what the Traveler* has generated and what containers of material have
been cut; change the Traveler* and tags as necessary to ensure they reflect
the desired production sequence.
|
Traveler*, material container tags
clearly reflect the desired production sequence |
| 6 |
Forging
Production Supervisor |
When
Traveler* box is full
|
Traveler* |
Submit to
Materials Manager for archiving per TOP-RECDS |
Completed
Traveler* archived |
*Traveler in M2M have taken the place of the Next Job ticket and Cutting
Ticket
**The Materials Manager
sometimes provides the BOM (Bill of Material) to
the Forging Production Supervisor with information from the Item
Master in M2M
***"Forging Production Supervisor " in this procedure may also refer to the
Production Control Manager or Production Leadman. |