|
STEP |
WHO |
WHEN |
INFO TO
USE |
WHAT TO DO |
RESULTS |
| 1 |
Machining Supervisor
|
As need to assign
operator(s) to a job
|
Machining
Schedule; Production
Floor Traveler; rest of job packet; own judgment
|
Determine what tasks need to be
accomplished and what resources are available; confirm which machines are to be used for routed tasks and which operators are to be assigned (be sure that operator expertise has
been established per TOP-TRECS); notify each
operator which machine(s) he/she is to operate and which operation is to be performed
(typically via Daily Assignment Sheet); be sure each
team member
has the appropriate Production
Floor Traveler, tools, fixtures and materials; answer questions and solve
problems
|
Operations assigned
|
| 2a
|
Operator*
|
Upon receiving assignment to
perform operation
|
Machining Supervisor's verbal
instructions; Production
Floor Traveler; print
and rest of job packet for machining (see
TOP-MORDR)
|
Verify that
Production
Floor Traveler packet is
complete and matches assignment; if for any reason you do not believe you
are qualified for the assignment, notify Leadman; coordinate with Material
Handler for material to be delivered to work area; if needed,
coordinate with Programmer for NC program to be downloaded to machine;
verify that kit is correct and complete; verify that machine is operational.
|
Operation initiated
by Operator
|
| 2b |
Production Welder
|
Upon receiving parts
and set-up to perform welding
|
Production
Floor Traveler; parts; print; gauges; own knowledge
|
Verify that print
and part match; that the Production Floor Traveler is in good order
and that the machining has been properly completed; Examine part against
print per print. Assure air/gas mixture meets welding and customer welding
specifications; Use gauges and/or measuring equipment per
TOP-MSURE and TOP-CALIB)
to verify parts are being assembled to print; coordinate with Machining
Manager to resolve any problem, bringing Machining Supervisor or Manager in as
deemed appropriate; All completed parts are recorded in the Assembly Process
Log for traceability of welded components. Any nonconforming or questionable
parts produced shall be turned over to The QC Inspector with Discrepancy
Report at the end of each shift.
|
Verifications
completed; Discrepancy Report of nonconforming or questionable parts turned
in; completed parts recorded in Assembly Process Log
|
| 3 |
Material Handler
|
As jobs require
material (typically forgings)
|
Machining Supervisor's verbal instructions; Production Floor Traveler; work
orders from Shipping; container tags
|
Transfer
forgings or other materials from storage to work area; verify that container
tags are correct; as operation progresses, keep
materials supplied
|
Materials in place
for operation
|
| 4 |
Programmer
|
As jobs require
program download
|
Machining Supervisor's verbal orders; schedule
|
Verify program matches
information on schedule and is correct for the machine to receive program; download to
machine
|
Program in place for machining
|
| 5 |
Operator*
|
Upon setting up a
machining operation
|
Production
Floor Traveler; print and rest of job packet
|
Read operation instructions, Production
Floor Traveler; review any setup photos; verify that
heat code
on material tag matches heat code on
Production Floor Traveler; set up the machine; if an NC program is
involved, verify that the program and revision match hard copy in job packet; run test
part(s), check for correctness (see
TOP-MSURE and TOP-CALIB) and make any necessary adjustments; If any raw material is found to be out of specifications, notify the Manager for disposition and to assess the need for a CAR initiation (See TOP-CARRR)
when first correct part is
produced, document dimensions on Inspection Records;
take part with
Production Floor Traveler and have QC
Inspector verify and document all
dimensions being machined; may have to perform this step multiple times to achieve buy-off); involve
Machining Supervisor as deem
appropriate or as appropriate by
Production Floor Traveler; turn all scrap or questionable parts
over to QC Inspector with discrepancy report at the end of each shift
|
Job set up; first correct part
produced and recorded on Inspection Records; nonconforming parts to QC
Inspector
|
6
|
Operator
and QC Inspector
|
Upon receiving parts
for inspection
|
Inspection Order;
Inspection Records; Production
Floor Traveler; part; print; work order or purchase order; rest of
job packet; own knowledge
|
Verify that
Inspection Order,
print and part match; verify that Production Floor
Traveler packet is in good order and that the operator has
properly completed his/her section of the Inspection Records; select measuring equipment
per TOP-MSURE and
TOP-CALIB; examine part
against print per Inspection Order; verify that part meets specification and that
operator's measurements (and, for welding, gage settings) are correct; coordinate with
Machine Operator to resolve any problem, bringing Machining Supervisor or Manager in as
deemed appropriate; upon first-part buy-off, record results in
Inspection Records then return documents to Machine Operator; for nonconforming parts produced subsequent to first
part buy-off, Scan off
job in M2M.
|
Parts inspected and discrepancies
resolved; Inspection Records maintained; Discrepancy Reports
produced as necessary
|
7
|
Operator*
|
As run operation
|
Inspection Order, Production
Floor Traveler; print and rest of job packet for operation
|
Keep equipment and work area safe
and clean; immediately report any machine or welding equipment malfunctions
to Machining Manager, Machining Supervisor, or
Maintenance Worker; produce parts per
Production Floor Traveler; ink stamping of operator ID is required;
use personal "logo" stamp (per
TOP-STAMP); keep all parts
containers and loose parts tagged (be sure the container you are working from, and to, has
a QC tag on it; if the containers do not
come out even, create or destroy the extra QC tags); perform quality
control as specified in Inspection Order; during the
processing of any Job Order requiring assembly, exercise
extreme caution to assure assemblies are free of any debris or foreign
objects as they are being closed or sealed: scan all time spent and part quantity machined into M2M; present
any suggestions for improvement of the operation to Machining Manager or
Machining Supervisor
or Programmer (also
remember the TOP-IDEAS!)
|
Machining, welding and other
operations conducted in safe, controlled manner; Inspection Records maintained; ideas for improvement brought forward; data scanned in M2M
|
| 8 |
Machining Supervisor or Machining Manager
|
As deemed appropriate
during course of job
|
Own judgment; any documentation
deemed appropriate
|
Observe running of operation;
verify that documents are correct and that part is being run per plan; verify that
Inspection Records are being maintained; review with the Operator and
possibly other team members how the operation could be improved.
|
Machining Supervisor
or Machining Manager review of process and opportunities for improvement
|
| 9 |
Operator*
|
As discovers
nonconforming parts
|
Own judgment; any documentation
deemed appropriate
|
Fill
out discrepancy
report and take parts to QC Inspector per TOP-MOPQC.
|
Nonconforming
parts taken to QC
Inspector and discrepancy report issued.
|
| 10 |
Material Handler
|
As containers of
machined parts are completed
|
Production Floor Traveler; container tags
|
Ensure that containers are
properly tagged; forward containers to QC area until final buyoff is
performed; confirm signed Production Floor Traveler is attached to
container; mark all boxes with a
green M; move container of parts to storage area;
observe TOP-MORDR for warehousing and (if complete) transfer to
Shipping; for partially-machined parts, ensure tags clearly indicate the stage of the parts'
progress
|
Parts moved and
warehoused
|
| 11 |
Operator*
|
As the end of job a is reached
|
All documents and remaining
materials
|
About 2 hours before you expect
the job to finish; notify the Machining Supervisor and the Material Handler; when last part is
complete, clean up tools and machine; return tools to
crib as appropriate; complete Job
TOP-MORDR; leave work area in a clean and safe condition; alert
Machining Supervisor you
are moving to next assignment, scan off job in M2M.
|
Machining Supervisor and Material Handler
notified prior to end of job; Production Floor Traveler completed; documentation, tools, etc. returned, scanned off job in M2M
|
12
|
Operator*
|
When machine is unable
to operate properly for any reason
|
Own observation
|
Scan downtime in M2M; notify Machining Supervisor or Maintenance Man.
|
Machining Supervisor
or Maintenance Man notified of downtime; scanned in M2M
|
