| 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 |
