STEP

WHO

WHEN

INFO TO USE

WHAT TO DO

RESULTS

1

Machining Department Manager

Upon review of daily schedule showing newly released Job Orders

Shop Schedule (Machining)

Review Job Order to be sure all necessary info is present; add operation's steps to the Router (may involve research to determine steps); forward daily revision (ShopShedule-Machine.xls) to Machining Clerk

Job Order and Schedule reviewed

2

Machining Clerk

On receipt of Job Order

Machining Job Order; Machining Schedule; MPS; print; possibly other documentation

Call up and review rough MPS, determine if any changes are needed to the MPS's operation orders or inspection orders per Job Order or to prints modified via e-mail, and make any needed MPS changes (other than "cover sheet" data) per TOP-MPSMM; update the MPS's "cover sheet" to reflect the specifics of the current order; print the whole MPS packet; pull print from Print Viewer; check for revision level and insert in packet; have the Machining Department Manager, Programmer or Supervisor review and sign-off on the MPS cover sheet when the MPS packet is set up; have Inspection Order reviewed and approved by QC Supervisor; after securing approval, file the packet in the Machining Job File.

Up-to-date MPS and Inspection Order; job packet of Machining Job Cover Sheet, Operation, and Inspection Orders (with page 1 of Inspection Records) printed and held; MPS approved and filed

3

Machining Clerk

Upon review of Machining Department Schedule for jobs scheduled to start within two weeks

Machine Shop Schedule

Pull the folder for each job being released and make any changes needed to bring the information up to date; return the cover sheet to the Machining Job File; build a job packet for each operation by adding copies of prints, NC program hard copies, weld logs and any other documents needing to go to the Machine Operator, Welder, QC Inspector, Crib Attendant or Material Handler.

Job verified as starting soon; job packets released to Crib Attendant; MPS cover sheets made

4

Programmer

Upon receiving copy of Machining Department Schedule

MPS; print; NC program (if any)

Review documents and program for revision level; determine what, if any, changes are needed, and, if so, modify CAM file; generate NC program and NC code file; move NC code file for the operation in the "approved-to-run" directory; the NC program should contain the following information: Die#, DSN#, Revision, Machine#,Operation# and variation code if needed; print the NC code file out as the "hard copy" and insert hard copy of the printed program in the operation's job packet; update the MPS if needed to reflect any program changes.

CAM files, NC program and Operation Orders updated and revision levels synchronized; hard copy of the printed program waiting for operator

5

Material Handler

Daily

Current Machine Job list; Shop Floor Travelers; product received from traffic

Verify that all paperwork and tags are complete and appear to be correct; transfer parts as needed to processing containers (while parts are being transferred, place container tag on the container you are transferring into; if container tags do not come out even, make or destroy extra QC tags); deliver material to the machines per TOP-MOPPP or to Material Storage racks if not immediately needed for production.

Incoming material coordinated with shop needs

6

Upon receiving new job packets

Information in job packet, Current Machine Shop Schedule

Go through the needs of each operation and kit the tools and supplies needed for each operation; notify Tool Maker of any needed fixtures or other tools; coordinate with QC Inspector 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 Machining Manager or Supervisor.

Operations are kitted and shortages are identified; Tool Maker informed of tool and fixture needs

7

Tool Maker

Upon notification that tool or fixture work is needed

Verbal notification; prints; Machining Department Manager's instructions

Work with Machining Department Manager, and others as needed, to determine what tools and fixture work is needed, and when it is needed; acquire the necessary materials and produce the tools and fixtures; secure Shop Floor Traveler for tooling work from Machining Department Manager or Supervisor; mark all pieces with the die number; turn the tools over to the Crib Attendant and fixtures to Material Handlers.

Tools produced to Machining Department Manager's satisfaction and submitted to Crib Attendant and Material Handler

8

Machining Department Clerk/ Supervisor

As time is approaching for an operation to begin (typically several hours ahead)

Personal judgment; Machining Schedule; job packets

Operator notification and any final verification done in a timely manner; QC notified

9

Operator*

Upon Machining Department Manager/Supervisor's notification that a new operation is to be initiated shortly

Machining Department Manager/Supervisor's verbal notification; job packet

Get operation's job packet and kit from Tool Crib; verify that the preparations for the job are complete and that the documents seem to be complete;check to be sure the kit appears to be correct and complete; if kit tag has a green dot, then kit is complete (red dot indicates that kit is incomplete); refer to kit tag for items that are short; notify NC Programmer need for program download; review the job for ideas and questions.

Operational and QC documents ready to go to the machine with tools and fixtures; NC Programmer notified

10

Programmer

Upon receiving notification of need for program download

Machine Department Schedule; Supervisor's instructions

Prepare NC file for download; verify NC file header information matches information on Machine schedule; place NC program in appropriate machine folder.

Program sent to machine and verified

Operator*

When time to run a new job

Machining Department Manager/Supervisor's verbal notification; Operation Order; Inspection Order and rest of job packet for machining

Get the kit for the operation to machine; check to be sure you have everything for the job, including material and NC program (if any); verify that all documents match the Operation Order (this includes prints - check revision level --, hard copies and photos); verify that the work pieces and container tags match the print and Operation Order; resolve any questions or suggestions with your Supervisor; set up and run the job per TOP-MOPPP when complete check job packet with last machined part from QC; return kit and unused materials back in with Crib Attendant to close out the operation(s).

Operation initiated, machined and closed out with materials returned to crib

12

Machining Manager

Upon receiving job packet documents back after operations complete

Operation Order, Inspection Order,and rest of job packet from machining; MPS; Shop Floor Traveler; Weld Logs;

Verify that operations have been completed to standards set out in MPS; review counts for accuracy; review materials issued to job; consider how the job might be improved next run; consider what steps can be taken to prevent potential problems in future runs; decide if a change is indicated for the MPS and, if so, initiate MPS change per TOP-MPSMM; forward completed packet to Machining Department Clerk.

Results of operation verified; improvements to job sought; MPSs maintained to reflect experience and improvements

13

Machining Department Clerk

Upon receiving job packet documents back after operations complete

Operation Order, Inspection Order, and rest of job packet from machining or subcontracted operation; MPS, Weld Logs

Discard duplicate print copies; scan all pertinent document into the Shared Directory for retention per TOP-RECDS.

Job documents held as records of the job

14

Material Handler

As jobs are complete or at a semi-finished hold

Shop Floor Traveler; Operation Order

If job is to be warehoused,mark part count on container; ensure that the product is securely packaged, properly tagged (or marked), and protected from deterioration; if the parts are to be warehoused for longer than one week ensure that they are tagged and dated with the date they are warehoused and that there is an Operation Order addressing their warehousing and preservation.

Parts warehoused short- or long-term

15

Material Handler

At least once every 3 months

Date on Container

Check machining division for stored machined parts; if box date is 3 months old or older, open and check parts for damage and deterioration; if parts are in good shape, stamp boxes with review stamp, inspection ID, and date; if damage is found on a machined part, notify Machining Department Manager immediately; perform steps as instructed by Machining Department Manager; upon completion of part repair, stamp boxes with review stamp, inspection id, and the date.

Machined parts monitored in Warehouse

16

Machining QC Inspector

Upon final inspection

Inspection Order; print; Shop Floor Traveler

Verify that Inspection Order, print, parts and tags match; fulfill inspection requirements specified in Inspection Order and record results on Inspection Order; coordinate with Operator or Material Handler to resolve any problem or question, bringing Supervisor or Manager in as deemed appropriate; for any nonconforming parts identified, initiate a Discrepancy Report and retain for Machine Department Manager per TOP-MOPPP; if non-conforming parts are found and are re-workable, then disposition will be made to rework; if a partial has been sent to Shipping, then QC will recall all parts for 100% inspection.

Parts inspected and discrepancies resolved; Inspection Records maintained; Discrepancy Reports produced as necessary

17

Machining QC Inspector; Material Handler

As jobs are ready to ship or return to Traffic for additional processing

Shop Floor Traveler; rest of job packet

When satisfied that product, documentation, packaging, preservation, tagging and marking are correct, sign off on the "machining" step of each container tag to approve the product for sealing and delivery; Stamp each container with green Machined stamp; mark part count and location on the face of the Shop Floor Traveler, along with the scrap count; notify Shipping Dept; stage product to be picked up by Shipping and shipped per TOP-FINIS; on final shipment, give all documents in job packet to Machining Manager for final review.

Parts verified ready to ship and shipped; MPS cover sheet updated; shipping paperwork to Machining Manager

18

Machining Department Clerk

As jobs are shipped

Shipping paperwork; Shop Floor Traveler; saved MPS cover sheet

Discard duplicate print copies; scan all pertinent document into the Shared Directory for retention per TOP-RECDS; when final shipment has been made, review labor entries for accuracy and correct as necessary. Complete Job Order status where appropriate.

Complete packet of machining job records verified for completeness and filed