|
STEP |
WHO |
WHEN |
INFO TO
USE |
WHAT TO DO |
RESULTS |
| 1 |
Machining Supervisor |
As need to assign
welder(s) to a job |
Machining
Schedule; Production
Floor Traveler; Job Packet; own judgment |
Determine what tasks need to be
accomplished and what resources are available; decide what welding equipment
is to be used for
which task and which welder(s) are to be assigned (be sure that the welder's expertise has
been established per TOP-TRECS); notify each
welder what equipment he/she is to operate and which operation is to be performed; be sure each
team member
has the appropriate Production
Floor Traveler, Job Packet, tools, fixtures and materials; answer questions and solve
problems. |
Welding operations assigned |
| 2 |
Welder |
Upon receiving assignment to
perform welding operation |
Supervisor's
instructions; Production
Floor Traveler; print and Job Packet |
Verify that
Production Floor Traveler is complete and matches assignment; for
production welding check heat code and material; check
consumables availability; coordinate with Material Handler for
material to be delivered to work area; communicate to
Materials Manager any weld consumables required. |
Welding operation initiated; weld consumables requirement communicated to Materials
Manager |
| 3 |
Material Handler |
As welding jobs require
material (typically dies; or tooling for die welding and machined parts; or
forgings for production welding) |
Supervisor's verbal instructions; Production Floor Traveler; container tags;
Welder's comments |
Transfer
forgings or machined parts from storage to work area; verify that container
tags are correct; as operation progresses, keep
materials supplied. |
Materials in place
for welding operation |
| 4a |
Welder |
Upon receiving parts for production welding |
Production Floor Traveler; print; own
knowledge; Weld Log |
Verify part and print match, Production
Floor Traveler is correct and any machining has been properly completed;
examine part against print; record first correct part produced on Inspection
Sheet; assure air/gas mixture meets Welding Specifications; use gages
and/or measuring equipment per
TOP-MSURE and TOP-CALIB to verify parts are
being assembled to print; coordinate with Supervisor to resolve any
problems, bringing Manager in as deemed appropriate; record all completed
parts in the Weld Log for traceability of welded components;
turn any nonconforming or questionable parts over to QC Inspector with a
Discrepancy Report at the end of each shift. |
Verifications completed for first correct part recorded;
production welding completed; any discrepancy reported to QC; Weld Log completed |
| 4b |
Welder |
Upon receiving dies or tooling for welding
|
Production Floor Traveler; print; own knowledge |
Verify the die and Production Floor Traveler
match and are correct; examine die for cracks/defects; perform dye penetrant
check, arc gouge, peen and temper as required; maintain required temperature
(pre-heat, post heat and cooling) during welding; assure air/gas mixture
meets Welding Specifications; use gages and/or measuring equipment per
TOP-MSURE and TOP-CALIB;
coordinate with Supervisor to resolve
any problems, bringing Die Shop Supervisor or Machining Manager in as deemed
appropriate; turn over nonconforming or questionable dies to the QC
Inspector with Discrepancy Report at end of each shift. |
Verifications completed; die/tooling welding
completed; any discrepancy reported |
5
|
QC Inspector |
Upon receiving dies/parts
for inspection |
Inspection Order;
Inspection Records; Weld Log; Production
Floor Traveler; print; 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 Welder 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
Welder's measurements and gage settings are correct; coordinate with
Welder to resolve any problem, bringing Supervisor or Machining Manager in as
deemed appropriate; upon first-part buy-off, record results in
Inspection Records then return documents to Welder; for nonconforming parts produced subsequent to first
part buy-off document nonconforming dimensions on Discrepancy Report and
submit to Supervisor for disposition; Scan discrepant quantity under
QC step in M2M. |
Parts/dies inspected and discrepancies
resolved; Inspection Records maintained; Discrepancy Reports
produced as necessary |
| 6 |
Supervisor or Machining Manager |
During course of job |
Inspection records; any documentation deemed
appropriate; own judgment |
Observe running of welding operation;
verify that documents are correct; welding is being run per plan; verify
that Inspection Records are being maintained; review with the Welder and
possibly other team members how the operation could be improved. |
Inspection Records monitored; ideas for
improvement brought forward |
| 7 |
Material Handler |
As containers of
welded parts are completed |
Production Floor Traveler; Weld Log; container tags |
Ensure that containers are
properly tagged; move container of parts to storage area;
observe TOP-MORDR for warehousing and (if complete) transfer to
Shipping with accompanying Production Floor Traveler and container tags; for partially-completed parts, ensure tags clearly indicate the stage of the parts'
progress. |
Parts moved and
warehoused |
| 8 |
Welder |
As reach end of job |
All documents and remaining
materials |
About 2 hours before you expect
the job to finish; notify Supervisor and Material Handler; when last part is
complete, clean up tools and machine, complete job per
TOP-MORDR; leave work area in a clean and safe condition; alert
Supervisor you are moving to next assignment, scan off job in M2M; notify
Supervisor of any consumables that need to be replenished. |
Supervisor and Material Handler notified
prior to end of job; Production Floor Traveler completed; documentation,
tools, etc. returned; job scanned off in M2M; consumables monitored |
9
|
Welder |
When welding equipment is unable
to operate properly for any reason; out of materials/consumables |
Own observation |
Scan downtime in
M2M; notify Supervisor and Material Handler. |
Supervisor notified of downtime; downtime
scanned in M2M |
