|
STEP |
WHO |
WHEN |
INFO TO USE |
WHAT TO DO |
RESULTS |
|
1 |
QC Specialist or QC Inspector II |
During forging; as job begins to run (this
includes a new crew moving to a different hammer since the QC Inspector II
moves with one or more crews, rather than being assigned a specific hammer);
or as significant changes are made to die or process; at least one per shift
for each hammer |
Contents of QC inspection folder; steel buggy/tub tag, blue prints; Production
Floor Traveler |
Help crew determine match for initial setup;
check heat code on part against heat code slip and tag on steel buggy or
tub; record hand-held pyrometer readings on the Part Inspection Sheet along
with date, time and Inspector stamp; if reading
outside of forging temperature guidelines or Jobs Info (see
TOP-FTEMP), report
immediately to Production Supervisor; take first production part from
each die impression to perform a hot inspection; if the part(s) fail hot
inspection, that part and any part made after that fails will be scrapped
at the hammer and recorded in the Hammer Scrap Log; after an acceptable part is
made it will be quickly cooled and cleaned; perform part inspection by checking all critical dimensions of
the part(s) and record them on the Part Inspection Sheet
and in SPC Data Format; If there is a
change of process, production equipment, blow pattern or tooling, or any discrepancy
visually or dimensionally, notify assigned
Engineer via
e-mail, document the change or discrepancy by stating
the problem and cause with proposed plan of action on the inspection
remarks sheet; after the change is made,
immediately re-inspect and document the
resolution regarding changes, discrepancies, and/or failures on the Part
Inspection Sheet; any change in temperature or blow
pattern must be noted on the Hot Cell Sheet and on the
Traveler; initial or stamp with
employee stamp per
TOP-QARTI; (note: forging does NOT stop for inspection unless so
ordered); IF INSPECTION FAILS, REPORT IMMEDIATELY TO THE QC SUPERVISOR and PRODUCTION SUPERVISOR. |
Job begun with temperature, match
and lettering approved; Part Inspection Sheet completed and results entered in SPC
Data Format;
Engineer notified via e-mail of
any changes |
|
2 |
Production Supervisor or Leadman |
During forging; (typically every 30 minutes) |
Own judgment; verbal information
provided by Quality Control; steel buggy/tub tag; Production Floor Traveler |
Perform hot
inspection of sample
parts being produced (looking for problems of match, lettering, scale, fill,
shuts, trim and hot gauging; confirm
heat code and stamping; resolve any problems encountered; if special tagging
or inspection is needed (for example, if there is the possibility that parts
will need rework) tell the QC Inspector III or QC Specialist. |
At hammer QC duties
performed |
| 3 |
Hammerman |
Before each heat break (typically
every 30 minutes) |
Personal knowledge |
Check forgings just made for fill,
scale, match and obvious chops; notify QC Inspector III of any problems, so bad
or questionable parts are tagged; record scrap on Hammer Scrap Log; initial hammer log. |
Forgings checked for fill, scale,
match and obvious chops; QC Inspector III notified of any problems; scrap recorded on Hammer Scrap Log; hammer log
initialed that this was done |
| 4 |
QC Inspector
II |
During forging; once each
"inspection cycle" (typically every 30
minutes) |
Contents of QC Inspection folder; Production Floor Traveler;
heat code slip, steel buggy/ tub tag, blue print,
Hotcell |
Verify heat codes; tag parts
containers not being initialed by originator and move to cooling /cleaning area; verify
Hotcell and Traveler is being strictly followed;
REPORT ANY PROBLEM OR QUESTION TO THE QC SPECIALIST; during the forging process
if there are any authorized changes to the parts or process the changes will
be documented and a sample part will be
re-inspected to see if the parts are adversely affected. |
At-hammer duties, especially hot
inspection, performed on schedule, parts ready for cleaning per
TOP-BLAST |
| 5 |
QC Inspector
II |
During Forging, each
"inspection cycle" (typically every 30 minutes): as parts are cooled then
clean |
Contents of QC inspection folder,
tags on parts containers, blue print(s); Production
Floor Traveler |
Inspect (and gage if required) sample parts for visible defects unless the Production Floor Traveler specifies some
other scheme; keep containers
tagged; record
date, time, and inspector stamp, measure and chart any dimensions
required; enter date and record all problems and decisions regarding corrective
action (Note that a minimum of one part per die impression is to be
inspected each cycle and recorded in the SPC Data
Format; REPORT ANY PROBLEM OR QUESTION TO THE QC SPECIALIST OR QC SUPERVISOR (if the QC Specialist is unavailable and you believe that bad
parts are being produced, perform the QC Specialist reporting
responsibilities per step 6); tag and move bad or questionable parts to re-inspection table or other place designated by the QC Supervisor; note that in this step "problems include any out-of -tolerance reading, any delay cleaning parts for inspection, any
recurring reason that parts are being scrapped; any concern the QC Inspector
may have about the process being out of control, or any concern that
defective parts may have escaped detection; inspector discovering flaws must
complete the HOLD tag including the die number, heat code and a brief
description of flaw, disposition parts per TOP-NOCON ; ensure parts scrapped at the hammer are recorded by
the hammerman on the Hammer Scrap Log per TOP-SCRAP. |
Ongoing completion
of SPC Data Format; bad and questionable parts separated out; flaw noted on
HOLD tag; tag removed and destroyed after completion of inspection; scrap at the hammer recorded on Hammer Scrap Log |
|
6 |
QC Specialist or QC Inspector
II |
Upon believing that defective or
nonconforming forgings are being produced |
Own judgment and
maybe others' ideas |
Double check
available data to ensure that you do believe bad parts are being produced;
if so, report to Production Supervisor or Leadman for correction; if problem
persists and production is not stopped, you must continue to report your
concerns to higher levels of Management until the problem is solved,
production is discontinued or you are presented with evidence that convinces
you that the parts being produced are good ("it's okay because
I'm the boss and I say it is") is by no means acceptable; the Managers or
Supervisors to whom you report the problem must sign the Production Floor
Traveler if they want to continue to run parts after they are advised the
parts have problem (s); it is the Manager/Supervisor's responsibility
to make sure the Production Floor Traveler is signed; failure to do
this will be considered a major violation of this TOP; if a
Manager/Supervisor will not sign for a problem, the job is to be shut down
immediately; report the problem to the QC Supervisor. |
Parts only run
while QC and management are satisfied with quality |
|
Note:
Neither QC Inspectors nor QC Specialists are authorized to stop production,
but all other positions cited in this step (Leadman to President) are so
authorized.
|
|
7 |
QC Specialist or QC Inspector
III |
After a job is completed at
the forging level |
Production
Floor Traveler; in process dimensions; visual inspection |
Perform last part inspection
and document in
SPC
Data Format; any last part
that is saved will be recorded on the Final Inspection Report as scrap and recorded on the Post
Forge Scrap Log and
scanned into M2M; place completed QC folder and Production Floor Traveler in
rack for further processing by Post Forge per
TOP-BLAST.
When dies or tooling exhibit excessive wear,
visual or dimensional problems fill out an Internal Process Review Form;
forward to QC Supervisor. |
Last part
inspection complete; any problems found during forging are communicated as
the job moves through Post Forge; scrap recorded on
the Post Forge Scrap Log Internal Process Review Form forwarded
to QC Supervisor. |
|
8 |
QC Supervisor |
When
an Internal Process Review Form is turned in |
Internal Process Review Form |
Review Internal Process Review Form; disposition parts; fill out QC
Supervisor's part of the form; forward to the Engineer assigned to customer for
die/tooling review. |
Internal Process Review Form reviewed; parts dispositioned; form forwarded
to Engineer for die/tooling review |
