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TOP-PROQC: In-Process Quality Inspection
REV:02/01/10

Scope: This procedure covers Forging Division in-process quality inspection procedures

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 actinon 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; when the hammer is down note in the “COMMENTS” section in SPC Data Format such conditions that prevents the recording of inspection data. 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 form; forward to Engineering Assistant. Internal Process Review Form reviewed; parts dispositioned; form forwarded to Engineer for die/tooling review
9 Engineering Assistant Upon receiving Internal Process Review Form Internal Process Review Form; Quality Control Data; Production emails; Die review information Review Internal Process Review Form; add job die/tooling information; forward to the Engineer assigned to customer for die/tooling review. Job die/tooling information added; form forwarded to assigned Engineer.
10 Engineer Upon receiving Internal Process Review Form Internal Process Review Form Review Internal Process Review Form; determine if any changes are required to die/tooling; forward back to Engineering Assistant for processing and scanning. Internal Process Review Form reviewed; completed form forwarded to Engineering Assistant.
11 Engineering Assistant Upon receiving completed Internal Process Review Form Internal Process Review Form Review Internal Process Review form for any action required; enter die/tooling job requirements into M2M Standard Router or Item Master as required; scan document into system. Die/tooling job information entered; Internal Process Review Form scanned into system.

For information on a document or record, including definition, primary responsibility and retention, refer to the Document and Record Master List.

Documents are controlled only when viewed on-line in the original English -- printed copies or translations are not controlled documents.
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