| STEP |
WHO
|
WHEN
|
INFO TO USE
|
WHAT TO DO
|
RESULTS
|
| STEPS 1 - 4 APPLY ONLY TO PURCHASE ORDERS
GENERATED WITHIN THE FORGING DIVISION (INCLUDING
THOSE GOING TO THE MACHINING
DEPARTMENT). |
| 1 |
Shipping Clerk, Shipping
Leadman |
When setting job up or upon determining a job
needs a subcontract service |
Jobs Info; Process Steps,
Production Traveler; less frequently: info received
from other team members or own observation; QA
Manager's instructions |
If Process Steps or Job info indicate customer
requirement for subcontract work, or if parts are
found to need outside rework and subcontractor is not
known notify QA Manager. |
Updated Process Steps |
| 2 |
*Engineer or QA Manager |
If question arises as to location of where
hardness is to be checked |
Specifications on print or customer
contact |
Add depth and location of hardness to QC print;
send one print to Shipping Clerk to be attached to
heat treat work order. Formalize print per
TOP-PRINT |
Location of hardness and depth marked; one print
forwarded to Shipping Clerk; new info added to master
drawing |
| 3 |
Post Forge Leadman; Shipping
Clerk |
Forgings are to be heat
treated |
Process Steps, print; notes in Jobs Info;
Traveler. |
If the process plan calls for separation by
furnace lot, any reheat treated parts must be kept
separated from the other parts of the same heat code
and coded differently unless all of that heat code is
reheat treated in the same furnace
lot. |
Determination made on how to handle reheat
treated parts requiring separation by furnace
lot |
| 4 |
QC Inspector; Post Forge team
member |
As parts are inspected after
forging |
Production Traveler |
Tag
containers with needed post-production
steps. |
Tagged containers of inspected
parts |
| 5 |
Post Forge Leadman; Post Forge Specialist;
Shipping Clerk |
Time to send parts out |
Jobs Info; Production Traveler;
container tags; Approved Supplier
List |
Choose subcontractor from Approved Supplier
List; prepare preliminary work order*; ensure
parts are weighed/counted and containers are properly
tagged/marked (be sure "ready for Heat
Treat" sticker is affixed to container); add
weight & count to preliminary work order; a copy
of MTRs (Mill Test Reports) to accompany parts
requiring tensile and charpy test. |
Subcontractor determined; preliminary work order
prepared; parts weighed and counted and containers
properly tagged/marked; weight and count added to
preliminary work order; MTRs sent with parts to heat
treater |
| *The Purchase Order is computer-generated from
M2M and can only be prepared for a supplier approved
for the particular type of subcontract
service. |
| REMAINING STEPS APPLY TO PURCHASE ORDERS
GENERATED FROM SHIPPING
DEPARTMENT. |
| 6 |
Shipping Leadman; Shipping Clerk;
Post Forge Supervisor |
After completing preliminary Purchase
Order or
receiving subcontractor Purchase
Order. |
Preliminary Purchase Order |
Complete Purchase Order and ensure that
arrangements have been made for getting parts to
subcontractor. |
Parts and paperwork ready for
subcontractor |
| 7 |
QA Manager; Shipping Leadman;
Shipping Clerk |
Purchase Order is completed except for review and
approval |
Process steps; notes from Jobs; Production and
Shipping schedule; Purchase Order |
Review and approve each Purchase Order that is
sent to an outside vendor; sign, stamp or initial,
and date. |
Each Purchase Order to an outside vendor reviewed and approved;
signed, stamped or initialed and
dated |
| 8 |
Post Forge Helper or Driver |
After receiving Purchase Order and when truck is ready |
Container tags; Purchase Order |
Turn parts over to subcontractor; have
subcontractor sign Purchase Order, keep 1 copy, give supplier 1 copy; 1 copy >placed in P.O.
file. |
Parts and 1 copy of Purchase Order in subcontractor's hands; one copy
of Purchase
Order to
Active Purchase
Order File;
one copy to Accounts Payable |
| 9 |
Authorized subcontractor |
Per schedule agreed to upon accepting Purchase
Order |
Purchase Order; other needed info such as copy of process steps
or customer spec |
Perform service ordered (CONTACT APPROPRIATE
TRINITY FORGE PERSONNEL TO RESOLVE ANY QUESTIONS
BEFORE PROCESSING PARTS). |
Processed parts returned with tagged containers,
packing slip and (if certified) 1 copy of
cert |
| 10 |
Shipping Leadman; Post Forge
Specialist |
When parts returned |
Container tags; Production
Traveler; Certifications; copy of Purchase
Order |
Ensure all parts have been returned, all
containers have been properly tagged, remove
"Ready for Heat Treat" sticker; move all
parts to next area, forward Production Traveler and shipping documents to
the QC Final Inspector for inspection of parts. NOTE:
Machined products can be easily damaged in handling
-- report any possible damage to Machining Department
Supervisor and QA Manager. |
Completed subcontract step; parts forwarded to QC
Department for inspection |
| 11 |
QC Production Inspector |
Upon receiving notification of returned
parts |
Traveler; print; any instructions from QC
Supervisor |
Examine parts received to determine if they meet
the requirements of the Purchase Order; heat codes
are traceable, quantities are correct, and steps in
the Traveler have not been skipped. If parts fail
inspection pass paperwork on to QC
Supervisor with details of
the nonconformity; otherwise, pass paperwork on
to Shipping Leadman or Shipping Clerk and skip Step
12. |
Inspection performed |
| 12 |
QC Supervisor; Machining Manager |
Upon notification that parts failed receiving
inspection |
Inspection data; copy of Purchase Order; print;
Production Traveler |
Have parts moved to MRB area. Make decision to
scrap or rework parts; resolve any issues and forward
paperwork to Shipping Leadman, Shipping
Clerk. |
Decision made to scrap or rework parts; issues
resolved, Paperwork forwarded to Shipping
Leadman; Shipping Clerk |
| 13 |
Shipping Leadman; Shipping
Clerk |
Upon receiving paperwork |
Returned paperwork; white copy of Purchase Order;
Production Traveler |
Close Purchase Order and print receiver, send
Purchase Order and Receiver to Accounts Payable;
certs to QA Assistant |
Computer updated; paperwork
done |
| 14 |
Production Control Manager |
At least twice per week |
Orders Due List, Job
Info; Purchase
Order status report in
M2M |
Check through outstanding Purchase Order to keep up with any that
are running late; involve Purchasing Manager for any
late jobs that are 1) not easily explained, or 2)
beyond 3 days late. |
No orders forgotten |
