Trinity Operating Procedures - TOPs

TOP-CASTS: Die Impression Casts

Rev: 12/06/2017

Scope: This procedure covers the inspection, approval and final dispostion of casts (dimensional representations of an impression of a forging die taken by pouring plaster or other material directly into the impression).

Procedure:

STEP	WHO	WHEN	INFO TO USE	WHAT TO DO
1	Die sinker or Die Shop Leadman	Upon receiving a newly (re) sunk or questionable die	Die number on die; own observations	Make one cast of each flash forming impression for any (re)sink, plus a second for new or modified dies (or if after cast(s) set, mark with die number, date, impression number, die sinker and shim thickness (if any); forward one cast of each impression to CMM Operator/Programmer.
2	CMM Programmer/Operator	Within 2 days of receiving cast	Forging Print with forging engineering notes on die sink tolerances and/or pattern; 3D Die Design Checksheet	Thoroughly inspect dimensions of cast (typically using CMM) or (scan dies with inspection arm and compare to 3D Model); for new or modified die also measure volume and calculate forging net weight from water displacement (if required); pass new weight on to appropriate Forging Engineer; give 3D Die Design Checksheet to Forging Engineer per TOP-SOLID.
3	Forging Engineer*	IF CAST IS DISAPPROVED INTERNALLY	3D Die Design Checksheet, Forging Print, pattern or previous cast	Determine degree of changes needed to die impression; notify Production Scheduler and team members listed on internal cast status via e-mail; report to VP-Quality & Engineering for die repair; temporarily hold 3D Die Design Checksheet unless in own judgment die repair is too minor to justify another cast; destroy disapproved cast and after die is corrected go back to Step 1.
4	Forging Engineer*	IF CAST IS APPROVED INTERNALLY	3D Die Design Checksheet	Notify Production Scheduler and team members listed on internal cast status via e-mail (be sure to notify A/R);  Verify M2M has been updated with new net weight, gross weight and material size.
5	Forging Engineer	Upon receipt of material size and weight via computer notification	Water weight & stock size	Enter material size, net weight and gross weight in M2M  .
IF CUSTOMER APPROVAL NOT NECESSARY, SKIP TO STEP 12
6	CMM Programmer/Operator	Cast is approved internally	Personal knowledge	Notify all Forging Engineering team members and Customer Service Representative that cast is approved.
7	Engineering Assistant	After receiving notification that cast is approved	Approval notification from CMM Programmer/Operator	Get Die Impression Cast Approval Letter ready; send cast and Die Impression Cast Approval Letter to customer; file copy of cover letter.
8	Engineering Assistant	Bi-weekly	List of outstanding cast approvals; Forging Engineering File	Check Forging Engineering Files to be sure approval has not been received: record notes on list; call customers who have not returned Die Impression Cast Approval Letter for 2 weeks (if approval is further delayed, notify sales person who services that customer's account).
9	Engineering Assistant	Upon receiving Die Impression Cast Approval Letter back	Die Impression Cast Approval Letter back from customer.	E-mail customer's approval/ disapproval; Die Impression Cast Approval Letter to Forging Engineer.
10	Forging Engineer	Upon receiving Die Impression Cast Approval Letter back	Die Impression Cast Approval Letter back from customer	Review and file cover letter in Forging Engineering File; determine next step; IF DISAPPROVED GO BACK TO STEP 3.
11	Forging Engineer	Once cast fully approved	Prints, Die Impression Cast Approval Letter, verbal communication	Turn cast (if any) over to Die Shop Leadman.
12	Die Shop Leadman	Upon receiving cast	Cast	Destroy cast and throw cast in trash.

* Forging Engineer" refers to the member of the Forging Engineering Department assigned the die in question. If there is any question as to which Forging Engineer is assigned a particular die, the VP-Quality & Engineering decides.

Revision history: