TOP-CUTIT

Trinity Operating Procedures - TOPs

TOP-CUTIT: Cutting Raw Material

Rev: 12/06/2017

Scope: This procedure covers the activities involved with the cutting of steel, as well as other raw materials, for forging.

Procedure:

STEP WHO WHEN INFO TO USE WHAT TO DO

1 Buyer or Production Scheduler As customer heat codes are needed Raw Material Certs; customer generated cert reports; Customer POs; emails from customer Determine which bundle to use either by customer or oldest bundle; review mill heat notes entered by Buyer; delete original assigned lot and create a new one with correct heat code; place in order name field and in needed Router ops.

2 Steelyard Specialist As production needs and shear/saw time dictate Steelyard Traveler; M2M inventory info; bundle tags; BOM (Bill of Material) Review Steelyard Traveler and BOM; if a specific heat code or codes are specified for a job, this information will print out on the Steelyard Traveler; if a note appears on the Steelyard Traveler to get approval before cutting, contact Buyer for approval; determine which bundle (or maybe just heat code) to cut, mark it on the Steelyard Traveler and give it to the Steelyard Helper; assign heat codes, print and put on steelyard clipboard.

3 Steelyard Specialist Before cutting (or, if unable to use computer, as soon as possible) Steelyard Traveler; M2M inventory info Enter the Steelyard Traveler line into M2M to validate that the bundle chosen is correct for the job; IF THE COMPUTER GIVES ANY WARNING OR ERROR MESSAGE, HAVE THE SITUATION RESOLVED BY THE BUYER, PRODUCTION SUPERVISOR OR Production Scheduler; if an urgent need necessitates cutting before all info is available, initial "entered" column on Steelyard Traveler

4 Steelyard Helper Upon starting Steelyard Traveler or new heat code for same job Steelyard Traveler; bundle tags; billet Job Order Pick List a) Select the proper bundle of steel to cut from and pull the steel up to the shear/saw;
b) verify heat code and write the bundle ID on the Steelyard Traveler;

c) have Steelyard Specialist double check bundle I.D., heat code and material container tags;

d) separate out the bars to be cut, and measure the bars;

e) write the bar length on the Steelyard Cutting Sheet;

f) set the shear/saw for the right cut length;

g) take 2 SAMPLES from shear/saw to QC area; mark cutting sheet "Mag";

h) continue to shear/saw unless informed of any findings out of range of 1.6% of diameter;

i) if same job/code is on more than one shear/saw, repeat process for each shear/saw;

j) check for mill seams and note yes or no on Steelyard Cutting Sheet;

k) If "yes" get a Supervisor's approval; do not take cut steel with seams to hammer;

l) adjust the shear/saw to give a clean cut;
m) note on Steelyard Traveler if job is an "upset job" and measure billet weights for upset jobs;

n) IF THERE ARE ANY PROBLEMS OR QUESTIONS TELL THE STEELYARD SUPERVISOR OR PRODUCTION SUPERVISOR.

5 Steelyard Helper As cut steel Steelyard Traveler; container tags a) Cut steel per Steelyard Traveler into empty container (container must be completely empty);
b) if the Steelyard Traveler notes it is an "upset job", weigh the bar ends to see if it's usable (over billet weight is usable, under billet weight is not usable);

c) if it is usable, saw to the billet weigh;

d) make sure buggy/tub is kept tagged correctly;

e) stack bar ends to side and keep an ongoing count of bars cut and be sure Steelyard Traveler is right;

f) when the container is full, count parts either by hand or weight counting and enter count on container tag and Steelyard Traveler;

g) occasionally check bundle tag against buggy/tub tag and Steelyard Traveler;

h) watch for seams and cracks in bars being cut; frequently check cut length;

i) dispose of bar ends and any nonconforming material in containers marked for scrap;

j) REPORT ANY PROBLEMS OR QUESTIONS TO THE STEELYARD SUPERVISOR OR PRODUCTION SUPERVISOR.

6 Steelyard Helper As buggy/tub filled up Steelyard Traveler; container tags; job Pick List Be sure container is tagged correctly; move filled container to hammer staging area (or to hammer if rush) or stud welding staging area; unless through with bundle, tag next container including a letter (A, B, C) showing which container this is for this heat code and make sure tub/container is empty (no bar ends).

7 Steelyard Helper Whenever new bundle of steel will be of different heat code from last Steelyard Traveler; bundle and container tags; job Pick List Mark new container tag with "CODE CHANGE"; be sure Steelyard Leadman knows about code change.

8 Steelyard Specialist As steel of a new heat code is cut for a job Steelyard Traveler; M2M inventory info; job Pick List Ensure new code is approved for job; if job has heat code stamped in die; retain Steelyard Traveler in steelyard office until needed for production.

9 Steelyard Helper As receive container to stud Container tags Weld on studs; be sure container is tagged correctly; move container to hammer staging area (or to hammer if rush).

10 Steelyard Supervisor As requested by Production Supervisor, typically every other hour Own observation Be sure all hammers have enough steel; move steel from staging area to hammer as needed; think ahead and be sure appropriate jobs are being cut so that bottlenecks are avoided; tell Steelyard Helpers of rush situations; be sure all empty containers have old tags removed and remove any type billets or drop offs; container must be empty.

11 Steelyard Helper Upon completing Steelyard Traveler Steelyard Traveler; Material Reference List Retag any partially-cut bundle and return to bin; double-check Steelyard Traveler to be sure everything is finished; return Steelyard Traveler to Steelyard Supervisor.

12 Steelyard Supervisor Upon receiving completed Steelyard Traveler Steelyard Traveler; M2M; inventory info; job Pick List; Steelyard Cutting Sheet Be sure all steel needed has been cut, Steelyard Cutting Sheet has been properly filled out and all computer entries made; return Steelyard Traveler to steelyard office.

13 Steelyard Supervisor Weekly (more or less) Steelyard Cutting Sheet; Steelyard Traveler Keep Steelyard Cutting Sheet in the steelyard in box until job is complete and no likelihood that more steel will need to be cut (if more is needed same sheet can be sent back out to steelyard); forward Steelyard Traveler, Steelyard Cutting Sheet and Pick List to Buyer when completed.

14 Machining Clerk Weekly (more or less) As receive steelyard records from Steelyard Supervisor Scan Steelyard Traveler, Pick List and Cutting Sheet in numeric order in closed Steelyard Traveler file. Discard documents after scanning. into Steelyard Cutting Sheet Folder.

Revision history:

Release Date	Description of Change	Owner	Approver
12/06/2017	Updated to comply with revised Quality Manual and new TOPs format.	Tim Ellis	Todd Sheppard

Documents are controlled only when viewed on-line at trinityforge.com in the original English -- printed copies or translations are not controlled documents.
? Trinity Forge & Machine

STEP	WHO	WHEN	INFO TO USE	WHAT TO DO
1	Buyer or Production Scheduler	As customer heat codes are needed	Raw Material Certs; customer generated cert reports; Customer POs; emails from customer	Determine which bundle to use either by customer or oldest bundle; review mill heat notes entered by Buyer; delete original assigned lot and create a new one with correct heat code; place in order name field and in needed Router ops.
2	Steelyard Specialist	As production needs and shear/saw time dictate	Steelyard Traveler; M2M inventory info; bundle tags; BOM (Bill of Material)	Review Steelyard Traveler and BOM; if a specific heat code or codes are specified for a job, this information will print out on the Steelyard Traveler; if a note appears on the Steelyard Traveler to get approval before cutting, contact Buyer for approval; determine which bundle (or maybe just heat code) to cut, mark it on the Steelyard Traveler and give it to the Steelyard Helper; assign heat codes, print and put on steelyard clipboard.
3	Steelyard Specialist	Before cutting (or, if unable to use computer, as soon as possible)	Steelyard Traveler; M2M inventory info	Enter the Steelyard Traveler line into M2M to validate that the bundle chosen is correct for the job; IF THE COMPUTER GIVES ANY WARNING OR ERROR MESSAGE, HAVE THE SITUATION RESOLVED BY THE BUYER, PRODUCTION SUPERVISOR OR Production Scheduler; if an urgent need necessitates cutting before all info is available, initial "entered" column on Steelyard Traveler
4	Steelyard Helper	Upon starting Steelyard Traveler or new heat code for same job	Steelyard Traveler; bundle tags; billet Job Order Pick List	a) Select the proper bundle of steel to cut from and pull the steel up to the shear/saw; b) verify heat code and write the bundle ID on the Steelyard Traveler; c) have Steelyard Specialist double check bundle I.D., heat code and material container tags; d) separate out the bars to be cut, and measure the bars; e) write the bar length on the Steelyard Cutting Sheet; f) set the shear/saw for the right cut length; g) take 2 SAMPLES from shear/saw to QC area; mark cutting sheet "Mag"; h) continue to shear/saw unless informed of any findings out of range of 1.6% of diameter; i) if same job/code is on more than one shear/saw, repeat process for each shear/saw; j) check for mill seams and note yes or no on Steelyard Cutting Sheet; k) If "yes" get a Supervisor's approval; do not take cut steel with seams to hammer; l) adjust the shear/saw to give a clean cut; m) note on Steelyard Traveler if job is an "upset job" and measure billet weights for upset jobs; n) IF THERE ARE ANY PROBLEMS OR QUESTIONS TELL THE STEELYARD SUPERVISOR OR PRODUCTION SUPERVISOR.
5	Steelyard Helper	As cut steel	Steelyard Traveler; container tags	a) Cut steel per Steelyard Traveler into empty container (container must be completely empty); b) if the Steelyard Traveler notes it is an "upset job", weigh the bar ends to see if it's usable (over billet weight is usable, under billet weight is not usable); c) if it is usable, saw to the billet weigh; d) make sure buggy/tub is kept tagged correctly; e) stack bar ends to side and keep an ongoing count of bars cut and be sure Steelyard Traveler is right; f) when the container is full, count parts either by hand or weight counting and enter count on container tag and Steelyard Traveler; g) occasionally check bundle tag against buggy/tub tag and Steelyard Traveler; h) watch for seams and cracks in bars being cut; frequently check cut length; i) dispose of bar ends and any nonconforming material in containers marked for scrap; j) REPORT ANY PROBLEMS OR QUESTIONS TO THE STEELYARD SUPERVISOR OR PRODUCTION SUPERVISOR.
6	Steelyard Helper	As buggy/tub filled up	Steelyard Traveler; container tags; job Pick List	Be sure container is tagged correctly; move filled container to hammer staging area (or to hammer if rush) or stud welding staging area; unless through with bundle, tag next container including a letter (A, B, C) showing which container this is for this heat code and make sure tub/container is empty (no bar ends).
7	Steelyard Helper	Whenever new bundle of steel will be of different heat code from last	Steelyard Traveler; bundle and container tags; job Pick List	Mark new container tag with "CODE CHANGE"; be sure Steelyard Leadman knows about code change.
8	Steelyard Specialist	As steel of a new heat code is cut for a job	Steelyard Traveler; M2M inventory info; job Pick List	Ensure new code is approved for job; if job has heat code stamped in die; retain Steelyard Traveler in steelyard office until needed for production.
9	Steelyard Helper	As receive container to stud	Container tags	Weld on studs; be sure container is tagged correctly; move container to hammer staging area (or to hammer if rush).
10	Steelyard Supervisor	As requested by Production Supervisor, typically every other hour	Own observation	Be sure all hammers have enough steel; move steel from staging area to hammer as needed; think ahead and be sure appropriate jobs are being cut so that bottlenecks are avoided; tell Steelyard Helpers of rush situations; be sure all empty containers have old tags removed and remove any type billets or drop offs; container must be empty.
11	Steelyard Helper	Upon completing Steelyard Traveler	Steelyard Traveler; Material Reference List	Retag any partially-cut bundle and return to bin; double-check Steelyard Traveler to be sure everything is finished; return Steelyard Traveler to Steelyard Supervisor.
12	Steelyard Supervisor	Upon receiving completed Steelyard Traveler	Steelyard Traveler; M2M; inventory info; job Pick List; Steelyard Cutting Sheet	Be sure all steel needed has been cut, Steelyard Cutting Sheet has been properly filled out and all computer entries made; return Steelyard Traveler to steelyard office.
13	Steelyard Supervisor	Weekly (more or less)	Steelyard Cutting Sheet; Steelyard Traveler	Keep Steelyard Cutting Sheet in the steelyard in box until job is complete and no likelihood that more steel will need to be cut (if more is needed same sheet can be sent back out to steelyard); forward Steelyard Traveler, Steelyard Cutting Sheet and Pick List to Buyer when completed.
14	Machining Clerk	Weekly (more or less)	As receive steelyard records from Steelyard Supervisor	Scan Steelyard Traveler, Pick List and Cutting Sheet in numeric order in closed Steelyard Traveler file. Discard documents after scanning. into Steelyard Cutting Sheet Folder.