TOP-FORGE

Trinity Operating Procedures - TOPs

TOP-FORGE: Forging

Rev: 12/06/2017

Scope: This procedure covers the forging of parts, including setup of the equipment. This procedure alone by no means covers the entire control of the forging process. (See also TOP-TRAIN, TOP-JSTRT, TOP-CUTIT, TOP-CDCHG, TOP-AFTFG, TOP-FTEMP, TOP-IMPTL, TOP-BRKDN, TOP-QCTRL.)

Procedure:

STEP WHO WHEN INFO TO USE WHAT TO DO

1 Production Supervisor or Prodcution Leadman ("Foreman") When determines that it is time to set up job after completing TOP-JSTRT and having initial steel cut per TOP-CUTIT and when determining need to change process Shop Schedule; personal knowledge of shop activities; Steelyard Traveler; Inspection print Check to be sure all preliminaries are ready to begin setup; assign team members as Hammerman and other positions needed for the job and equipment; tell Hammerman any special instructions regarding job based on experience from last run; if needed, notify Die Prep Leadman to set up trim/punch tooling; place die warmer on trim tooling; notify QC Supervisor or QC Leadman if this job is to run on a previously idle hammer; notify Maintenance Leadman if special equipment is needed. If process changes, notify QC Supervisor or QC Leadman of need to modify (step-up) inspection.

2 Prodcution Leadman; Maintenance Leadman (if requested by Foreman) As Foreman reports new job being set up needing their services Foreman request Perform task as quickly as possible, calling on Production Helper, and Production Trimmer for help as needed; if there is any holdup or reason to think the quality of parts produced might be questionable, report to the Foreman immediately.

3 Hammerman (and others involved in set up) As assigned by Foreman Instructions from Foreman; Production Floor Traveler; Inspection Print Verify die number on Traveler, match tooling and container tags; as soon as setup is complete, forge first parts and inspect for mismatch and heat code letters and part numbers, get first steel heating; unless the job has already been partially run, and the container tags should show this to be the first container for the heat code; start a new line for the job on the Hammerlog showing at least the die number and the heat code ("code letter") on the part, on the container tags and on the Production Floor Traveler; adjust hammer and make test forgings until match looks good; as soon as possible trim (and punch, hot pad, bend or whatever as required) to produce test pieces and make adjustments until you and QC Inspector, Production Leadman or Production Supervisor agree that part looks good; scrap all defective parts and record them in the Hammer Scrap Log; if test bar is required by the Production Floor Traveler, work with Foreman to ensure that one is produced and marked with Job Order number and heat code; unless specifically ordered by Foreman or QC Leadman, do not hold up job waiting for full first-part inspection (the risk of scrap is just not worth the lost production time); document any changes that deviate from the Production Floor Traveler and forward to the Production Supervisor .

4 Hammerman Container full or at work center completion Router/Traveler and product tag Identify the next operation to be performed and identify back of product tag with next operation number.

5 Prodcution Leadman, QC Inspector, Hammerman At start-up when first set of production parts are forged Production Floor Traveler; Inspection Print Validate first forged parts; disposition any parts that are flawed or questionable; contact a QC team member when further assistance is required concerning flawed or questionable parts.

6 Hammerman (and hammer crew under his leadership)
After job is set up Personal observation; advice from QC Inspector or others; container tags; parts; furnace controls; Inspection Print; Production Floor Traveler Run job as productively as possible; keep Hammerlogs; Hammerman , Reliefman and Production Trimmer continually watch each hot part for forging defects; periodically check parts against Inspection print to assure compliance; Furnace Operator, Hammerman and Reliefman continually watch color of steel to prevent over-heats or under-heats; at least once each hour compare heat codes on tub/buggy, Production Floor Traveler and parts buggy; discard flashings into scrap tub, which is to be dumped into scrap bins as soon as full; put a tag on all containers of questionable parts telling job number and heat code (this step includes parts or billets awaiting reheating); make sure no parts are left behind the hammer and no billets are left around the furnace; IF THERE IS ANY QUESTION THAT BAD PARTS ARE BEING PRODUCED (OTHER THAN A FEW FROM SIMPLE FORGING ERRORS) STOP FORGING, INFORM QC INSPECTORr AND OTHER CREW MEMBERS, AND HAMMERMAN REPORT TO THE FOREMAN.

7 Production Supervisor or Steelyard Leadman When a job is pulled, but the order is not completed Shop Schedule; Hammerlogs; Production Floor Traveler Note on Production Floor Traveler the quantity of parts produced at the time the job was pulled; let the Foreman know what buggy letter was pulled so note can be added to the Shop Schedule; put the box of steel that was pulled in the Steelyard holding area, see Steelyard Leadman.

8 Hammerman At end of shift Hammerlogs Submit Hammerlogs with the correct die number and die configuration; if test bar is required by Production Floor Traveler, work with Foreman to ensure that one is produced and marked with job number and heat code.

9 Hammer Crew At the end of each job or at end of shift Production Floor Traveler; Hammerlogs Place all scrap parts in the designated scrap barrel or table at each hammer; Trimmer man is responsible for placing the scrap in the barrel and the Hammerman is responsible for obtaining the scrap count from the barrel and recording it on the Hammer Scrap Log and scanning into M2M; if the Production count does not equal the Steelyard count, the problem must be resolved at the end of each job; make sure no parts are left behind the hammer and no billets are left around the furnace.

10 Hammerman At end of job (or if down) None Report to Foreman for reassignment; on all jobs, report any issues to the Production Supervisor and QC Leadman in order to create Internal Process Review to document and resolve issues; tag with job number; make sure no parts left behind hammer; no billets left over before next job run.

11 Production Supervisor Typically daily Hammerlogs and Hammer Scrap Log Collect Hammerlogs and Hammer Scrap Log and forward to QA Assistant

12 QA Assistant Hammerlogs and Hammer Scrap Log received Hammerlogs and Hammer Scrap Log Enter Hammerlog and Hammer Scrap Log data into M2M.

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	Production Supervisor or Prodcution Leadman ("Foreman")	When determines that it is time to set up job after completing TOP-JSTRT and having initial steel cut per TOP-CUTIT and when determining need to change process	Shop Schedule; personal knowledge of shop activities; Steelyard Traveler; Inspection print	Check to be sure all preliminaries are ready to begin setup; assign team members as Hammerman and other positions needed for the job and equipment; tell Hammerman any special instructions regarding job based on experience from last run; if needed, notify Die Prep Leadman to set up trim/punch tooling; place die warmer on trim tooling; notify QC Supervisor or QC Leadman if this job is to run on a previously idle hammer; notify Maintenance Leadman if special equipment is needed. If process changes, notify QC Supervisor or QC Leadman of need to modify (step-up) inspection.
2	Prodcution Leadman; Maintenance Leadman (if requested by Foreman)	As Foreman reports new job being set up needing their services	Foreman request	Perform task as quickly as possible, calling on Production Helper, and Production Trimmer for help as needed; if there is any holdup or reason to think the quality of parts produced might be questionable, report to the Foreman immediately.
3	Hammerman (and others involved in set up)	As assigned by Foreman	Instructions from Foreman; Production Floor Traveler; Inspection Print	Verify die number on Traveler, match tooling and container tags; as soon as setup is complete, forge first parts and inspect for mismatch and heat code letters and part numbers, get first steel heating; unless the job has already been partially run, and the container tags should show this to be the first container for the heat code; start a new line for the job on the Hammerlog showing at least the die number and the heat code ("code letter") on the part, on the container tags and on the Production Floor Traveler; adjust hammer and make test forgings until match looks good; as soon as possible trim (and punch, hot pad, bend or whatever as required) to produce test pieces and make adjustments until you and QC Inspector, Production Leadman or Production Supervisor agree that part looks good; scrap all defective parts and record them in the Hammer Scrap Log; if test bar is required by the Production Floor Traveler, work with Foreman to ensure that one is produced and marked with Job Order number and heat code; unless specifically ordered by Foreman or QC Leadman, do not hold up job waiting for full first-part inspection (the risk of scrap is just not worth the lost production time); document any changes that deviate from the Production Floor Traveler and forward to the Production Supervisor .
4	Hammerman	Container full or at work center completion	Router/Traveler and product tag	Identify the next operation to be performed and identify back of product tag with next operation number.
5	Prodcution Leadman, QC Inspector, Hammerman	At start-up when first set of production parts are forged	Production Floor Traveler; Inspection Print	Validate first forged parts; disposition any parts that are flawed or questionable; contact a QC team member when further assistance is required concerning flawed or questionable parts.
6	Hammerman (and hammer crew under his leadership)	After job is set up	Personal observation; advice from QC Inspector or others; container tags; parts; furnace controls; Inspection Print; Production Floor Traveler	Run job as productively as possible; keep Hammerlogs; Hammerman , Reliefman and Production Trimmer continually watch each hot part for forging defects; periodically check parts against Inspection print to assure compliance; Furnace Operator, Hammerman and Reliefman continually watch color of steel to prevent over-heats or under-heats; at least once each hour compare heat codes on tub/buggy, Production Floor Traveler and parts buggy; discard flashings into scrap tub, which is to be dumped into scrap bins as soon as full; put a tag on all containers of questionable parts telling job number and heat code (this step includes parts or billets awaiting reheating); make sure no parts are left behind the hammer and no billets are left around the furnace; IF THERE IS ANY QUESTION THAT BAD PARTS ARE BEING PRODUCED (OTHER THAN A FEW FROM SIMPLE FORGING ERRORS) STOP FORGING, INFORM QC INSPECTORr AND OTHER CREW MEMBERS, AND HAMMERMAN REPORT TO THE FOREMAN.
7	Production Supervisor or Steelyard Leadman	When a job is pulled, but the order is not completed	Shop Schedule; Hammerlogs; Production Floor Traveler	Note on Production Floor Traveler the quantity of parts produced at the time the job was pulled; let the Foreman know what buggy letter was pulled so note can be added to the Shop Schedule; put the box of steel that was pulled in the Steelyard holding area, see Steelyard Leadman.
8	Hammerman	At end of shift	Hammerlogs	Submit Hammerlogs with the correct die number and die configuration; if test bar is required by Production Floor Traveler, work with Foreman to ensure that one is produced and marked with job number and heat code.
9	Hammer Crew	At the end of each job or at end of shift	Production Floor Traveler; Hammerlogs	Place all scrap parts in the designated scrap barrel or table at each hammer; Trimmer man is responsible for placing the scrap in the barrel and the Hammerman is responsible for obtaining the scrap count from the barrel and recording it on the Hammer Scrap Log and scanning into M2M; if the Production count does not equal the Steelyard count, the problem must be resolved at the end of each job; make sure no parts are left behind the hammer and no billets are left around the furnace.
10	Hammerman	At end of job (or if down)	None	Report to Foreman for reassignment; on all jobs, report any issues to the Production Supervisor and QC Leadman in order to create Internal Process Review to document and resolve issues; tag with job number; make sure no parts left behind hammer; no billets left over before next job run.
11	Production Supervisor	Typically daily	Hammerlogs and Hammer Scrap Log	Collect Hammerlogs and Hammer Scrap Log and forward to QA Assistant
12	QA Assistant	Hammerlogs and Hammer Scrap Log received	Hammerlogs and Hammer Scrap Log	Enter Hammerlog and Hammer Scrap Log data into M2M.