Trinity Operating Procedures - TOPs

TOP-IMPTL: Improving Tooling & Process

Rev: 12/06/2017

Scope: This procedure covers the actions taken by production management to improve tooling, material size and the forging process. It is divided up into three sections, any of which may pertain in a given instance. The first run of a die sometimes involves all three of the sections.

Procedure:

STEP	WHO	WHEN	INFO TO USE	WHAT TO DO
TO IMPROVE MATERIAL DIAMETER OR CUT
a1	Foreman*	As determine the material size used on a job could be improved	Personal observation; possibly discussion with Forging Engineer; Tooling Program	Change die info and notify Forging Engineer of steel changes needed via e-mail or IPR
a2	Forging Engineer	Upon receiving notification and report via email	Email notification from Foreman regarding steel changes needed. Tooling Program;	Verify feasibility of material size specified on message; if okay, update information in M2M, Tooling Program; if size feasible (unavailable or uneconomical) resolve material size with Foreman*
TO IMPROVE (OR REPAIR) TOOLING
b1	Foreman*	Upon determining that tooling needs improvement (either because it has deteriorated from use or because means of improving quality, reliability or economics have been identified)	Dies, flashings, sample parts, QC reports, etc.	Determine the extent of modification needed to the die or other tooling
b2	Foreman*	If change can easily be made in forge shop by Foreman	Decision from step b1	Make change to die; if the problem was due to the way the die was (re)sunk, or is new idea, provide Forging Engineer and Die Shop Supervisor a Die Improvement Slip
b3	Foreman*	If change requires Die Shop help	Decision from step b1	Have dies or other tooling pulled out and sent to Die Shop; tell Forging Engineer, Die Shop Supervisor or Die Shop Leadman what is required
b4	Die Shop Leadman, or Die Specialist	As requested by Foreman*	Verbal request	Make changes as quickly as possible then notify production (if repair looks to take longer than one shift, or if it must be sent to an outside supplier, notify Foreman of delay); if work is an attempt to improve tooling, give the Forging Engineer a Die Improvement Slip and/or a marked up Print or Die Layout showing the changes clearly.
b5	Foreman*	After repaired die returned by Die Shop	Notification from Die Shop	Check changes to die.
b6	Foreman*	If change requires die resink or rework by outside die shop	Decision from step b1	Have dies or other tooling pulled out and sent to Die Shop; tell Forging Engineer (or Die Shop Leadman what is required and provide IPR to Forging Engineer via e-mail, with a copy to Customer Service Representative, VP-Manufacturing , and Die Shop Supervisor.
b7	Engineer or Die Shop Leadman	As requested by Foreman*	IPR	Verify that die does need resinking; if not, get back with Foreman and discuss proper actions to take; if verify that die does need resinking, do so per TOP-SINKR, get estimate of time frame and notify Foreman and Production Scheduler of delay.
b8	Engineering Manager	Upon receiving Die Improvement Slip	Die Improvement Slip; own judgment	Review Die Improvement Slip, possibly after die change has been tried in production, and if agree that the improvement needs to be remembered at the next resink, put in file with Die Layout in Engineering File; take whatever action deemed appropriate
TO IMPROVE PROCESS (SUCH AS HAMMER PREFERENCE OR BLOW PATTERN)
c1	Foreman*	As identify different hammer preference for jobs	Own ideas, others' suggestions	Change hammer preference in M2M
c2	Any manager (typically Foreman or QC Supervisor)	Upon having suggestions to improve next run of job (or to record problems to watch for)	Own ideas, others' suggestions	Notify Forging Engineer of Traveler changes and make appropriate necessary updates in M2M.
c3	QC Supervisor	Upon notification of change to the Traveler	Notes received on required changes to Traveler	Update Traveler to reflect any suggested areas of concern on the next run

*"Foreman" as used in this procedure refers especially to the Production Supervisor or Leadman, but in some cases may involve VP-Manufacturing **Die Impression Cast Approval Letter will eventually replace Dies info, but until then information entered in both programs.

Revision history: