Trinity Operating Procedures - TOPs

TOP-JSTRT: Starting a Production Forging Job

Rev: 07/16/2020

Scope: This procedure covers the production steps to determine that a forging job needs to be run and the steps to get it started.

Procedure:

STEP	WHO	WHEN	INFO TO USE	WHAT TO DO
1	Production Scheduler	Demand for a Job Order appears in the Job Order Queue in M2M	M2M Job Order Queue; PDF file of Customer Purchase Order	Determine which Job Orders need released, quantity, any special instructions; if customer requires their heat code, edit BOM, All  orders need, at least, two setup parts (min) plus all required additional test parts. It is critical for orders below 150 to use this criteria. Notify Steelyard and Die Prep if "rush job".
2	Production Supervisor	As soon as possible as production needs change	Shop Schedule; Traveler; personal knowledge of production resources	Decide to start preparation for a forging job (sometimes based on what is currently stamped in die and/or print); assign first article part number per TOP-QARTI; verify the hammer blow pattern is printed on the Traveler.
3	Steelyard Leadman	Upon receiving BOM	Traveler; M2M inventory data	Carefully verify the BOM and Router; report any problems or questions back to Forging Engineer or Production Scheduler; if chemical check analysis is required, initiate TOP-CHEMC; Print Pick List; determine first lot to cut for the job; pull the bundle up to the shear or saw; write the bundle and heat code on the Traveler in large black letters and initial it; add heat code to Traveler in computer; print Traveler in Steelyard office; begin cutting steel. (TOP-CUTIT)
4	Die Prep Helper	As determine that a die needs to be prepared (may be because of Traveler, call from  Production Supervisor or simply Shop Schedule)	Shop Schedule; print or notes from computer or hard copy; Traveler; Material Reference List; QC Print	Pull the die from the racks (or from Die Shop); if there are multiple die versions, verify the die version pulled matches BOM; open die up; clean and polish dies and other tooling; repair any minor damage that you can; notify  Production Supervisor , VP-Quality & Engineering, Production Scheduler or Die Shop Supervisor if there are problems you cannot quickly fix; take QC Print and Traveler to the hammer; (DO NOT IGNORE ANY DIE OR TOOLING PROBLEM AND LET IT GET TO THE HAMMER); determine the correct lettering and stamp it in the die or use clay to read numbers and letters to avoid seeing a mirror image; if tooling for hot stamping is needed, send Traveler to Die Shop Die Preparer for assembly and check (see steps 5-9); insert the stencils (IF YOU HAVE QUESTIONS, ASK!); get Traveler from Steelyard office; sign the Traveler; call the Die Prep Leadman to verify the die and lettering and be sure they co-sign the Traveler; scan stamping approval into M2M; take the Traveler, die, and other tooling to die preheat furnace nearest hammer to be used; preheat to 400° F minimum; pre-heat trim tools.
5	Production Leadman	At heat code change (when hot stamping is used)	Shop Schedule; Traveler	Call Die Shop and inform Die Shop Helper of need for heat code change; determine if change can be done at the press or if the tooling needs to be taken to the die shop; if tooling needs to be taken to Die Shop provide them with the Traveler.
6	Die Shop Die Preparer	Upon receiving Traveler on a hot stamping job; do not continue unless Traveler is available	Traveler; QC Print	Assemble heat code for hot stamping; if forge die is not in Die Shop, notify Die Prep Helper that hot stamping tooling is ready; if forge die is in die shop; notify QC Inspector to check tooling; notify Die Prep Helper to pick up die.
7	Die Prep Helper	Upon notification that tooling for a hot stamping job has been prepared	Traveler	If forge die is in die prep area, retrieve hot stamping tooling from Die Shop, notify QC Inspector that tooling is ready to be checked; If both die and tooling were in die shop, retrieve assembled and checked die from die shop.
8	QC Inspector	Upon notification that die or hot stamp tooling has been prepared	Traveler; QC Print	Verify all stamping to the print and Traveler are clearly visible and correctly stamped; review condition of die/hot stamp tooling; if approve, initial or stamp Traveler and return Traveler to Die Prep Helper; if not approved notify Die Prep Leadman to redo all stamping to match QC Print and Traveler until approved by QC Inspector.
9	Die Prep Helper	When Traveler is returned from QC Inspector	Traveler	If hot stamp punch was assembled and checked in die shop, pick up hot stamp tooling.
10	Production Supervisor	Upon determining the need to change the planned production sequence of heat codes for a die after the Traveler has been initiated	Own judgment; Traveler; Container Tag	Match what the Traveler has generated and what containers of material have been cut; change the Traveler and tags as necessary to ensure they reflect the desired production sequence.
11	Production Supervisor	Traveler completed	Any changes to Router steps	Forward to VP-Manufacturing; request updated Router
12	VP-Manufacturing	Request made for Router changes	M2M past run history	Approve changes to Router; forward to Forging Engineer for Router update.
13	Forging Engineer	Router change approved	Standard Router; Traveler	Update Standard Router information; destroy Traveler

Revision history: