TOP-MWELD

Trinity Operating Procedures - TOPs

TOP-MWELD: Performing Welding Operations

Rev: 12/06/2017

Scope: This procedure covers production welding operations.

Procedure:

STEP WHO WHEN INFO TO USE WHAT TO DO

1 Machining Superintendent As need to assign Production Welder(s) to a job Machining Schedule; Production Floor Traveler; MPS Job Packet; own judgment Determine what tasks need to be accomplished and what resources are available; decide what welding equipment is to be used for which task and which Production Welder(s) are to be assigned (be sure that the Production Welder's expertise has been established per TOP-TRAIN); notify each Production Welder what equipment he/she is to operate and which operation is to be performed; be sure each team member has the appropriate Production Floor Traveler, MPS Job Packet, tools, fixtures and materials; answer questions and solve problems.

2 Production Welder Upon receiving assignment to perform welding operation Die Sinking Supervisor's instructions; Production Floor Traveler; print and MPS Job Packet Verify that Production Floor Traveler is complete and matches assignment; for production welding check heat code and material; check consumables availability; coordinate with Machining Department Material Handler for material to be delivered to work area; communicate to Materials Manager any weld consumables required.

3 Machining Department Material Handler
As welding jobs require material (typically dies; or tooling for die welding and machined parts; or forgings for production welding) Machining Department Supervisor's verbal instructions; Production Floor Traveler; container tags; Production Welder's comments Transfer forgings or machined parts from storage to work area; verify that container tags are correct; as operation progresses, keep materials supplied.

4a Production Welder Upon receiving parts for production welding Production Floor Traveler; print; own knowledge; Pocket Assembly Log Verify part and print match, Production Floor Traveler is correct and any machining has been properly completed; examine part against print; record first correct part produced on Part Inspection Sheet; assure air/gas mixture meets Welding Specifications per production floor traveler; use gages and/or measuring equipment per TOP-MSURE and TOP-CALIB to verify parts are being assembled to print; coordinate with Machining Department Supervisor to resolve any problems, bringing Machining Superintendent in as deemed appropriate; record all completed parts in the Assembly Process Log for traceability of welded components; turn any nonconforming or questionable parts over to QC Inspector with a Discrepancy Report at the end of each shift.

4b Production Welder Upon receiving dies or tooling for welding Production Floor Traveler; print; own knowledge Verify the die and Production Floor Traveler match and are correct; examine die for cracks/defects; perform dye penetrant check, arc gouge, peen and temper as required; maintain required temperature (pre-heat, post heat and cooling) during welding; assure air/gas mixture meets Welding Specifications per production floor traveler; use gages and/or measuring equipment per TOP-MSURE and TOP-CALIB; coordinate with Machining Department Supervisor to resolve any problems, bringing Die Shop Supervisor or Machining Superintendent in as deemed appropriate; turn over nonconforming or questionable dies to the QC Inspector with Discrepancy Report at end of each shift.

5 QC Inspector Upon receiving dies/parts for inspection Inspection Order; Inspection Records; Assembly Process Log; Production Floor Traveler; print; MPS Job Packet; own knowledge Verify that Inspection Order, print and part match; verify that Production Floor Traveler packet is in good order and that the Production Welder has properly completed his/her section of the Inspection Records; select measuring equipment per TOP-MSURE and TOP-CALIB; examine part against print per Inspection Order; verify that part meets specification and that Production Welder's measurements and gage settings are correct; coordinate with Production Welder to resolve any problem, bringing Machining Superintendent in as deemed appropriate; upon first-part buy-off, record results in Inspection Records then return documents to Production Welder; for nonconforming parts produced subsequent to first part buy-off document nonconforming dimensions on Discrepancy Report and submit to Machining Department Supervisor for disposition; Scan discrepant quantity under QC step in M2M.

6 Machining Superintendent During course of job Inspection Records; any documentation deemed appropriate; own judgment Observe running of welding operation; verify that documents are correct and welding is being run per plan; verify that Inspection Records are being maintained; review with the Production Welder and possibly other team members how potential problems could be minimized and how the operation could be improved.

7 Machining Department Material Handler As containers of welded parts are completed Production Floor Traveler; Assembly Process Log; container tags Ensure that containers are properly tagged; move container of parts to storage area; observe TOP-MORDR for warehousing and (if complete) transfer to Shipping with accompanying Production Floor Traveler and container tags; for partially-completed parts, ensure tags clearly indicate the stage of the parts' progress.

8 Production Welder As reach end of job All documents and remaining materials About 2 hours before you expect the job to finish; notify Machining Department Supervisor and Machining Department Material Handler; when last part is complete, clean up tools and machines, complete job per TOP-MORDR; leave work area in a clean and safe condition; alert Machining Department Supervisor you are moving to next assignment, scan off job in M2M; notify Machining Department Supervisor of any consumables that need to be replenished.

9 Production Welder When welding equipment is unable to operate properly for any reason; out of materials/consumables Own observation Scan downtime in M2M; notify Machining Department Supervisor and Machining Department Material Handler.

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.
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STEP	WHO	WHEN	INFO TO USE	WHAT TO DO
1	Machining Superintendent	As need to assign Production Welder(s) to a job	Machining Schedule; Production Floor Traveler; MPS Job Packet; own judgment	Determine what tasks need to be accomplished and what resources are available; decide what welding equipment is to be used for which task and which Production Welder(s) are to be assigned (be sure that the Production Welder's expertise has been established per TOP-TRAIN); notify each Production Welder what equipment he/she is to operate and which operation is to be performed; be sure each team member has the appropriate Production Floor Traveler, MPS Job Packet, tools, fixtures and materials; answer questions and solve problems.
2	Production Welder	Upon receiving assignment to perform welding operation	Die Sinking Supervisor's instructions; Production Floor Traveler; print and MPS Job Packet	Verify that Production Floor Traveler is complete and matches assignment; for production welding check heat code and material; check consumables availability; coordinate with Machining Department Material Handler for material to be delivered to work area; communicate to Materials Manager any weld consumables required.
3	Machining Department Material Handler	As welding jobs require material (typically dies; or tooling for die welding and machined parts; or forgings for production welding)	Machining Department Supervisor's verbal instructions; Production Floor Traveler; container tags; Production Welder's comments	Transfer forgings or machined parts from storage to work area; verify that container tags are correct; as operation progresses, keep materials supplied.
4a	Production Welder	Upon receiving parts for production welding	Production Floor Traveler; print; own knowledge; Pocket Assembly Log	Verify part and print match, Production Floor Traveler is correct and any machining has been properly completed; examine part against print; record first correct part produced on Part Inspection Sheet; assure air/gas mixture meets Welding Specifications per production floor traveler; use gages and/or measuring equipment per TOP-MSURE and TOP-CALIB to verify parts are being assembled to print; coordinate with Machining Department Supervisor to resolve any problems, bringing Machining Superintendent in as deemed appropriate; record all completed parts in the Assembly Process Log for traceability of welded components; turn any nonconforming or questionable parts over to QC Inspector with a Discrepancy Report at the end of each shift.
4b	Production Welder	Upon receiving dies or tooling for welding	Production Floor Traveler; print; own knowledge	Verify the die and Production Floor Traveler match and are correct; examine die for cracks/defects; perform dye penetrant check, arc gouge, peen and temper as required; maintain required temperature (pre-heat, post heat and cooling) during welding; assure air/gas mixture meets Welding Specifications per production floor traveler; use gages and/or measuring equipment per TOP-MSURE and TOP-CALIB; coordinate with Machining Department Supervisor to resolve any problems, bringing Die Shop Supervisor or Machining Superintendent in as deemed appropriate; turn over nonconforming or questionable dies to the QC Inspector with Discrepancy Report at end of each shift.
5	QC Inspector	Upon receiving dies/parts for inspection	Inspection Order; Inspection Records; Assembly Process Log; Production Floor Traveler; print; MPS Job Packet; own knowledge	Verify that Inspection Order, print and part match; verify that Production Floor Traveler packet is in good order and that the Production Welder has properly completed his/her section of the Inspection Records; select measuring equipment per TOP-MSURE and TOP-CALIB; examine part against print per Inspection Order; verify that part meets specification and that Production Welder's measurements and gage settings are correct; coordinate with Production Welder to resolve any problem, bringing Machining Superintendent in as deemed appropriate; upon first-part buy-off, record results in Inspection Records then return documents to Production Welder; for nonconforming parts produced subsequent to first part buy-off document nonconforming dimensions on Discrepancy Report and submit to Machining Department Supervisor for disposition; Scan discrepant quantity under QC step in M2M.
6	Machining Superintendent	During course of job	Inspection Records; any documentation deemed appropriate; own judgment	Observe running of welding operation; verify that documents are correct and welding is being run per plan; verify that Inspection Records are being maintained; review with the Production Welder and possibly other team members how potential problems could be minimized and how the operation could be improved.
7	Machining Department Material Handler	As containers of welded parts are completed	Production Floor Traveler; Assembly Process Log; container tags	Ensure that containers are properly tagged; move container of parts to storage area; observe TOP-MORDR for warehousing and (if complete) transfer to Shipping with accompanying Production Floor Traveler and container tags; for partially-completed parts, ensure tags clearly indicate the stage of the parts' progress.
8	Production Welder	As reach end of job	All documents and remaining materials	About 2 hours before you expect the job to finish; notify Machining Department Supervisor and Machining Department Material Handler; when last part is complete, clean up tools and machines, complete job per TOP-MORDR; leave work area in a clean and safe condition; alert Machining Department Supervisor you are moving to next assignment, scan off job in M2M; notify Machining Department Supervisor of any consumables that need to be replenished.
9	Production Welder	When welding equipment is unable to operate properly for any reason; out of materials/consumables	Own observation	Scan downtime in M2M; notify Machining Department Supervisor and Machining Department Material Handler.