TOP-PROQC

Trinity Operating Procedures - TOPs

TOP-PROQC: In-Process Quality Inspection

Rev: 12/06/2017

Scope: This procedure covers Forging Division in-process quality inspection procedures

Procedure:

STEP WHO WHEN INFO TO USE WHAT TO DO

1
QC Inspector During forging; as job begins to run (this includes a new crew moving to a different hammer since the QC Inspector moves with one or more crews, rather than being assigned a specific hammer); or as significant changes are made to die or process; at least one per shift for each hammer Contents of QC Inspection Folder; steel container tags; QC Prints; Production Floor Traveler Help crew determine match for initial setup; check heat code on part against in process parts container tag and tag on steel container; record hand-held pyrometer readings on the Part Inspection Sheet along with date, time and Inspector stamp; if reading outside of forging temperature guidelines or Production Floor Traveler info (see TOP-FTEMP), report immediately to Forging Superintendent; take first production part from each die impression to perform a hot inspection; if the part fails hot inspection, that part and any part made after that fails will be scrapped at the hammer and recorded in the Hammer Scrap Log; after an acceptable part is made it will be quickly cooled and cleaned; perform part inspection by checking all critical dimensions of the part and record them on the Part Inspection Sheet and in SPC Program if required; if there is a change of process, production equipment, blow pattern or tooling, or any discrepancy visually or dimensionally, notify Production Leadman , document the change or discrepancy by stating the problem and cause with proposed plan of action on the inspection remarks sheet; after the change is made, immediately re-inspect and document the resolution regarding changes, discrepancies, and/or failures on the Part Inspection Sheet; any change in temperature or blow pattern must be noted on the Traveler; initial or stamp with employee stamp per TOP-QARTI; (note: forging does NOT stop for inspection unless so ordered); IF INSPECTION FAILS, Click here for a helpful hint: Discrepancy Flow Chart ;REPORT IMMEDIATELY TO THE QC Supervisor when the hammer is down; note in the “COMMENTS” section in SPC Program such conditions that prevents the recording of inspection data.

Perform 100% inspection on first part on every Job Order for any kind of flaw (dimensional, laps, cold shuts and roll marks); grind trim line burrs to inspect for any trim tears and hidden flaws; if there are findings, stop job and notify QC Supervisor or Forging Superintendent .

2 Forging Superintendent, Production Leadman During forging (typically every 30 minutes) Own judgment; verbal information provided by Quality Control; steel container tag; Production Floor Traveler Perform hot inspection of sample parts being produced (looking for problems of match, lettering, scale, fill, shuts, trim and hot gaging); confirm heat code and stamping; resolve any problems encountered; if special tagging or inspection is needed (for example, if there is the possibility that parts will need rework) tell the QC Inspector; contact QC Supervisor to add Router steps to applicable Router with rework instructions; re-print Production Floor Traveler.

3 Hammerman , Crew Before each crew member takes a break (typically every 10 to 30 minutes) Personal knowledge Check 3 to 4 forgings just made for fill, scale, match and obvious chops; notify QC Inspector, Production Leadman or Forging Superintendent of any problems, so bad or questionable parts are tagged; record scrap on Hammer Scrap Log; initial Hammerlog.

4 QC Inspector During forging; once each "inspection cycle" (typically every 30 minutes) Contents of QC Inspection Folder; Production Floor Traveler; in process parts container tag; steel container tag, QC Prints
Verify heat codes; tag parts containers not being initialed by originator and move to cooling/cleaning area; verify Traveler is being strictly followed; REPORT ANY PROBLEM OR QUESTION TO THE QC Supervisor, Forging Superintendent AND LEADMAN; if there are any authorized changes to the parts or process during the forging process, document the changes and re-inspect a sample part to see if the parts are adversely affected; any changes to fix forging tooling issues or material issues verses additional spending costs for re-work in Post Forge has to be approved by the VP-Manufacturing, VP-Quality & Engineering orForging Superintendent.

NOTE: Any Inspector still in probationary period must have inspections verified by at least QC Leadman.

5 QC Inspector During forging, each "inspection cycle" (typically every 30 minutes): as parts are cooled then clean Contents of QC Inspection Folder, tags on parts containers, QC Print(s); Production Floor Traveler Inspect (and gage if required) sample parts for visible defects unless the Production Floor Traveler specifies some other scheme; keep containers tagged; record date, time, and inspector stamp, measure and chart any dimensions required; enter date and record all problems and decisions regarding corrective action (note that a minimum of one part per die impression is to be inspected each cycle and recorded); REPORT ANY PROBLEM OR QUESTION TO THE QC SUPERVISOR, FORGING SUPERINTENDENT AND PRODUCTION LEADMAN (if none are available and you believe that bad parts are being produced, perform the reporting responsibilities per step 6); tag and move bad or questionable parts to re-inspection table or other place designated by the QC Supervisor; inspector discovering flaws must complete the HOLD tag including the die number, heat code and a brief description of flaw, disposition parts per TOP-NOCON; ensure parts scrapped at the hammer are recorded by the Hammerman on the Hammer Scrap Log per TOP-SCRAP.

NOTE: If QC Inspector is still on 90 day probation, all checks must be verified by QC Leadman.

6 QC Inspector Upon believing that defective or nonconforming forgings are being produced Own judgment and maybe others' ideas Double check available data to ensure that you do believe bad parts are being produced; if so, report to Forging Superintendent or Production Leadman for correction; if problem persists and production is not stopped, you must continue to report your concerns to higher levels of management until the problem is solved,Click here for a helpful hint: Discrepancy Flow Chart, production is discontinued or you are presented with evidence that convinces you that the parts being produced are good; the manager or supervisor to whom you report the problem must sign the Production Floor Traveler if they want to continue to run parts after they are advised the parts have problem(s); it is the manager or supervisor's responsibility to make sure the Production Floor Traveler is signed; failure to do this will be considered a major violation of this TOP; if a manager or supervisor will not sign for a problem, the job is to be shut down immediately; report the problem to the QC Supervisor.

7 QC Supervisor Upon believing that defective or nonconforming forgings are being produced Information from QC Inspector; own knowledge of issue Update Router for any special rework requirements for any forging issues; increase inspection requirements for forging issues identified.

8
QC Inspector After a job is completed at the forging level Production Floor Traveler; in process dimensions; visual inspection Perform last part inspection and document in SPC Program; any last part that is saved will be recorded In the Inspection Report as scrap and recorded on the Post Forge Scrap Log and scanned into M2M; place completed QC Inspection Folder and Production Floor Traveler in rack for further processing by Post Forge per TOP-BLAST; when dies or tooling exhibit excessive wear, visual or dimensional problems fill out an Internal Process Review Form and forward to QC Supervisor.

9 QC Supervisor When an Internal Process Review Form is turned in Internal Process Review Form Review Internal Process Review Form; disposition parts; fill out QC Supervisor's part of Internal Process Review Form and forward to Engineering Assistant.

10 Engineering Assistant Upon receiving Internal Process Review Form Internal Process Review Form; quality control data; Production emails; die review information Review Internal Process Review Form; add job die/tooling information; forward to the Forging Engineer assigned to customer for die/tooling review.

11 Forging Engineer Upon receiving Internal Process Review Form Internal Process Review Form Review Internal Process Review Form; determine if any changes are required to die/tooling; forward back to Engineering Assistant for processing and scanning.

12 Engineering Assistant Upon receiving completed Internal Process Review Form Internal Process Review Form Review Internal Process Review Form for any action required; enter die/tooling job requirements into M2M, update M2M Standard Router or M2M Item Master as required; scan Internal Process Review Form into system.

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	QC Inspector	During forging; as job begins to run (this includes a new crew moving to a different hammer since the QC Inspector moves with one or more crews, rather than being assigned a specific hammer); or as significant changes are made to die or process; at least one per shift for each hammer	Contents of QC Inspection Folder; steel container tags; QC Prints; Production Floor Traveler	Help crew determine match for initial setup; check heat code on part against in process parts container tag and tag on steel container; record hand-held pyrometer readings on the Part Inspection Sheet along with date, time and Inspector stamp; if reading outside of forging temperature guidelines or Production Floor Traveler info (see TOP-FTEMP), report immediately to Forging Superintendent; take first production part from each die impression to perform a hot inspection; if the part fails hot inspection, that part and any part made after that fails will be scrapped at the hammer and recorded in the Hammer Scrap Log; after an acceptable part is made it will be quickly cooled and cleaned; perform part inspection by checking all critical dimensions of the part and record them on the Part Inspection Sheet and in SPC Program if required; if there is a change of process, production equipment, blow pattern or tooling, or any discrepancy visually or dimensionally, notify Production Leadman , document the change or discrepancy by stating the problem and cause with proposed plan of action on the inspection remarks sheet; after the change is made, immediately re-inspect and document the resolution regarding changes, discrepancies, and/or failures on the Part Inspection Sheet; any change in temperature or blow pattern must be noted on the Traveler; initial or stamp with employee stamp per TOP-QARTI; (note: forging does NOT stop for inspection unless so ordered); IF INSPECTION FAILS, Click here for a helpful hint: Discrepancy Flow Chart ;REPORT IMMEDIATELY TO THE QC Supervisor when the hammer is down; note in the “COMMENTS” section in SPC Program such conditions that prevents the recording of inspection data. Perform 100% inspection on first part on every Job Order for any kind of flaw (dimensional, laps, cold shuts and roll marks); grind trim line burrs to inspect for any trim tears and hidden flaws; if there are findings, stop job and notify QC Supervisor or Forging Superintendent .
2	Forging Superintendent, Production Leadman	During forging (typically every 30 minutes)	Own judgment; verbal information provided by Quality Control; steel container tag; Production Floor Traveler	Perform hot inspection of sample parts being produced (looking for problems of match, lettering, scale, fill, shuts, trim and hot gaging); confirm heat code and stamping; resolve any problems encountered; if special tagging or inspection is needed (for example, if there is the possibility that parts will need rework) tell the QC Inspector; contact QC Supervisor to add Router steps to applicable Router with rework instructions; re-print Production Floor Traveler.
3	Hammerman , Crew	Before each crew member takes a break (typically every 10 to 30 minutes)	Personal knowledge	Check 3 to 4 forgings just made for fill, scale, match and obvious chops; notify QC Inspector, Production Leadman or Forging Superintendent of any problems, so bad or questionable parts are tagged; record scrap on Hammer Scrap Log; initial Hammerlog.
4	QC Inspector	During forging; once each "inspection cycle" (typically every 30 minutes)	Contents of QC Inspection Folder; Production Floor Traveler; in process parts container tag; steel container tag, QC Prints	Verify heat codes; tag parts containers not being initialed by originator and move to cooling/cleaning area; verify Traveler is being strictly followed; REPORT ANY PROBLEM OR QUESTION TO THE QC Supervisor, Forging Superintendent AND LEADMAN; if there are any authorized changes to the parts or process during the forging process, document the changes and re-inspect a sample part to see if the parts are adversely affected; any changes to fix forging tooling issues or material issues verses additional spending costs for re-work in Post Forge has to be approved by the VP-Manufacturing, VP-Quality & Engineering orForging Superintendent. NOTE: Any Inspector still in probationary period must have inspections verified by at least QC Leadman.
5	QC Inspector	During forging, each "inspection cycle" (typically every 30 minutes): as parts are cooled then clean	Contents of QC Inspection Folder, tags on parts containers, QC Print(s); Production Floor Traveler	Inspect (and gage if required) sample parts for visible defects unless the Production Floor Traveler specifies some other scheme; keep containers tagged; record date, time, and inspector stamp, measure and chart any dimensions required; enter date and record all problems and decisions regarding corrective action (note that a minimum of one part per die impression is to be inspected each cycle and recorded); REPORT ANY PROBLEM OR QUESTION TO THE QC SUPERVISOR, FORGING SUPERINTENDENT AND PRODUCTION LEADMAN (if none are available and you believe that bad parts are being produced, perform the reporting responsibilities per step 6); tag and move bad or questionable parts to re-inspection table or other place designated by the QC Supervisor; inspector discovering flaws must complete the HOLD tag including the die number, heat code and a brief description of flaw, disposition parts per TOP-NOCON; ensure parts scrapped at the hammer are recorded by the Hammerman on the Hammer Scrap Log per TOP-SCRAP. NOTE: If QC Inspector is still on 90 day probation, all checks must be verified by QC Leadman.
6	QC Inspector	Upon believing that defective or nonconforming forgings are being produced	Own judgment and maybe others' ideas	Double check available data to ensure that you do believe bad parts are being produced; if so, report to Forging Superintendent or Production Leadman for correction; if problem persists and production is not stopped, you must continue to report your concerns to higher levels of management until the problem is solved,Click here for a helpful hint: Discrepancy Flow Chart, production is discontinued or you are presented with evidence that convinces you that the parts being produced are good; the manager or supervisor to whom you report the problem must sign the Production Floor Traveler if they want to continue to run parts after they are advised the parts have problem(s); it is the manager or supervisor's responsibility to make sure the Production Floor Traveler is signed; failure to do this will be considered a major violation of this TOP; if a manager or supervisor will not sign for a problem, the job is to be shut down immediately; report the problem to the QC Supervisor.
7	QC Supervisor	Upon believing that defective or nonconforming forgings are being produced	Information from QC Inspector; own knowledge of issue	Update Router for any special rework requirements for any forging issues; increase inspection requirements for forging issues identified.
8	QC Inspector	After a job is completed at the forging level	Production Floor Traveler; in process dimensions; visual inspection	Perform last part inspection and document in SPC Program; any last part that is saved will be recorded In the Inspection Report as scrap and recorded on the Post Forge Scrap Log and scanned into M2M; place completed QC Inspection Folder and Production Floor Traveler in rack for further processing by Post Forge per TOP-BLAST; when dies or tooling exhibit excessive wear, visual or dimensional problems fill out an Internal Process Review Form and forward to QC Supervisor.
9	QC Supervisor	When an Internal Process Review Form is turned in	Internal Process Review Form	Review Internal Process Review Form; disposition parts; fill out QC Supervisor's part of Internal Process Review Form and forward to Engineering Assistant.
10	Engineering Assistant	Upon receiving Internal Process Review Form	Internal Process Review Form; quality control data; Production emails; die review information	Review Internal Process Review Form; add job die/tooling information; forward to the Forging Engineer assigned to customer for die/tooling review.
11	Forging Engineer	Upon receiving Internal Process Review Form	Internal Process Review Form	Review Internal Process Review Form; determine if any changes are required to die/tooling; forward back to Engineering Assistant for processing and scanning.
12	Engineering Assistant	Upon receiving completed Internal Process Review Form	Internal Process Review Form	Review Internal Process Review Form for any action required; enter die/tooling job requirements into M2M, update M2M Standard Router or M2M Item Master as required; scan Internal Process Review Form into system.