At any point in the manufacturing process product can be deemed a scrap item. Identification of scrap can be made by anyone, however, approval to scrap will only be done by a supervisory level person. Once supervision agrees that product is scrap then the data must accurately be recorded.

Scrap Recording

Scrap will be recorded at each work center throughout the process as the employee scans off of a specific job. In conjunction with scanning the scrap into M2M the employee must enter the scrap totals and scrap cause on the Scrap Log associated with their area. Steelyard scrap is scanned and the scrap causes are logged on to the Steelyard Scrap Log. Hammer scrap is scanned by the Hammerman only and the scrap causes are entered on the Hammer Scrap Log. Postforge scrap is scanned and the scrap causes are logged onto the Postforge Scrap Log. Machine and weld scrap is logged on Discrepancy Reports.

Entering Scrap Causes

Scrap Logs are gathered and delivered to clerks and entered on a daily basis. If the scrap causes or data is inaccurate the documents will be returned to the appropriate supervisor and fixed within 1 day. Machine and weld scrap is entered by the Machinin QC Supervisor twice weekly; in the Machining QC Supervisor's absence, the QC Leadman enters the machine and weld scrap twice weekly.

Scrap Reporting

Postforge QC Inspectors or Machining QC Inspectors will monitor total scrap %, using JobReport.xls, on each Job Order as the last step prior to releasing the job to Shipping. Report as per instructions below in Review and Approval. It is determined that 1/2% of the total cut quantity² is an allowable scrap miscount. Any lower threshold may be directed by specific customer requirements as recorded on the Router per TOP-TPSMM. Any more than this and the scrap must be researched and adjusted before the Job Order can be closed.

Scrap: Review and Approval

• Forge scrap exceeding 5% will have a review¹ led by the Forge QC Supervisor.
• Machine scrap exceeding 2% will have a review¹ led by the Machine QC Supervisor.
• Forge scrap exceeding 15% will have a CAR, per TOP-CARRR, created by Forge QC Supervisor.
• Machine scrap exceeding 5% will have a CAR, per TOP-CARRR, created by Machine QC Supervisor.

The QA Manager will use the spreadsheet ScrapReporting.xls to evaluate and monitor scrap cause, evaluate accuracy of scrap cause data input, and review cost associated with this scrap. In their respective areas, the Forging Superintendent and Machining Superintendent will conduct a weekly review of the scrap data and verify review of Job Orders that exceed the criteria established above, and present their findings to the VP-Manufacturing.  Any other relevant data discovered during this review will also be presented.

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² Total cut quantity equals the number of parts a billet can make.