VIII.  QUALITY CONTROL DURING MANUFACTURE

  1. MANUFACTURING ORDER AND TRAVELER
    1. THE PRODUCTION CONTROL DEPARTMENT WILL ISSUE A MANUFACTURING ORDER (SHOP ORDER) SHOWING ALL NECESSARY INFORMATION REQUIRED BY MANUFACTURING TO PRODUCE CASTINGS.
  2. FOUNDRY MELT CONTROL
    1. ALL CASTINGS POURED WILL BE ASSIGNED A HEAT NUMBER IF REQUESTED.
    2. THE MELTING DEPARTMENT WILL MAINTAIN A DAILY MELT LOG FOR EACH FURNACE OPERATED DURING THE SHIFT. THE LOG WILL INDICATE THE FOLLOWING:
      1. FURNACE NUMBER
      2. ALLOY
      3. TEMPERATURE
      4. ALLOY CONDITION
    3. THE QUALITY CONTROL REPRESENTATIVE ON DUTY OF THE FOUNDRY FLOOR WILL MONITOR THE LOGS THROUGH THE SHIFT TO INSURE ACCURATE AND TIMELY ENTRIES ARE BEING MADE.
    4. ALL ALLOYS SHALL BE COLOR-CODED BY PAINTING, INGOT, GATES, RISERS, ETC.
  3. FOUNDRY CONTROL
    1. FOUNDRY CONTROL INSPECTION SHALL CONSIST OF NON-DESTRUCTIVE AND, WHEN APPLICABLE, DESTRUCTIVE TESTING OF FIRST RUN SAMPLES IN ORDER TO ASCERTAIN WHETHER GATING AND POURING TECHNIQUES ARE ADEQUATE TO MAINTAIN CONSISTENCY DURING PRODUCTION.
  4. FIRST ARTICLE INSPECTION
    1. A FIRST ARTICLE DIMENSIONAL LAYOUT WILL BE PERFORMED, IF REQUIRED BY THE CUSTOMER, OR WHEN ANY OF THE FOLLOWING CONDITIONS EXIST:
      1. NEWLY BUILT TOOLING IS PUT INTO WORK
      2. TRANSFER TOOLING IS PUT INTO WORK
      3. DIMENSIONAL CHANGES ARE MADE TO EXISTING TOOLS
      4. FOUNDRY TECHNIQUES ARE CHANGED THAT MIGHT DIMENSIONALLY EFFECT CASTINGS
      5. MATERIAL IS CHANGED
      6. SPECIAL CUSTOMER REQUIREMENTS
  5. HOT INSPECTION
    1. THE HOT INSPECTOR WILL INSPECT ALL CASTINGS IMMEDIATELY AFTER POURING FOR DIRT, NON-FILLS, SHRINKAGE, AND DAMAGE.
  6. FLOOR INSPECTION
    1. THE FLOOR INSPECTOR WILL VISUALLY AND WITH THE AID OF CALIPERS, MICROMETERS, AND FIXTURES, INSPECT CASTINGS DURING THE CLEAN-UP AND STRAIGHTENING PROCESSES.
  7. FINAL INSPECTION
    1. THE FINAL INSPECTOR WILL, WITH THE AID OF NECESSARY INSPECTION TOOLS, JIGS, AND FIXTURES, ASCERTAIN THAT CASTINGS MEET THE DIMENSIONAL REQUIREMENTS OF CUSTOMER PURCHASE ORDER AND ENGINEERING DRAWINGS.
    2. THE FINAL INSPECTOR WILL ALSO ASCERTAIN THAT ALL REQUIRED SPECIAL PROCESSING, HEAT TREAT, PENETRANT, X-RAY, ETC., HAS BEEN PERFORMED.
    3. UPON COMPLETION OF FINAL INSPECTION, THE INSPECTOR WILL STAMP THE TRAVELER.
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