TMS/SPECIALTIES SOP LIST - tmsco.com · TMS/SPECIALTIES SOP LIST ... remove the job and flip off switch. ... All maintenance performed on that machine will be compliance to the Lock

TMS/SPECIALTIES

SOP LIST

* - Specialties Old SOP’s combined with TMS __ - Specialties Old SOP’s -TMS SOP’S

SOP NO.

Rev. Issue date

Description

1 4/01/06 Pedestal grinder 14”– 6” (SOP > 1, 2, *6.5, *6.6)

3 4/01/06 Air to Blow Shavings and Dust 4 4/01/06 Bandsaw (SOP > *17.4) 5 4/01/06 Belt Sanders (SOP > 20) 6 4/01/06 Bench Drill (SOP > *5.1) 7 4/01/06 Bench Grinder (SOP > *6.5) 8 4/01/06 Blanchard Surface Grinder 9 4/01/06 Vertical & Horizontal Milling Machine (SOP > *12.1, *12.2 10 4/01/06 Cincinnatti Milling Machine 11 4/01/06 CNC Machine (SOP > *11.2) 12 4/01/06 Cranes and Hoist (SOP > *3, 20, *7) 13 4/01/06 Vertical Bandsaw (SOP > *17.2)

15 4/01/06 Engine Lathes (SOP > *11.1) 16 4/01/06 Flame Hardening (SPO > *28) 17 4/01/06 G&E Gear Machine 18 4/01/06 Gear (hobbers) 19 4/01/06 Handtools

21 4/01/06 Horizontal Bandsaw (SOP > *17.1) 22 4/01/06 Hydraulic Ram (SOP > *8) 23 4/01/06 Hydraulic Vertical Press 24 4/01/06 Impact/Air Tools (SOP > 14, *6.2) 25 4/01/06 Keyway and Broach Machine 26 4/01/06 Large Hand Grinders (SOP > *6.3) 27 4/01/06 Lockout/Tagout 28 4/01/06 Nails and Banding Material 29 4/01/06 Oil Bath 30 4/01/06 Oxygen / Acetylene (SOP > *22)

SOP NO.

Rev. Issue date

Description

31 4/01/06 Paint Spray Gun (SOP > *13) 32 4/01/06 Portable Circular Saw (SOP > *17.7) 33 4/01/06 Portable Electrical Hand Drill (SOP > *5.2) 34 4/01/06 Pneumatic Nail Driver 35 4/01/06 Radial Drill (SOP > *5.4) 36 4/01/06 Small Mills 37 4/01/06 Stick Welder (SOP > *24.3) 38 4/01/06 Fork Lift (SOP > *10) 39 4/01/06 Vehicles and Railroad Crossing 40 4/01/06 Wire Welder (SOP > *24.4) 41 4/01/06 Inspection Purchase Orders 42 4/01/06 Calibration of Outside Micrometer (SOP > *29.1) 43 4/01/06 Calibration of Depth Micrometer (SOP > *29.3) 44 4/01/06 Calibration of Inside Micrometer (SOP > *29.2) 45 4/01/06 Welding 46 4/01/06 Lifting 47 4/01/06 Turret Lathes 48 4/01/06 Shaper Machines 49 4/01/06 Color Code 50 4/01/06 Calibration of Height Gage 51 4/01/06 Crysta 707 Apex CMM 52 4/01/06 Horizontal Boring Machines 53 4/01/06 Liquid Nitrogen 54 4/01/06 Machine or Equipment Sampling Inspection Procedure 55 4/01/06 Vertical Lathes 56 4/01/06 6 ft Pexto Handbrake (SOP > 1.3) 57 4/01/06 10’-200 Ton Capacity Brake Press (SOP > 1.4) 58 4/01/06 Circle Burner (SOP > 2.2) 59 4/01/06 Line Burner (SOP > 2.1 & 2.3) 60 4/01/06 Plasma & Torch Cutting Machine (SOP > 4.2 & 4.4)



SOP NO.

Rev. Issue date

Description

61 4/01/06 Burny CNC & Linde Tracer Torch & Plasma Cutter (SOP > 4.1)

62 4/01/06 Koike Aronson Torch and Plasma Cutter (SOP > 4.3) 63 4/01/06 Porta-Magnetic Drill (SOP > 5.3)

64 4/01/06 Iron Workers Shear (SOP > 9) 65 4/01/06 Davi CNC Plate Roll (1”x 10’) (SOP > 14.1) 66 4/01/06 TSMC 1/2"x 8’ Plate Roll (SOP > 14.2) 67 4/01/06 Wysong 16 ga. x 72” Plate Roll (SOP > 14.3) 68 4/01/06 3/16” x 48” Plate Roll (SOP > 14.4) 69 4/01/06 Electric Pipe Threader (SOP > 15) 70 4/01/06 12” Cut Off Saw (SOP > 17.3) 71 4/01/06 Peerless Automatic Saw (SOP > 17.6) 72 4/01/06 Sand Blaster (SOP > 18) 73 4/01/06 12 ft Columbia Mechanical Shear (SOP > 19.1) 74 4/01/06 Standard 10’ – 1/2" Capacity Hydraulic Shear (SOP > 19.2) 75 4/01/06 Steam Cleaner (SOP > 21) 76 4/01/06 Water Table (SOP > 23) 77 4/01/06 Heli-Arc Welde (SOP > 24.1) 78 4/01/06 Rex-Spot Welder (SOP > 24.2) 79 4/01/06 Punch (SOP > 27) 80 4/01/06 Inside & Outside Calipers (SOP > 29.4) 81 4/01/06 Paint Gun Cleaner 82 4/01/06 Paint Pot 83 4/01/06 Paint Shaker 84 4/01/06 Paint Thinner Recycler 85 4/01/06 Brake Press (SOP > 1.1 & 1.2) 86 10/31/08 CNC Laser Cutter 87 4/15/09 Inspection Tolerances 88 6/30/09 TD Williamson Work Instruction 89 2/1/10 Process Control Expedited Orders “Normal Business Hours” 90 2/1/10 Process Control Expedited Orders “After Hours”

TMS / Specialties

Title: 6” Pedestal Grinder

J.W.

SOP # 1 (6.5)

Revision: 3/1/06

CONTROLLED Page 1 of 1

1 RESPONSIBILITY

1.1 The Supervisor is responsible for the training of the Standard Operation Procedure (SOP) of this machine.

2 PROCEDURE

2.1 Check rock, replace if needed. 2.2 Always keep steady rest 1/8” from the face and to give guard ¼” from rock. 2.3 Never grind on the side of the wheel, only on the face. 2.4 Turn switch on to start operation. 2.5 Bring material to rock. 2.6 When you are through grinding, remove the job and flip off switch. 2.7 Never apply pressure to rock to stop it from turning. 2.8 In an emergency, remove job from grinding rock, hit emergency stop button

and leave area. 2.9 The following personal protective equipment should be worn during this

operation: A. Safety Glasses. B. Steel Toe Safety Shoes. C. Close fitting clothing, nothing loose, sleeves rolled up or buttoned, apron

strings tied in back, and shirttail tucked in.

TMS / Specialties

Title: Pedestal Grinders

J.W.

SOP # 1 (6.6)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Check rock, replace if needed. 2.2 Always keep steady rest 1/8” from the face and to give guard ¼” from rock. 2.3 Never grind on the side of the wheel, only on the face. 2.4 Turn switch on to start operation. 2.5 Bring material to rock. 2.6 When you are through grinding, remove the job and flip off switch. 2.7 Never apply pressure to rock to stop it from turning. 2.8 In an emergency, remove job from grinding rock, hit emergency stop button




TMS / Specialties


J.W.

SOP # 1, *6.5, *6.6

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 All maintenance performed on that machine will be compliance to the Lock

Out Tag Out procedure. 2.2 If rock needs changing, see your supervisor.

2.3 Always keep steady rest 1/8” from the face.

2.4 Never grind on the side of the wheel, only on the face.

2.5 Check rock for any bad places on the wheel before turning switch on.

2.6 When through grinding, remove the job and turn off switch.

2.7 Never apply pressure to rock to stop rock from turning.

2.8 The following personal protective equipment should be worn during this



TMS / Specialties


J.W.

SOP # 2

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 All maintenance performed on that machine will be compliance to the Lock Out Tag Out procedure.

2.2 If rock needs changing, see your supervisor.

2.3 Always keep steady rest 1/8” from the face.

2.4 Never grind on the side of the wheel, only on the face.

2.5 Check rock for any bad places on the wheel before turning switch on.

2.6 When through grinding, remove the job and turn off switch.

2.7 Never apply pressure to rock to stop rock from turning.




TMS / Specialties

Title: Air to Blow Shavings and Dust

J.W.

SOP # 3

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY

1.1 The Supervisor is responsible for the training of the Standard Operation Procedure (SOP) of this device.

2 PROCEDURE

2.1 Only OSHA approve nozzles shall be installed for use in blow down operations.

2.2 All personal using Air will be instructed in its proper and safe use. New employees will be trained when hired.

2.3 When blowing chips and dust from machines, operator should wear proper safety equipment such as Glasses, Gloves, Mask, etc.

2.4 Always direct Air away from your body and try not to blow in the direction of other employees.

2.5 Do not blow into a fan or other air path which will transport particles and dust to other areas, dust particles can be carried along ways and irritate others in the Air path.

2.6 When blowing in a blind hole position yourself so the discharged chips will not hit your body, when possible cover the hole with a loose rag.

2.7 Do not play with Air, do not point Air at anyone, Air can impel particles into the skin and Air itself can cause burns and injuries.

2.8 Any employee found not using Air safely will be reprimanded and if continues to abuse the rules will be dismissed.

2.9 The following personal protective equipment should be worn during this operation: A. Safety Glasses. B. Steel Toe Safety Shoes. C. Close fitting clothing, nothing loose, sleeves rolled up or buttoned, apron


TMS / Specialties

Title: Horizontal Band Saw

J.W.

SOP # 4 (17.4)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Check that all guards are in place. 2.2 Place job on the saw table and secure. 2.3 Flip switch to start and cut. 2.4 When finished, turn switch to off position and remove part. 2.5 In an emergency, hit emergency stop button and leave the area. 2.6 The following personal protective equipment should be worn during this

operation: A. Safety Glasses. B. Steel Toe Safety Shoes. C. Work gloves. D. Close fitting clothing, nothing loose, sleeves rolled up or buttoned, apron


TMS / Specialties

Title: Manual Band Saw

SOP # 4 (17.5)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Raise blade with handle to upright position. 2.2 Place job on saw table and secure in vice. 2.3 Flip start switch. 2.4 Place hand on handle and advance blade just enough to cut material without

slowing blade. 2.5 Let blade go to it lowest position in order to obtain cut. 2.6 Return blade to its most upright position and stop saw. 2.7 When finished, stop saw, remove part and return saw blade to its lowest

position when not in use. 2.8 In an emergency, unplug saw and leave the area. 2.9 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Band Saw

J.W.

SOP # 4, *17.4

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY


2 PROCEDURE


2.2 Always keep safety guards in proper working position.

2.3 Keep the floor around the Band Saw clear of waste and scrap materials.

2.4 Avoid overloading the Band Saw. 2.5 Keep your hands and fingers from extending over the edge of the stock. 2.6 Do not attempt to raise or lower the guide while Saw is in motion.

2.7 When a Saw blade breaks, shut off the Band Saw and let wheel stop before

changing.

2.8 Never push work with your hands in line with the Saw blade.

2.9 When Saw blade is dull, change immediately.



TMS / Specialties

Title: Horizontal & Vertical Belt Sanders

J.W.

SOP # 5 (20)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Turn on belt sander. 2.2 Hold part firmly with both hands and place against belt. 2.3 Never use excessive force because this will stall the motor or damage the

belt. 2.4 When finished turn the machine off. 2.5 In an emergency, hit emergency stop button and leave area. 2.6 The following personal protective equipment should be worn during this


strings tied in back, and shirttail tucked in. D. Work gloves.

TMS / Specialties

Title: Belt Grinding

J.W.

SOP #5, (20)

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY


2 PROCEDURE


2.2 The following personal protective equipment must be worn during grinding.

A. Safety Glasses. B. Steel Toe Safety Shoes. C. Face Shield.

2.3 Check Belt for cuts or worn areas. 2.4 Check Belt for correct tension.

2.5 Make sure table rest is not over 1/8” from Belt.

2.6 Adjust Belt to keep it in center of pulley.

TMS / Specialties

Title: Bench Drill

J.W.

SOP # 6 (5.1)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Place materials in vice and clamp securely in such a manner the bit will not

damage the vice or drill table. 2.2 Flip switch on. 2.3 Manually feed drill with lever located on the side. 2.4 Bring the drill back up, turn power off, and remove the material. 2.5 In an emergency, hit emergency stop button and leave area. 2.6 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Bench Drill

J.W.

SOP #6, *5.1

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY


2 PROCEDURE


2.2 Put Drill bit in chuck and tighten securely.

2.3 Place part in a vice or clamp to table securely.

2.4 Bring Drill bit down to part with lever first.

2.5 Bring Drill bit back up, turn switch off before removing the part.



strings tied in back, shirttails tucked in.

TMS / Specialties

Title: Bench Grinder

J.W.

SOP # 7

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY


2 PROCEDURE


2.2 Always keep safety guards in proper working position.

2.3 Keep the floor around the Bench Grinder clear of waste and scrap materials.

2.4 Before grinding, inspect grinding rock for any bad pleases or creaks that may

be on it. 2.5 Avoid overloading the Bench Grinder. 2.6 Keep tool rest set 1/8” from the wheel.

2.7 Stand to one side of the Bench Grinder when starting the wheel.

2.8 Never use a rag to hold the object that is being ground. Hold small objects in

a jig or some kind of clamping device.

2.9 Report any mechanical or physical hazard that comes to your attention.

2.10 The following personal protective equipment must be worn during this operation: A. Safety Glasses. B. Steel Toe Safety Shoes.

TMS / Specialties

Title: Blanchard Surface Grinder

SOP # 8

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY


2 PROCEDURE

2.1 In an Emergency, press the Red Emergency Shut Off Button on the control

panel or turn main power off. 2.2 To start, turn main power on at the power box located on the wall at end of

the machine. 2.3 Always inspect Grinding Rock before starting machine. 2.4 Stand to one side of the wheel and push the start button. 2.5 All operators should be familiar with all machine controls and movements

before operating. 2.6 Be sure all guards and covers are properly in place. 2.7 Keep working area around machine clear of any obstacles. O. D. Grinder 2.8 Attach a driver to the work piece. 2.9 Mount part between centers in the machine. 2.10 Turn Grinding Wheel on; make sure it is clear of the part. 2.11 Engage spindle and touch off on the part. Blanchard and Surface Grinder 2.12 Put part on the table; make sure the Grinding Head is above it. 2.13 Turn the magnet on and bring the head over the part. 2.14 Turn the table and the Grinding Head on and touch off wheel to the part. 2.15 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Vertical Mill

J.W.

SOP # 9 (12.1)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Place job in vice or clamp and secure work. 2.2 Place cutting tool in to the vertical head. 2.3 Set cutting tool speed. 2.4 Set table speed to manual or automatic. 2.5 Set feed speed. 2.6 Once job is finished, stop machine and remove part. 2.7 In an emergency, stop machine and leave area. 2.8 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Horizontal Mill

J.W.

SOP # 9 (12.2)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Make sure cutting tool is clear of the table. 2.2 Place work on the machine table and secure. 2.3 Push start button and start machine. 2.4 Once job is finished, stop machine and remove part. 2.5 In an emergency, stop machine and leave the area. 2.6 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Bridgeport Vertical Milling Machine

J.W.

SOP # 9, *12.1, *12.2

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY


2 PROCEDURE


2.2 Place job vice or clamp to secure the part.

2.3 Place cutting tool into Vertical Head.

2.4 Push switch either forward or reverse depending on the tool.

2.5 Manually run table in the direction you want to cut in. 2.6 Place switch in middle position to turn off, wait for cutting tool to stop before

removing the part. 2.7 The following personal protective equipment should be worn during this


strings tied in back, shirttail tucked in.

TMS / Specialties

Title: Cincinnati Milling Machine

J.W.

SOP # 10

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY

1.1 The Supervisor is responsible for the training of the Standard Operation

Procedure (SOP) of this machine.

2 PROCEDURE


2.2 Check oil level by sigh glass daily.

2.3 Place work on the fixture on the machine, tighten the four allen screws to hold

the material, check height so cutter will clear the table.

2.4 Push start button, which will engage table travel forward.

2.5 When Table is all the way forward turn off machine, unscrew allen screws, remove work, blow fixture off with air, return table to original starting position.

2.6 In an emergency shut down, push stop button.

2.7 The following Personal Protective Equipment should be worn.

A. Safety Glasses. B. Steel Toe Safety Shoes. C. Close fitting clothing, nothing loose, sleeves rolled up or buttoned, apron

strings tied in back, and shirttails tucked in.

TMS / Specialties

Title: CNC Turret Lathe

J.W.

SOP # 11 (11.2)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Turn main power breaker on at rear of machine. 2.2 Press power on button located on right side of machine control. 2.3 When control comes on, the machine is in an e-stop condition. Reset e-stop

button and press reset on control panel. 2.4 Reference X, Y and Z-axis tool changer and tool chain as instructed in

operating manual. 2.5 Reference probe and tool length indicator. 2.6 Startup procedure is now complete and operator can now proceed to setup or

run the machine. 2.7 All operators should be familiar with all machine controls and movements

before operating. 2.8 Be sure all guards and covers are properly in place and all doors are closed

and fastened during operation of machine. 2.9 When the job is complete, shut the machine down before unloading part. 2.10 In an emergency, hit emergency stop button, flip main power switch located

on the back of the machine and leave area. 2.11 The following personal protective equipment should be worn during this



TMS / Specialties

Title: CNC Machines

J.W.

SOP # 11, *11.2

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY


2 PROCEDURE


2.2 Start up procedure, air compressor must be on and air pressure must be at a minimum of 80 p.s.i.

2.3 Turn main power breaker on at rear of machine. 2.4 Press power on button located on left side of machine controls. 2.5 When controls come on the machine is in an E-Stop condition, reset E-Stop

button and press reset on the control panel. 2.6 Reference X, Y, Z, Axis, Tool Changer, and Tool Chain as instructed in

operating manual. 2.7 Reference Probe and Tool length indicator. 2.8 Startup Procedure is now complete and operator can now proceed to setup

or run the machine. 2.9 In operation of machine, all operators should be familiar with all machine

controls and movements before operating. 2.10 Notify immediate Supervisor if machine is malfunctioning in any way. 2.11 Keep working area around your machine clear of any obstacles that could

result in injury. 2.12 Use proper Tool Jig to hold Tools. 2.13 Make sure Cutting Tools are securely fastened and mounted in Spindle and

the work piece is properly mounted and held. 2.14 To shutdown machine press Emergency Stop button, press control off button

and then turn main breaker off at rear of machine. 2.15 The following Personal Protective Equipment should be worn during

operation: A. Safety Glasses. B. Steel Toe Safety Shoes. C. Work Gloves where you deem necessary.

TMS / Specialties

Title: Overhead Cranes

SOP # 12 (3)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Do not lift over capacity of crane or hoist. 2.2 Know the lifting capacity of chains and straps that are being used to lift a

load. Do no lift over the capacity. 2.3 Make sure load is centered on hook before lifting. 2.4 Never make side pulls that misalign cable with hoist drum. 2.5 Do not allow load to contact other objects. 2.6 Never leave operating position with load suspended. 2.7 If crane is not operating properly – do not use - report defects to supervisor. 2.8 Never stand under load. 2.9 Make sure you are familiar with the controls before operating with a load. 2.10 Always be aware of other cranes and where they are because if you run into

another crane that has a load, it could result in another person or yourself being injured.

2.11 All cranes must have a safety latch on the hook. 2.12 In an emergency, lower the load and leave area. 2.13 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Hoists

J.W.

SOP # 12 (7)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Check the chain and rigging for wear and check the safety latches to make

sure they are secured and operational. 2.2 Do not lift beyond capacity of hoist or rigging. 2.3 Do not stand under load while lifting. 2.4 Push down button to lower. 2.5 Hold load to steady until lowered. 2.6 In an emergency, lower load to the floor and leave area. 2.7 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Cranes and Hoist

J.W.

SOP # 12, *3, *7

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY


2 PROCEDURE


2.2 Check slings and hooks to be sure they are not worn or broken. 2.3 If using more then one sling be sure they are the same length and have the

same load rating. 2.4 Be sure that hoist chain is free and centered over load. 2.5 Lift load enough to tighten the sling to be sure the load is balanced and sling

capacity is sufficient. 2.6 Do not place hands, feet, or any body parts under load. 2.7 Be sure the route you will travel with the load is free of obstacles and

personal traffic. 2.8 Get help with moving or balancing load if it is too heavy or awkward for one

person to handle. 2.9 Exercise caution when lowering and releasing a load so it does not move,

roll, or settle after slings are released. 2.10 The following personal protective equipment should be worn during this

operation: A: Safety Glasses B: Steel Toe Safety Shoes

TMS / Specialties

Title: Vertical Band Saw

J.W.

SOP # 13 (17.2)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Make sure all guards are in place. 2.2 Turn switch on. 2.3 Place material on the saw table. 2.4 Use slide guide by blade to guide material across machine. 2.5 Slowly hand feed through the blade keeping hands away from the blade. 2.6 Turn switch off and remove cut part. 2.7 In an emergency, hit stop switch and leave area. 2.8 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Delta Vertical Band saw

J.W.

SOP #13, *17.2

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY


2 PROCEDURE


2.2 Make sure all guards are in place.

2.3 Turn switch on, located on the bottom left hand side of machine.

2.4 Place material on the saw table and clamp down.

2.5 Use slide guide by the blade to guide material into machine. 2.6 Slowly hand feed material through the blade. 2.7 Turn switch off before removing cut piece. 2.8 The following Personal Protective Equipment should be worn during this

operation: A: Safety Glasses. B: Steel Toe Safety Shoes. C: Close fitting clothing, nothing loose, sleeves rolled up or buttoned, apron strings tied in back, shirttail tucked in.

TMS / Specialties

Title: Die Grinder

J.W.

SOP # 14 (6.2)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Power up to the grinder by pressing air valve switch. 2.2 Hold with both hands depressing lever and apply to the metal. 2.3 When finished grinding, release lever. Store grinder in a safe place to prevent

it from getting knocked over. 2.4 In an emergency, release lever and push bit against metal to stop from

turning. Lay grinder down and leave area. 2.5 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Die Grinder

J.W.

SOP #14

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY


2 PROCDURE

2.1 Visually inspect airline by making sure all hose clamps are tight.

2.2 If there is any doubt as to the operational safety of the grinder, contact your Supervisor before you use it. Do not use the grinder if damage is observed.

2.3 Hold with both hands depressing lever and apply to the metal. 2.4 When finished grinding release lever and store grinder in a safe place to

prevent it from getting knocked off.

2.5 The following Personal Protective Equipment should be worn during this operation: A: Safety Glasses. B: Steel Toe Safety Shoes. C: Close fitting clothing, nothing loose, sleeves rolled up or buttoned, apron strings tied in back, shirttail tucked in.

TMS / Specialties

Title: Clausing Lathe (17” & 15”)

SOP # 15 (11.1)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Check all guards to be in place and all objects removed from the chuck. 2.2 Make sure machine is in neutral. 2.3 Push start button to start machine. 2.4 Take job, place it in the chuck, tighten the chuck with chuck key, remove

chuck key and proceed to machine by moving lever to make chuck turn. 2.5 Set speed and feed for desired application. 2.6 To stop the chuck, push manual foot brake or disengage lever wait for chuck

to stop, loosen the chuck, remove the work and push the stop button. 2.7 In an emergency, hit emergency stop button and leave area. 2.8 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Engine Lathes

J.W.

SOP #15, *11.1

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY


2 PROCEDURE

2.1 All maintenance performed on this machine will be compliance to the Lock Out Tag Out procedure.

2.2 All operators should be familiar with all machine controls and movements

before operating.

2.3 Be sure all guards and covers are properly in place during operation of machine.

2.4 Notify Supervisor if machine is malfunctioning in any way. Do not run

machine. 2.5 Do not attempt to stop chuck from rotating by hand. Allow it to stop by itself. 2.6 Remove chuck wrench from chuck before starting, never leave the wrench in

the chuck and leave the machine unattended. 2.7 Make sure cutting tools are securely fastened and the work piece is properly

held. 2.8 The following Personal Protective Equipment should be worn during this

operation: A: Safety Glasses. B: Steel Toe Safety Shoes. C: Close fitting clothing, nothing loose, sleeves rolled up or buttoned, apron strings tied in back, shirttail tucked in.

TMS / Specialties

Title: FLAME HARDENING

J.W.

SOP # 16, *28

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY 1.1 The Supervisor is responsible for the training of the Standard Operation

Procedure (SOP).

2 PROCEDURE


2.2 The safety committee cannot anticipate all possible factors that could cause an accident, but are listing general safety considerations as an aid to the operator becoming safety oriented.

2.3 In case of accident while using tools, notify supervisor and get medical

attention if needed. 2.4 Visually inspect every hand tool before using it. Look for excessive wear on

any part of the tool. Look for cracks that may have developed from prior use. Check to see if the tool has been damaged in any way.

2.5 Make sure you use the proper tool for the job. Never put yourself in danger by

using the wrong tool.

2.6 Never leave tools on the floor where they could be stepped on, tripped over or damaged.


operation: A. Safety Glasses. B. Steel Toe Safety Shoes.

TMS / Specialties

Title: G & E GEAR MACHINE

J.W.

SOP # 17

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE


2.2 Press Red emergency off button located on right side of gear machine

viewing from the front.

2.3 If circumstances prevent operator from doing the above, turn main power off at main power control panel or power inlet box.

2.4 Turn reset button clockwise to release



and fastened during operation of machine.

2.7 Notify immediate supervisor if machine is malfunctioning in any way. Do not run machine.

2.8 Keep working area around your machine clear of any obstacles that would

result in injury.

2.9 Select arbor, hob, and fixtures suitable for parts to be cut and install on machine.

2.10 Set lead angle on head.

2.11 Select and mount change gears for the particular gear your are going to cut.

2.12 Set rpm’s for the machine.

TMS / Specialties

Title: G & E GEAR MACHINE

J.W.

SOP # 17

Revision: 3/1/06

CONTROLLED Page 2

2.13 Turn on the power. 2.14 Start table turning and indicate the work piece.

2.15 Traverse head up or down to clear work piece.

2.16 Set depth of cutter

2.17 Touch off on outside diameter of the gear

2.18 Start spindle and engage the feed for the head



TMS / Specialties

Title: GEAR (HOBBERS)

J.W.

SOP # 18

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE


2.2 Press Red emergency off button located on right side of gear machine

viewing from the front.


2.4 Turn reset button clockwise to release



and fastened during operation of machine. 2.7 Notify immediate supervisor if machine is malfunctioning in any way. Do not

run machine.

2.8 Keep working area around your machine clear of any obstacles that would result in injury.

2.9 Select arbor, hob, and fixtures suitable for parts to be cut and install on

machine. 2.10 Set lead angle on head.

2.11 Select and mount change gears for the particular gear your are going to cut.

2.12 Set rpm’s for the machine.

TMS / Specialties

Title: GEAR (HOBBERS)

J.W.

SOP # 18

Revision: 3/1/06

CONTROLLED Page 2

2.13 Turn on the power. 2.14 Start table turning and indicate the work piece.

2.15 Traverse head up or down to clear work piece.

2.16 Set depth of cutter

2.17 Touch off on outside diameter of the gear

2.18 Start spindle and engage the feed for the head



TMS / Specialties

Title: HAND TOOLS

J.W.

SOP # 19

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 In case of accident while using tools, notify supervisor and get medical attention if needed.

2.2 Visually inspect every hand tool before using it. Look for excessive wear on

any part of the tool. Look for cracks that may have developed from prior use. Check to see if the tool has been damaged in any way.

2.3 Make sure you use the proper tool for the job. Never put yourself in danger by

using the wrong tool.

2.4 The following personal protective equipment should be worn during this operation: A. Safety Glasses. B. Steel Toe Safety Shoes.

TMS / Specialties

Title: HOIST

J.W.

SOP # 20

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY 1.1 The Supervisor is responsible for the training of the Standard

Operation Procedure (SOP) of this machine.

2 PROCEDURE


2.2 Make sure object being listed does not exceed the rated capacity of

hoist. 2.3 Check chain/cable for worn or broken links.

2.4 Check electrical wire, push buttons or air hose for worn or broken

lines.

2.5 When lifting casting make sure they are secured with chain/hook.

2.6 Do not under any circumstances get any body parts under load wile lifted.

2.7 Always keep work area clean so if casting does fall you will have an

escape route.

2.8 Do not pull on electrical wire or air hose to move casting around in area.

2.9 Inspect chain/hooks or other lifting devices daily.

2.10 The following personal protective equipment should be worn during

this operation: A. Safety Glasses. B. Steel Toe Safety Shoes.

TMS / Specialties

Title: Hyd-Mech Saw (13” & 16”)

SOP # 21 (17.1)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Check coolant level in saw. 2.2 Turn power on. 2.3 Check blade for compatibility of material to be cut. 2.4 Make sure all guards are in place. 2.5 Set speed of blade for type of material to be cut. 2.6 Set frame advance. 2.7 Set height of frame allowing room under blade for material to advance. 2.8 Turn on coolant. 2.9 Set front and back clamps to width of material. 2.10 Set manual-automatic select switch to desired setting. 2.11 Load saw and place material in clamps, when you have correct length clamp

material in place. 2.12 In an emergency, hit emergency stop button and leave area. 2.13 The following personal protective equipment should be worn during this



TMS / Specialties

Title: HORIZONTAL BANDSAW

J.W.

SOP # 21, *17.1

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 Check to see if there is correct amount of cutting fluid in saw before starting, if not add fluid.

2.2 Check band saw blade for damage and sharpness. If damage or dull replace

blade. To change blade, disconnect power supply, open saw blade cover & let tension off blade by turning pulley tension knob. Remove old blade, install new blade, and tighten tension on blade and close cover.

2.3 Raise saw to highest position and lock in position.

2.4 Adjust saw vice to correct size and tighten piece to be cut into correct position

with blade.

2.5 Start saw by turning switch on. Unlock saw from highest position and saw will fall slowly until blade reaches part to be sawed. Watch closely when blade starts to cut into part to make sure it is cutting where you want it.

2.6 Adjust cutting fluid to correct amount before blade reaches part to be cut.

2.7 Do not leave saw unattended while cutting.

2.8 When part is cut saw will automatically stop. When finished loosen vise and

remove part.

2.9 In and emergency shut down, turn saw to off position and leave plant.

2.10 The following personal protective equipment should be worn during this operation: A. Safety Glasses. B. Steel Toe Safety Shoes.

TMS / Specialties

Title: Portable Hydraulic Ram

J.W.

SOP # 22 (8)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Check fluid in pump. 2.2 Check hoses for damage, leaks, etc. 2.3 Never operate beyond the capacity of this equipment. 2.4 Place ram squarely against work surface and surface to be moved. 2.5 Switch pump to the on position allowing fluid to enter ram, observing square

ness and position of ram at all times. Advance ram slowly in small increments, changing ram position as needed.

2.6 When changing position of ram, switch to off position to release fluid pressure from ram.

2.7 When finished with job, switch pump to off and remove ram. 2.8 In an emergency, turn pump off and remove ram. Place ram in safe place




TMS / Specialties

Title: HYDRAULIC RAM

J.W.

SOP # 22, *8

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE 2.1 In case of busted hydraulic line stay clear of pump and notify supervisor.

Clean up any hydraulic oil that may have spilled in the work area. 2.2 In case of draw bar breaking always stay clear of the in line path of draw

bars. Carefully dispose of broken bars or nuts. 2.3 In case of hydraulic oil getting in your eyes. Wash your eyes out at the wash

station in the break room. Then notify your supervisor. 2.4 Visually inspect hydraulic lines for holes, leaks or cracks. 2.5 Visually inspect hydraulic cylinder for cracks. 2.6 Visually inspect hydraulic pump for damage. 2.7 Make sure pressure gauge is working properly. 2.8 Inspect any rods or plates for damage. 2.9 Visually inspect any part pumping on or off and use the safest procedure. 2.10 Clear area where you will be using ram. Make sure that the path of the rod

has a clear path. 2.11 Close the valve on the pump and begin to pump the handle up and down.

Note: Never exceed 7500 PSI on the pressure gauge. If heat is necessary use a rose bud.

2.12 After pumping ram out always open valve to release the ram to allow it inside the cylinder.

2.13 Always make sure ram is inside cylinder. 2.14 Always clean hydraulic ram before storage. 2.15 Place ram in a safe and dry storage place. 2.16 The following personal protective equipment should be worn during this


TMS / Specialties Title: Hydraulic Vertical 90 Ton Press

J.W.

SOP # 23 (16)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Never press over the capacity of this machine. 2.2 Always check and make sure that the control lever is in the neutral position. 2.3 Set the table; adjust position to the job being pressed. 2.4 When pressing long vertical pieces, the material needs to be straight (no

angles). 2.5 Never stand directly in front of the machine. 2.6 When job is finished, return ram to the neutral position. 2.7 Remove the job; place a block of wood on the table and let the ram rest on it. 2.8 Make sure the control leaver is in the neutral position and push the stop

button. 2.9 In an emergency, hit emergency stop button and leave the area. 2.10 The following personal protective equipment should be worn during this



TMS / Specialties

Title: HYDRAULIC VERTICAL PRESS

J.W.

SOP # 23

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY


2 PROCEDURE

2.1 In an emergency shut down push stop button and leave the area.

2.2 Never press over 90 tons 2.3 All operators should be familiar with all machine controls and movements

before operating. 2.4 Always check and make sure that the control lever is in the neutral position 2.5 Push the start button. 2.6 Set the table; adjust position to the job pressing.

2.7 When pressing long vertical pieces, the material needs to be straight, no

angle.

2.8 Never stand directly in front of the machine, always to the side.

2.9 When completed pressing, return the ram to the neutral position.

2.10 Make sure the lever is in neutral position and push the stop button.




TMS / Specialties

Title: IMPACT/AIR TOOLS

J.W.

SOP # 24, *6.2

Revision: 3/1/06

CONTROLLED Page 1


Procedure (SOP).

2 PROCEDURE

2.1 Visually check all airlines for holes or cracks. Repair as needed. Check all clamps.

2.2 Visually check your air tool making sure there are no problems.

2.3 Add 2 to 3 drops of air tool oil to your tool each day you use them.

2.4 Inspect any sockets for cracks or broken areas.

2.5 Connect the tool to the airline. 2.6 Press button on tool to allow start up or operation of tool. 2.7 Make sure that you have the proper amount of air pressure.

2.8 Return tool to proper place after cleaning up tool.

2.9 Roll up air hose so it will not trip up any employee.


operation: A. Safety glasses B. Steel toe safety shoes C. Earplugs.

TMS / Specialties

Title: KEYWAY AND BROACH MACHINE

SOP # 25

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 If circumstances require, press the off or emergency shutdown button on the control panel.

2.2 If circumstances prevent operator from doing the above, turn main power off

at main power control panel or power inlet box.

2.3 Turn main power breaker on. 2.4 Startup procedure is now complete and operator can now proceed to setup or

run the machine.

2.5 All operators should be familiar with all machine controls and movements before operating.

2.6 Keep working area free of obstacles that may cause an injury.

2.7 The actual cutting operation can produce sharp edges and heat. Be aware.

2.8 Select proper broach, guide and fixtures for the work piece and install on the

machine.

2.9 Clamp work piece to the guide or fixture.

2.10 Turn machine to the on position.

2.11 The following personal protective equipment should be worn during this operation:

A. Safety glasses B. Steel toe safety shoes

TMS / Specialties

Title: Hand Grinders 4-1/2 & 9-1/2

J.W.

SOP # 26 (6.3)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Make sure that rock or grinding pads are properly tightened before starting

the grinder. Be aware of other employees around your work area. 2.2 Start grinder and hold with both hands. 2.3 When you are ready to grind, always hold grinder away from you. While you

are grinding surface, place grinder on material so it is pulling away from you. If you have to operate the grinder with it pushing toward you, always use extreme caution. Never allow grinder to be stopped suddenly by forcing it or wedging the rock or pad as this may result in an accident.

2.4 Unplug grinder and place in area that it will not be knocked over. Do not lay grinder down with the rock or pad touching the floor or any other surface. Do not hand grinder by rock or pad.

2.5 In an emergency, stop grinder by releasing switch, touch to metal surface to stop rock or pad. Place grinder down properly with rock or pad up and leave area.

2.6 The following personal protective equipment should be worn during this operation: A. Safety Glasses. B. Steel Toe Safety Shoes. C. Face shield D. Ear plugs (if needed) E. Close fitting clothing, sleeves rolled up or buttoned, shirttails tucked in and

apron strings tied in back.

TMS / Specialties

Title: Large Hand Grinders

J.W.

SOP # 26, *6.3

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 In case of busted rock or grinding material, unplug grinder and notify supervisor. Do not operate under unsafe conditions. Replace rock or grinder material.

2.2 Make sure all guards are in place.

2.3 Visually inspect all guards, stones, handles and cord.

2.4 Plug grinder up only if switch is not in the on position. 2.5 Make sure grinder is off the part you are grinding and press the button to start

up.

2.6 After grinding release button and place grinder against the part to stop the rock. Never store the grinder with the rock touching the ground or any other item. Always store grinder in a safe place, free from damage.


operation: A. Safety glasses B. Steel toe safety shoes C. Earplugs. D. Face shield.

TMS / Specialties

Title: Lockout /Tagout

J.W.

SOP # 27

Revision: 3/1/06

CONTROLLED Page 1


Procedure (SOP).

2 PROCEDURE

2.1 Make a survey to locate and identify all isolating devices such as switches, valves, or other energy devices which is to locked out and tagged out. More then one energy source (electrical or mechanical or other may need to be locked out.

2.2 Alert the operator and other users of the system to be shut off/down. 2.3 Plan the shutdown to ensure that the system will be off.

2.4 Place your padlock on the control switch, lever, or valve, even though

someone has locked the control before you. You will not be protected unless you put your own padlock on it.

2.5 Test the lockout to be sure the system is really off/down.

2.6 When through working remove your won padlock and tag. Never permit

someone else to remove your lock or tag.

2.7 Verify that the equipment is clear and post a watch if necessary.

2.8 Because of the grave risk to life, lockout procedures shall be a must with all maintenance personnel.

2.9 Employees are responsible for notifying maintenance supervisor of damaged

or inoperable lockout and locks in his possession.

2.10 The appropriate supervisors will coordinate shift Changes. Coordination will include, changing locks to insure that equipment remains locked out at all times during shift changes, retesting to insure de-energization, notification of start up and /or testing to be performed and changes in the job that may affect the hazardous energy control procedure.

TMS / Specialties

Title: Lockout /Tagout

J.W.

SOP # 27

Revision: 3/1/06

CONTROLLED Page 2

2.11 Outside personnel or contractors involved in lockout of equipment or machinery that affects in house employees must submit written energy control procedures to the maintenance supervisor prior to beginning work. All affected employees must be briefed in the contractor’s submitted procedures.

2.12 In order to protect in house employees, the contractor’s work area will be

isolated and access will be restricted whenever possible. If these cannot be accomplished, the maintenance supervisor must assure that the contractor complies with proper energy isolation procedure be observing work in progress.

2.13 Contractors failing to adhere to the provisions of the OSHA hazardous energy

control standard will be required to stop work until their program is brought into compliance to the satisfaction of the maintenance supervisor.


operation: A. Safety glasses B. Steel toe safety shoes

TMS / Specialties

Title: Nails and Banding Material

J.W.

SOP # 28

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 It is the policy of Talladega Machine & Supply to require anyone taking boxes apart or building boxes or receiving pallets that may have nails protruding out of such said material; that they be removed or bent over so that they shall not be a hazard of injuring anyone.

2.2 Steel banding material shall bot be left on the floor, hanging loose from

pallets or crates.

2.3 Caution will have to be made when cutting banding steel. Sudden release from the tension could cause injury.

2.4 It is recommended that gloves be worn when cutting the steel bands.


operation: A: Safety Glasses B: Steel Toe Safety Shoes

TMS / Specialties

Title: OIL BATH

J.W.

SOP # 29

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 In case of fire use your fire extinguisher to extinguish the flame and turn the burner off by the main valve.

2.2 In case of hot oil spill stay clear and notify immediate supervisor then wait until oil is cool before clean up.

2.3 If hot Oil gets on your skin cool burned area immediately with cool water, notify supervisor and get medical attention if needed.

2.4 Place container with oil in the center of a well-cleared area. 2.5 Run gas line to quick-connect coupling and place burner under container. 2.6 Carefully light pilot and main burner. 2.7 Never let oil exceed the flash point of 370 to 390 degrees. 2.8 Always place parts in the container before applying heat. 2.9 After heating part, always handle parts and container while hot with proper

gloves and safety equipment. 2.10 Turn burner off. 2.11 Disconnect gas line. 2.12 After cooling move burner and container back to the proper place. 2.13 Clean all oil up from the area. 2.14 Keep working area around your machine clear of any obstacles that would

result in injury. 2.15 The actual cutting operation can produce sharp edges, and heat. Be aware. 2.16 Make sure cutting tools and work piece securely fastened and mounted in

turret and the work piece is properly held. 2.17 The following personal protective equipment should be worn during this

operation: A. Safety glasses B. Steel toe safety shoes C. Proper gloves. D. Face shield.

TMS / Specialties

Title: Oxygen / Acetylene

SOP # 30

Revision: 10/30/08

CONTROLLED Page 1



2 PROCDURE

2.1 Always store oxygen & acetylene separately. 2.2 Never transport oxygen & acetylene uncapped. 2.3 Always store & transport oxygen and acetylene upright. 2.4 Never use oil in anyway on any part or parts that go on either of these

products. 2.5 Always secure oxygen and acetylene in all cases. 2.6 Make sure tanks are securely chained down. 2.7 Connect gauges to tanks. 2.8 Oxygen regulator goes on clockwise. 2.9 Acetylene regulator goes on counter clockwise. 2.10 Hoses and gauges are coded for safety purposes. Green to oxygen. Red to

acetylene. 2.11 Fasten hoses to torch, after cleaning line. 2.12 Make sure torch is off by turning all knobs clockwise until they stop. 2.13 Check valves on oxygen and acetylene. 2.14 Open oxygen about two rounds. 2.15 Open acetylene about ½ turn. 2.16 Set oxygen regulator on about 40 PSI. Fore thicker steel you may have to

increase oxygen pressure. 2.17 Set acetylene regulator on (no more) then 15 LBS. Usually around 10 PSI. 2.18 Check acetylene valve on hand torch, light torch. 2.19 Start to open oxygen valve. When desired flame is reached you are ready to

start. 2.20 Pre-heat metal with torch by holding tip about ¼ of and inch away. When

metal starts to flow pull oxygen lever and start across metal. 2.21 When you complete the cut let go of oxygen lever & move torch away from

hot metal. Cut off acetylene knob first then cut off oxygen knob last. 2.22 Move over to you bottles or cylinders and cut off both cylinders one at a time. 2.23 The following personal protective equipment should be worn during this

operation: A. Dark safety glasses B. Steel toe safety shoes C. Flame retardant gloves

TMS / Specialties

Title: Oxygen / Acetylene

J.W.

SOP # 30, *22

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 Always store oxygen & acetylene separately. 2.2 Never transport oxygen & acetylene uncapped. 2.3 Always store & transport oxygen and acetylene upright. 2.4 Never use oil in anyway on any part or parts that go on either of these

products. 2.5 Always secure oxygen and acetylene in all cases. 2.6 Make sure tanks are securely chained down. 2.7 Connect gauges to tanks. 2.8 Oxygen regulator goes on clockwise. 2.9 Acetylene regulator goes on counter clockwise. 2.10 Hoses and gauges are coded for safety purposes. Green to oxygen. Red to

acetylene. 2.11 Fasten hoses to torch, after cleaning line. 2.12 Make sure torch is off by turning all knobs clockwise until they stop. 2.13 Check valves on oxygen and acetylene. 2.14 Open oxygen about two rounds. 2.15 Open acetylene about ½ turn. 2.16 Set oxygen regulator on about 40 PSI. Fore thicker steel you may have to

increase oxygen pressure. 2.17 Set acetylene regulator on (no more) then 15 LBS. Usually around 10 PSI. 2.18 Check acetylene valve on hand torch, light torch. 2.19 Start to open oxygen valve. When desired flame is reached you are ready to

start. 2.20 Pre-heat metal with torch by holding tip about ¼ of and inch away. When

metal starts to flow pull oxygen lever and start across metal. 2.21 When you complete the cut let go of oxygen lever & move torch away from

hot metal. Cut off acetylene knob first then cut off oxygen knob last. 2.22 Move over to you bottles or cylinders and cut off both cylinders one at a time. 2.23 The following personal protective equipment should be worn during this


TMS / Specialties

Title: Spray Paint Gun

SOP # 31 (13)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Check air pressure gauge (operating pressure – 40-60 PSI) 2.2 Check exhaust air filter, change if needed. 2.3 Fill paint gun with 2/3 paint and 1/3 paint thinner, depending on application. 2.4 Attach air hose to the gun and set at 30-40 PSI of pressure. 2.5 Proceed to spray part. 2.6 When you are finished painting, remove air. 2.7 Return any left over paint to separate storage can. 2.8 In an emergency, set spray gun down on the floor and leave area. 2.9 The following personal protective equipment should be worn during this

operation: A. Safety Glasses. B. Steel Toe Safety Shoes. C. Respirator D. Close fitting clothing, nothing loose, sleeves rolled up or buttoned, apron


TMS / Specialties

Title: Paint Spray Gun

J.W.

SOP # 31, *13

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 Turn exhaust fans on. 2.2 Keep floor area clear of tripping hazards. 2.3 Check and make sure air pressure gauge does not have more than 40 to 60

pounds of pressure. 2.4 Never smoke in this area. 2.5 Check exhaust filter for wear; change if needed. 2.6 Place paint in spray gun, 2/3 full of paint mix and 1/3 full of thinner. 2.7 Attach spray gun to beaker. 2.8 Attach air hose to the gun and set at 30 to 40 pounds of pressure. 2.9 Proceed to spray by pressing lever. 2.10 When through remove air hose and beaker. 2.11 Return any left over paint to a separate storage can. 2.12 Pick up area of tape or other material. 2.13 Dump waste cans daily. 2.14 In an emergency shut down set spray gun down on the floor and leave the

building. 2.15 The following personal protective equipment should be worn during this

operation: A) Safety glasses. B) Steel toe safety shoes. C) Charcoal vapor breather respirator. D) Rubber gloves.

TMS / Specialties

Title: Portable Circular Saw

J.W.

SOP # 32, *17.7

Revision: 3/1/06

CONTROLLED Page 1



2 PROCDURE 2.1 Before using the circular saw, inspect the electric cord for breaks or signs of

abuse. Do not use if damage is observed with the circular saw and notify supervisor.

2.2 Inspect the circular saw and ensure that it is in good condition, properly lubricated, that all adjustments are tight, bits are sharp and that all safety guards present and in good operating order. Ensure that the switch is in the off position.

2.3 Be sure the correct blade is on the circular saw and that it is properly secured. 2.4 Be sure that the work to be cut is solidly supported. 2.5 Ensure that the blade guard is operating freely and in the proper position. 2.6 Make certain that the circular saw is properly connected to the electrical circuit

and safely grounded. 2.7 Plug the circular saw into the proper power outlet; making certain that electric

cord will not become fouled during drilling operation. 2.8 Never use the circular saw while standing on a wet or damp floor. 2.9 Always disconnect the circular saw from its power supply before changing

blades. 2.10 Grasp the circular saw firmly with one hand making sure the other hand is well

out of danger. 2.11 Start the circular saw will clear of the work. 2.12 If the circular saw stalls during cut, do not release the switch. Instead carefully

back the saw enough to allow it to resume speed. Note: If circular saw stalls excessively disconnect the power cord and check blade for dullness.

2.13 When you reach the end of the cut release the switch and allow the blade to stop.

2.14 Ensure that the blade guard has returned to the closed position before laying the saw down. Note: never bring the circular saw to rest against any part of the body. The blade guard can become jammed, leaving the blade exposed. This could result in serious injury.


A. Safety glasses B. Steel toe safety shoes C. Face shield.

TMS / Specialties

Title: Portable Circular Saw

J.W.

SOP # 32 (17.7)

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE 2.1 Before using the circular saw, inspect the electric cord for breaks or signs of

abuse. Do not use if damage is observed with the circular saw and notify supervisor.

2.2 Inspect the circular saw and ensure that it is in good condition, properly lubricated, that all adjustments are tight, bits are sharp and that all safety guards present and in good operating order. Ensure that the switch is in the off position.

2.3 Be sure the correct blade is on the circular saw and that it is properly secured. 2.4 Be sure that the work to be cut is solidly supported. 2.5 Ensure that the blade guard is operating freely and in the proper position. 2.6 Make certain that the circular saw is properly connected to the electrical circuit

and safely grounded. 2.7 Plug the circular saw into the proper power outlet; making certain that electric

cord will not become fouled during drilling operation. 2.8 Never use the circular saw while standing on a wet or damp floor. 2.9 Always disconnect the circular saw from its power supply before changing

blades. 2.10 Grasp the circular saw firmly with one hand making sure the other hand is well

out of danger. 2.11 Start the circular saw will clear of the work. 2.12 If the circular saw stalls during cut, do not release the switch. Instead carefully

back the saw enough to allow it to resume speed. Note: If circular saw stalls excessively disconnect the power cord and check blade for dullness.

2.13 When you reach the end of the cut release the switch and allow the blade to stop.

2.14 Ensure that the blade guard has returned to the closed position before laying the saw down. Note: never bring the circular saw to rest against any part of the body. The blade guard can become jammed, leaving the blade exposed. This could result in serious injury.


A. Safety glasses B. Steel toe safety shoes C. Face shield.

TMS / Specialties

Title: Hand Drills

J.W.

SOP # 33 (5.2)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Select proper bit, place in chuck and tighten with chuck key. 2.2 Place job on table or work surface and clamp securely. 2.3 Hold securely and start drill. 2.4 Do not use excessive force so as not to stall drill, damage bit or cause injury. 2.5 Place drill in center of punch mark and proceed. 2.6 When finished, turn drill off by depressing finger switch. 2.7 In an emergency, stop drill, place on table or work area and leave area. 2.8 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Portable Electrical Hand Drill

J.W.

SOP # 33, *5.2

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 Before using the drill, inspect the electric cord for breaks or signs of abuse. Do not use if damage is observed with the drill and notify supervisor.

2.2 Inspect the drill and ensure that it is in good condition, properly lubricated,

that all adjustments are tight, bits are sharp and that all safety guards present and in good operating order. Ensure that the switch is in the off position.

2.3 Be sure drill bit is in place and drill chuck properly tightened.

2.4 Be sure work is properly secured.

2.5 Make certain that the drill is properly connected to the electrical circuit and

safely grounded.

2.6 Plug the drill into the proper power outlet; making certain that electric cord will not become fouled during drilling operation.

2.7 Never use the drill while standing on a wet or damp floor.

2.8 Always disconnect the drill from its power supply before changing drill bits.

2.9 If drill hangs up, put drill in reverse and back out slowly.

2.10 When drilling operation is complete back drill out slowly and release switch.



TMS / Specialties

Title: Pneumatic Nail Driver

J.W.

SOP # 34

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE 2.1 Never hold a pneumatic tool with the trigger depressed unless you intend to

drive a fastener.

2.2 Never point a pneumatic tool toward yourself or anyone else.

2.3 Always wear eye protection along with Steel Toe Safety Shoes and anyone in the area should also have eye protection on when the pneumatic nail driver is being used.

2.4 Always disconnect the air supply when not in use. When clearing a jam or

when performing any maintenance. 2.5 Always read and understand the manual before operating the pneumatic nail

driver.


A. Safety glasses B. Steel toe safety shoes C. Earplugs. D. Face shield.

TMS / Specialties

Title: Radial Arm Drill

SOP # 35 (5.4)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Clamp material securely in vice. 2.2 Turn coolant on and switch machine to on. 2.3 Set drill speed compatible to material. 2.4 Set drill advance compatible to drill speed. 2.5 Manually turn lever to bring bit in contact with material to be drilled then pull

lever to automatic advance position. 2.6 When bit is through material, release lever by pushing back to neutral

position and raise bit back to highest point. 2.7 Switch machine to off. 2.8 Remove part from vice or clamp. 2.9 In an emergency, hit emergency stop button and leave area. 2.10 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Radial Drill

J.W.

SOP # 35, *5.4

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 If circumstances require, turn main power breaker off located on back off machine.



2.3 Turn main power breaker on at rear of machine


2.5 Be sure all guards and covers are properly in place and all doors are closed


run machine.


2.8 Make sure cutting tools and work piece securely fastened and mounted in

turret and the work piece is properly held. 2.9 The following personal protective equipment should be worn during this


TMS / Specialties

Title: Small Mills

J.W.

SOP # 36

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 If circumstances require. Turn main power breaker off located on back of machine.



2.3 Turn main power breaker on at rear of machine


2.5 Be sure all guards and covers are properly in place and all doors are closed


run machine.


2.8 Do not attempt to stop chuck from rotating. Allow it to stop by itself.

2.9 Make sure cutting tools and work piece are securely fastened.



TMS / Specialties

Title: Stick welder

J.W.

SOP # 37, *24.3

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 Check electrode and all leads for wear and burns.

2.2 Main disconnect should be in off position before plugging or unplugging the machine.

2.3 Place electrode into rod holder.

2.4 Turn power switch on located on front of machine.

2.5 Check tip to be sure it is free from debris.

2.6 Adjust machine for heat compatibility with material.

2.7 Make sure shield is down before starting to weld.

2.8 Proceed to weld.

2.9 When finished turn power switch off, hang electrode up, and turn off main

disconnect.

2.10 In an emergency shut down, turn off main disconnect and leave the area.


a) Steel toe safety shoes. b) Work gloves c) Safety Glasses d) Welding hood e) Close fitting clothing, nothing loose, sleeves rolled up or buttoned,

apron strings tied in back, shirttails tucked in.

TMS / Specialties

Title: Stick welder

J.W.

SOP # 37 (24.3)

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 Check electrode and all leads for wear and burns.

2.2 Main disconnect should be in off position before plugging or unplugging the machine.

2.3 Place electrode into rod holder.

2.4 Turn power switch on located on front of machine.


2.6 Adjust machine for heat compatibility with material.

2.7 Make sure shield is down before starting to weld.

2.8 Proceed to weld.

2.9 When finished turn power switch off, hang electrode up, and turn off main

disconnect.

2.10 In an emergency shut down, turn off main disconnect and leave the area.


a) Steel toe safety shoes. b) Work gloves c) Safety Glasses d) Welding hood e) Close fitting clothing, nothing loose, sleeves rolled up or buttoned,

apron strings tied in back, shirttails tucked in.

TMS / Specialties

Title: Lift Trucks

J.W.

SOP # 38 (10)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Operator must be familiar with every control on the forklift before operating. 2.2 Never exit forklift while it is running or while the forks are raises. 2.3 Set emergency brakes before exiting. 2.4 Do not leave forklift unattended while running. 2.5 All warning lights and beepers must be in operational condition at all times. 2.6 When the operator is going through a door or any time that his vision is

impaired, he will blow the horn to let others know he is approaching. 2.7 Always carry load as low to the floor as possible, taking in to consideration

other objects along your path. 2.8 Do not allow any other employee to ride with you. 2.9 All other employees have the right of way when you are operating the forklift. 2.10 In an emergency, lower forks to the floor, turn switch off and leave area. 2.11 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Forklift

J.W.

SOP # 38, *10

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY 1.1 An authorized trainer is responsible for the training of the Standard Operation


2 PROCEDURE

2.1 Check oil and hydraulic systems fluid levels. 2.2 Always carry load low. 2.3 Never exit forklift while engine is running or while forks is in raised position. 2.4 Set emergency brake before exiting forklift. 2.5 All warning light systems and beepers must be in operational condition at all

times. 2.6 In an emergency shut down turn engine off, lower forks to floor, set hand

brake, and leave area. 2.7 Seatbelt must be worn at all time while operating the Forklift. 2.8 All body parts should be kept inside safety area while operation the Forklift. 2.9 The following personal protective equipment should be warn during this

operation: A) Safety glasses B) Steel Toe Safety Shoes

3 TRAINING

3.1 OSHA REQUIREMENTS 3.2 REFUELING 3.3 JUMPSTART 3.4 LOADING and UNLOADING 3.5 BACKING 3.6 INCLINES and RAMPS 3.7 HIGH LIFTS 3.8 DOCKS 3.9 PARKING 3.10 WORKING NEAR EMPLOYEES 3.11 LOAD LIMITS 3.12 PRE-START 3.13 VEIW VIDEO TRAINING TAPE 3.14 TAKE WRITTEN TEST

TMS / Specialties

Title: Vehicles and Railroad Crossing

SOP # 39

Revision: 3/1/06

CONTROLLED Page 1


Procedure (SOP) for all employees using company vehicles..

2 PROCEDURE

2.1 When approaching railroad tracks that have a stop sign always come to a complete stop. Look both ways, and listen before crossing.

2.2 When approaching railroad tracks that have the warning signals only, cross

with caution when lights are not blinking (slow down and look both ways if visibility is clear, stop if visibility is not clear). When lights are blinking stop, look both ways and listen. If a train is coming, stop and wait.

2.3 When approaching railroad tracks that have the warning signals and the arm,

cross with caution when lights are not blinking (slow down and look both ways. If visibility is clear, stop if visibility is not clear. When lights are blinking and arm is down, do not ever go around the arm to cross.

2.4 When approaching railroad tracks that have nothing always stop. Look both

ways and listen.

2.5 If your vehicle should stall on the tracks get out of your vehicle. If a train is coming get off the tracks, run in the direction in which the train is coming from.


operation: A. Seat belt.

TMS / Specialties

Title: WIRE WELDER

J.W.

SOP # 40, *24.4

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 Check spool for the amount of wire on it.

2.2 Main disconnect should be in off position before plugging the machine in or unplugging the machine.

2.3 Turn on power switch located on the front of the machine.

2.4 Turn gas bottle on slowly until pressure on gauge reaches maximum lever.


2.6 Adjust machine for heat compatible with material.

2.7 Make sure your shield is down before you start to weld. 2.8 Turn power switch off. Close gas valve on bottle, turn off main disconnect.


operation:

2.9.1 Steel toe safety shoes 2.9.2 Safety glasses 2.9.3 Work gloves. 2.9.4 Welding hood

TMS / Specialties

Title: WIRE WELDER

J.W.

SOP # 40 (24.4)

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 Check spool for the amount of wire on it.

2.2 Main disconnect should be in off position before plugging the machine in or unplugging the machine.

2.3 Turn on power switch located on the front of the machine.

2.4 Turn gas bottle on slowly until pressure on gauge reaches maximum lever.


2.6 Adjust machine for heat compatible with material.

2.7 Make sure your shield is down before you start to weld. 2.8 Turn power switch off. Close gas valve on bottle, turn off main disconnect.


operation:

2.9.1 Steel toe safety shoes 2.9.2 Safety glasses 2.9.3 Work gloves. 2.9.4 Welding hood

TMS / Specialties

Title: Inspection purchase orders

J.W.

SOP # 41

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY 1.1 The Supervisor is responsible for the training of this Standard Operation

Procedure (SOP).

2 PROCEDURE

2.1 Purchase Orders are to be removed from Purchase Order book in consecutive order.

2.2 Purchase Orders are to be written to only authorized venders. 2.3 If a purchase Order is to be written to a new vender a Supervisor must

approve it.

2.4 Three copies of the Purchase Order must be made:

A) The Original will be turned in to the data entry department. B) One copy will be sent to the vender with any necessary drawings and

information.

C) One copy will be placed in the open PO file, which will be pulled when the order is completed.

D) The last copy will be put in the PO bot, which is used as a reference for

future PO’s to the vender.

TMS / Specialties

Title: CALIBRATION OF OUTSIDE MICROMETERS

J.W.

SOP # 42, *29.1

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY 1.1 The Management Representative is responsible for assigning qualified

individuals to conduct Calibration activities assuring procedures are followed.

2 PROCEDURE

2.1 Thoroughly clean the entire micrometer. 2.2 Visually inspect the micrometer for obvious damage. 2.3 Repair any damage found or take out of service if micrometer is unrepairable. 2.4 Check that the mechanical actions move freely throughout the full travel of

the micrometer. Adjust the barrel thread nut if necessary. 2.5 Close the micrometer spindle to the zero mark (verify calibration with a

traceable calibrated standard) open spindle to the 1” mark (verify calibration with a calibrated standard) adjust micrometer if required. Verify this calibration test three times.

2.6 Outside micrometers must be adjusted if off .0002”

TMS / Specialties

Title: CALIBRATION OF OUTSIDE MICROMETERS

J.W.

SOP # 42 (29.1)

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 Thoroughly clean the entire micrometer. 2.2 Visually inspect the micrometer for obvious damage. 2.3 Repair any damage found or take out of service if micrometer is unrepairable. 2.4 Check that the mechanical actions move freely throughout the full travel of

the micrometer. Adjust the barrel thread nut if necessary. 2.5 Close the micrometer spindle to the zero mark (verify calibration with a

traceable calibrated standard) open spindle to the 1” mark (verify calibration with a calibrated standard) adjust micrometer if required. Verify this calibration test three times.

2.6 Outside micrometers must be adjusted if off .0002”

TMS / Specialties Title: CALIBRATION OF DEPTH MICROMETERS

J.W.

SOP # 43 (29.3)

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 Thoroughly clean the entire micrometer and extension rods. 2.2 Visually inspect the micrometer and the extension rods for obvious damage. 2.3 Any micrometer found damaged must be repaired or taken out of service if

micrometer is unrepairable. 2.4 Check that the mechanical actions move freely throughout the full travel of

the micrometer.

2.5 Insert and tighten the extension rod into the micrometer.

2.6 Using Gage Blocks calibrate with a traceable calibrated standard check and set if required

2.7 With the base wrung to a precision flat surface, lower the rod and set at zero.

2.8 Depth micrometers must be adjusted if off .001”

TMS / Specialties Title: CALIBRATION OF INSIDE MICROMETERS

J.W.

SOP # 44, *29.2

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 Wipe Clean the measuring faces of the micrometer and the set ring. 2.2 Visually inspect the micrometer for obvious damage. 2.3 Any micrometer found damaged must be repaired or taken out of service if

micrometer is unrepairable.

2.4 Check that the mechanical actions move freely throughout the full travel of the micrometer.

2.5 Place the ring on a flat worktable; inset the micrometer perpendicularly into

the set ring.

2.6 Rotate the thimble until the measuring face of the anvils gently contacts the measuring face of the set ring.

2.7 Rotate the ratchet 5 to 6 turns to make sure that the micrometer reading is

stable.

2.8 If the micrometer reading is different from the reference dimension on the set ring, adjust the micrometer while it is set in the set ring. Loosening the outer sleeve set screw and rotating the outer sleeve carefully until the micrometer reading represents the set ring diameter. Then gently tighten the setscrew.

2.9 Recheck micrometer.

2.10 Repeat steps 5 through 8 if adjustments are required.

2.11 Inside micrometer must be reset if calibration is off .0002”

TMS / Specialties Title: CALIBRATION OF INSIDE MICROMETERS

J.W.

SOP # 44 (29.2)

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 Wipe Clean the measuring faces of the micrometer and the set ring. 2.2 Visually inspect the micrometer for obvious damage. 2.3 Any micrometer found damaged must be repaired or taken out of service if

micrometer is unrepairable.

2.4 Check that the mechanical actions move freely throughout the full travel of the micrometer.

2.5 Place the ring on a flat worktable; inset the micrometer perpendicularly into

the set ring.

2.6 Rotate the thimble until the measuring face of the anvils gently contacts the measuring face of the set ring.

2.7 Rotate the ratchet 5 to 6 turns to make sure that the micrometer reading is

stable.

2.8 If the micrometer reading is different from the reference dimension on the set ring, adjust the micrometer while it is set in the set ring. Loosening the outer sleeve set screw and rotating the outer sleeve carefully until the micrometer reading represents the set ring diameter. Then gently tighten the setscrew.

2.9 Recheck micrometer.

2.10 Repeat steps 5 through 8 if adjustments are required.

2.11 Inside micrometer must be reset if calibration is off .0002”

TMS / Specialties

Title: WELDING

J.W.

SOP # 45

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 Inspect rod holder and all leads for wear and burns. Check fire extinguisher and make sure it is located on the welding machine and also make sure it is filled.

2.2 Cut welding machines on with flip switch, also set switch for either wire weld

or stick weld. 2.3 Place welding rod into rod holder. Attach ground clamp to table or casting

(depending on size of casting).

2.4 Put flash shield down and apply rod to casting or material being welded.

2.5 When finished hang up rod holder, disconnect ground clamp, and cut machine off.


operation: A. Safety glasses B. Steel toe safety shoes C. Proper gloves D. Welding hood

TMS / Specialties

Title: Lifting

J.W.

SOP # 46

Revision: 3/1/06

CONTROLLED Page 1


Procedure (SOP) for lifting.

2 PROCEDURE 2.1 No single employee is to lift anything weighing over 50lbs. If something is

over 50 lbs. And must be moved, ask some one to help you. Use and overhead crane a hoist or get someone trained in driving a forklift to lift it.

2.2 Never lift anything with your knees straight and bending over at the back or

waist area. Always lift by bending your knees to a squatting position. Keep your back straight at all times and lift using your legs. If you discover that you can only lift small amounts in this position is positive proof that you need the assistance of another.

2.3 Never lift anything in a twist. While carrying loads, keep your back straight

with your waist and hips. When you turn, turn using your feet and take smaller steps.



TMS / Specialties

Title: Turret Lathes

J.W.

SOP #47

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY


2 PROCEDURE


before operating.



machine. 2.4 Do not attempt to stop chuck from rotating by hand. Allow it to stop by itself. 2.5 Remove chuck wrench from chuck before starting, never leave the wrench in

the chuck and leave the machine unattended. 2.6 Make sure cutting tools are securely fastened and the work piece is properly


operation:

A: Safety Glasses. B: Steel Toe Safety Shoes. C: Close fitting clothing, nothing loose, sleeves rolled up or buttoned, apron strings tied in back, shirttail tucked in.

TMS / Specialties

Title: Shaper Machines

J.W.

SOP # 48

Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE

2.1 Press Red emergency off button located on right side of gear machine viewing from the front.


2.3 Turn reset button clockwise to release 2.4 All operators should be familiar with all machine controls and movements



run machine. 2.7 Keep working area around your machine clear of any obstacles that would

result in injury. 2.8 Select arbor, cutter, and fixtures suitable for parts to be cut and install on

machine. 2.9 Select and mount change gears for the particular gear your are going to cut. 2.10 Set rpm’s for the machine. 2.11 Turn on the power. 2.12 Start table turning and indicate the work piece. 2.13 Traverse head up or down to clear work piece. 2.14 Touch off on part, dial in depth. 2.15 Start spindle and engage the feed for the head. 2.16 The following personal protective equipment should be worn during this


TMS / Specialties

Title: Color Code

SOP #49

Revision: 3/1/06

CONTROLLED Page 1

1 DEFINITIONS

1.1 4140 hot rolled > White 1.2 4149 heat treat > Red / White

1.3 C1144 > Blue

1.4 8620 > Blue / White

1.5 1045 > Green

1.6 1018 cold rolled > Red

1.7 4340 > Orange

1.8 52100 bearing steel > Green / White

2 RESPONSIBILITY

2.1 The Supervisor is responsible for the training of the Standard Operation Procedure (SOP).

3 PROCEDURE

3.1 Any other grade of metal or material to be machined is to be tagged or marked to specify its grade as soon as it is received.

3.2 If you cut the color code off when you saw a piece of stock be sure to paint it back on.

TMS / Specialties

Title: CALIBRATION OF HEIGHT GAGE

J.W.

SOP # 50

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY 1.1 The Management Representative or Plant Manager is responsible for

assigning qualified individuals to conduct Calibration activities assuring procedures are followed.

2 PROCEDURE

2.1 Thoroughly clean the entire height gages. 2.2 Visually inspect the height gage for obvious damage. 2.3 Any height gage found damaged must be repaired or taken out of service if

micrometer is unrepairable. 2.4 Check that the mechanical actions move freely throughout the full travel of

the height gage.

2.5 Insert and tighten height gage scriber into the height gage.

2.6 With the base wrung to a precision flat surface, lower the scriber and set at zero.

2.7 Using Gage Blocks calibrate with a traceable calibrated standard check and

set if required

2.8 Height Gage must be checked and set to zero before each use.

2.9 Height gage must be adjusted if off .0005.

TMS / Specialties

Title: CRYSTA 707 APEX CMM

J.W.

SOP # 51

Revision: 3/1/06

CONTROLLED Page 1

1 DEFINITIONS

1.1 CMM (Coordinate Measuring Machine) when used in this Document refers to the Mitutoyo Measuring Crysta 707 apex.

2 RESPONSIBILITY 2.1 The Management Representative or Plant Manager is responsible for

assigning qualified individuals to conduct Calibration activities assuring procedures are followed.

3 PROCEDURE

3.1 Only authorized personnel are allowed to operate the CMM. 3.2 Thoroughly clean the entire CMM. 3.3 Air pressure must be on before starting the CMM. 3.4 Turn on CMM at front panel at switch marked power. 3.5 Activate Geo Measure program on attached computer. 3.6 Start up procedure must be followed to assure accuracy. 3.7 Calibration procedure will only be required if reports are to be retained for

permanent records. 3.8 Quick check to verify diameters will not require Calibration procedure at this

time unless a report is to be written that will be retained for permanent records.

3.9 Should the CMM be found damaged or out of calibration it must be repaired or taken out of service until accuracy can be verified.

3.10 Shut down CMM by first turning off power switch at front panel. 3.11 Turn off air at rear of CMM 3.12 The following personal protective equipment should be worn during this


TMS / Specialties

Title: HORIZONTAL BORING MACHINES

J.W.

SOP # 52 Revision: 3/1/06

CONTROLLED Page 1



2 PROCEDURE 2.1 Establish work clearances required, X, Y, Z, W&B axis.

2.2 Verify there are no pinch points in Z or B axis between table, work piece,

fixture, or outboard attachments. 2.3 All work pieces, tooling, fixtures, support bearing, attachments etc… should

be securely affixed. 2.4 All tool holders should be properly oriented. (Dimple side away from drive

key) 2.5 When possible, operator should position oneself out of harm’s way to avoid

flying cuttings or broken parts. 2.6 In case of dangerous situations master cutoff switch should immediately be

engaged. 2.7 When loading or unloading parts with the aid of crane’s or hoists, extreme

care should be exercised so that operator does not endanger oneself or others. Table should be backed away from spindle area when loading/unloading to avoid damaging spindle, tooling, readouts, & controls. Verify ample clearance of clamps fixtures etc.

2.8 Table should not be rapid traversed while loaded without clamps to prevent

work piece shift. 2.9 The following personal protective equipment should be worn during this


TMS / Specialties

Title: Liquid Nitrogen

J.W.

SOP # 53

Revision: 3/1/06

CONTROLLED Page 1


Procedure (SOP) of Liquid Nitrogen.

2 PROCEDURE

2.1 Only authorized and trained personnel are allowed to use Liquid Nitrogen.

2.2 Handling: Valves on bottles should be opened slowly to avoid trapping oxygen in containers and causing a burst of liquid nitrogen, causing cryogenic burns, frostbite or asphyxiation.

2.3 Should be used only in well-ventilated areas to avoid asphyxiation.

2.4 Extreme care should be used with parts, as most metals will become brittle.

Avoid impact or dropping of parts and never use a glass container.

2.5 A safe area of operation should be maintained to avoid tripping, spills or danger to bystanders.

2.6 Spills: Vacate area and allow to evaporate.

2.7 First Aid: For brief localized contact, flush area with water, for more serious

contact medical treatment will be needed.

2.8 Only approved containers may be with and used to store Liquid Nitrogen. Must be kept upright and under lock & key when not in uses.


operation:

A. Safety Glasses. B. Face Shield. C. Steel Toe Safety Shoes. D. Long, loose fitting heavily insulated gloves. E. An apron should be used.

TMS / Specialties Title: Machine or Equipment Sampling Inspection

Procedure

J.W.

SOP # 54

Revision: 3/1/06

CONTROLLED Page 1


Procedure (SOP) of Sampling Inspection.

2 PROCEDURE

2.1 Machine Shop: (a) Every 10% of parts made. (b) If 10 parts or less are made, all parts will be checked.

2.2 Laser and Burn Table:

(a) If up to a hundred parts are made 10% will be checked. (b) If more than a hundred parts are made 5% will be checked.

TMS / Specialties

Title: Vertical Lathes

J.W.

SOP #55

Revision: 3/1/06

CONTROLLED Page 1

1 RESPONSIBILITY


2 PROCEDURE


before operating.



machine. 2.4 Do not attempt to stop chuck from rotating by hand. Allow it to stop by itself. 2.5 Never leave the machine unattended. 2.6 Make sure cutting tools are securely fastened and the work piece is properly


operation:

A: Safety Glasses. B: Steel Toe Safety Shoes. C: Close fitting clothing, nothing loose, sleeves rolled up or buttoned, apron strings tied in back, shirttail tucked in.

TMS / Specialties

Title: 6’ Pexto Handbrake

SOP # 56 (1.3)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Never use over 14-gauge material. 2.2 Always securely clamp the material. 2.3 Open the top of the machine; place the job on the marks as to where you

want the material bent. 2.4 Close the top and make sure the material is in the machine tightly, move the

side and manually push lever down. 2.5 Remove the job and close the top of the machine. 2.6 In an emergency, hit the emergency stop button and leave the area. 2.7 The following personal protective equipment should be worn during this



TMS / Specialties

Title: 10’ 200 ton Brake Press

J.W.

SOP # 57 (1.4)

Revision: 3/1/06


1 RESPONSIBILITY

1.1 The Supervisor is responsible for the training of the Standard Operation


2 PROCEDURE

2.1 Select the proper top and bottom dies for the thickness of metal to be bent. 2.2 Put select key in inch mode and start the machine. When machine is started

place key to single stroke and only – hand foot select key to hand only. Now you can work from the pedestal to achieve the right clearance to install top and bottom dies. Once the dies are installed, use two hand controls on pedestal to bring ram down to tighten dies, then by using allen wrench to lock top dies.

2.3 Once dies are in place, push inch up button on pedestal to achieve clearance for the two blocks used to calibrate stops equipped on this brake press with the dies you are using. When using stops, every time you change dies, you have to recalibrate the stops.

2.4 When all of the above has been done, using inch up button, remove the two calibrating blocks and place back in storage area on machine.

2.5 Using pedestal controls, you will need to set limit switches for the up and down travel of the ram.

2.6 Before you start the actual job to be bent, it is a good policy to use scrap of the same thickness to see if your limit switches are set properly taking care not to let the ram come down too far and also come up too far.

2.7 Never operate this press beyond its capacity. 2.8 All the above instructions are for manual operation. This brake press is

equipped with a 30-program memory. This is for volume parts and parts that we know we will do in the future. When a program is to be punched in, your supervisor will refer you to someone qualified to do this.

2.9 Always bend in the middle of the brake press. 2.10 In case of an emergency, hit emergency stop button and leave the area. 2.11 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Circle Burner

J.W.

SOP # 58 (2.2)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Place material to be cut on table or work surface securely. 2.2 Place circle burner on material and align with punch mark made on material.

Lower alignment shaft into punch mark. 2.3 Plug machine into 110 V power supply. 2.4 Attach gas lines and tighten. 2.5 Set speed for thickness of material to be cut. 2.6 Light torches and set to thickness of material. 2.7 Preheat material and proceed to cut. 2.8 When finished, turn power off, turn torches off, unplug AC cord, turn gas

bottles off, and remove gas lines. 2.9 In an emergency, hit emergency stop button and leave area. 2.10 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Bug-O Line Burner

J.W.

SOP # 59 (2.1)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Place material on work surface securely. 2.2 Place torch and track on material. 2.3 Adjust track for cut to be made and place securely to material. 2.4 Plug machine in with power off to machine. 2.5 Attach all gas lines and tighten. 2.6 Adjust speed for thickness of material. 2.7 Light torch and adjust. 2.8 Preheat material and proceed to cut. 2.9 When finished, turn power off. Turn torches off, take gas lines off and roll up.

Return them to their proper place. 2.10 In an emergency, hit emergency stop button and leave area. 2.11 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Line Burner

J.W.

SOP # 59 (2.3)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Place material on work surface securely. 2.2 Place torch and track on material. 2.3 Adjust track for cut to be made and clamp securely to material. 2.4 Plug machine in with power off to machine. 2.5 Attach all gas lines and tighten. 2.6 Adjust speed for thickness of material. 2.7 Light torch and adjust. 2.8 Preheat material and proceed to cut. 2.9 When finished, turn power off, turn torches off, take gas lines off, roll up and

return them to their proper place. 2.10 In an emergency, hit emergency stop button and leave area. 2.11 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Hand Plasma Cutter

J.W.

SOP # 60 (4.2)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Check tip for excessive wear and size for material to be cut. 2.2 Check air pressure for desired setting, which is 80 – 100 PSI. 2.3 Turn on plasma with switch located at front of machine. 2.4 Set to desired temperature for thickness of metal to be cut. 2.5 Place job on table or work area securely and proceed to cut. 2.6 When finished, turn off machine power switch. Disconnect air. 2.7 Place unused portion of metal back in rack and identify it. 2.8 In an emergency, hit emergency stop button and leave area. 2.9 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Max 40 & 200 Plasma Cutter

J.W.

SOP # 60 (4.4)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Check tips for excessive wear and size for material to be cut. 2.2 Check air pressure (80 – 100 PSI) 2.3 Turn plasma on with switch located at front of machine. 2.4 Adjust temperature for material to be cut. 2.5 Place material on table squarely. 2.6 Cut parts desired and turn unit off 2.7 Identify all parts by job number and place on pallet. Return unused portion of

material to rack and identify. 2.8 In an emergency, hit emergency stop button and leave area. 2.9 The following personal protective equipment should be worn during this

operation: A. Safety Glasses - cutting glasses or face shield with 3 to 5 shades lens. B. Steel Toe Safety Shoes. C. Close fitting clothing, nothing loose, sleeves rolled up or buttoned, apron


TMS / Specialties

Title: Burny CNC Plasma Cutter

SOP # 61 (4.1)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Make sure torches are in the up position. 2.2 Check torch tips for excessive wear and make sure you have the right size tip

for material to be cut. 2.3 Before loading, move torches aside or away to prevent damage during

loading. 2.4 Load material to be cut. 2.5 Set torches to the desired pre-heat and cutting temperature. 2.6 Enter CNC program of part to be cut or part drawn by carbon pencil to be

traced by Linde Tracer. 2.7 Preheat part to desired temperature and begin cut. 2.8 When job is finished, unload part and identify with job number. Identify

unused portion of material and put back in rack. 2.9 In an emergency, hit emergency stop button and leave area. 2.10 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Koike Torch & Plasma Cutter

J.W.

SOP # 62 (4.3)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Make sure torches are in the up position 2.2 Check all torch tips for excessive wear and make sure they are clean. Also

check for size of material to be cut. 2.3 Check torch and plasma carriage guide to make sure no hoses or debris is in

its’ path of travel. 2.4 Before loading, advance torch and plasma carriage all the way to one end or

to a point that will allow you to galt water table. 2.5 Place material squarely on the table. 2.6 Once you have loaded water table usage is as follows:

A. When using torch, bring water up 2” from bottom of material B. When using plasma, bring water up to the very bottom of material

2.7 You cannot use water when cutting some metals; refer to operator’s manual. 2.8 Purge system lines of all trapped explosive air gas mixtures. 2.9 When you are ready to begin cutting, select gas or plasma cutting mode on

control panel. Once you have made your selection and punched in the CNC program, you will need to make a trial run in some cases to check the program, insure maximum usage of material and also correct speed for cut.

2.10 Set pre-heat time for thickness of metal on control panel, Light and adjust low preheat flame (one torch), Adjust preheat flame – both valves, oxy-pretylene. Adjust high preheat flame (one torch) flip pre-heat switch to high and trim flame if necessary by adjusting the Hi Fuel pilot regulator for higher or lower pressure. Do not touch valve settings. Close torch cutting oxygen valve.

2.11 Check hi-lo transition and set cutting oxygen ease-on. Cut preheat switch to high and then low, open all torch cutting oxygen valves. Flip preheat switch from low to high and turn on cut. Turn cut off and on 2-3 times to check for flameouts. When all the above is done, you are ready to begin cutting.

2.12 Preheat metal (refer to manual for all thickness of metal preheat time). 2.13 After preheat time expires, machine will begin to cut. 2.14 When you have finished cutting, turn torches off, raise and advance torch and

plasma carriage assembly far away enough to unload water table. 2.15 Unload parts, identify job # and place on pallets. Unload unused portion of

mater, identify and place back in rack.

TMS / Specialties

Title: Koike Torch & Plasma Cutter

J.W.

SOP # 62 (4.3)

Revision: 3/1/06


2.16 In an emergency, hit emergency stop button, turn torches off, turn all gas off and leave area.



TMS / Specialties

Title: Porta Magnetic Drill

J.W.

SOP # 63 (5.3)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Place material on table or work area and secure. 2.2 Place drill on material and magnetize drill. 2.3 Select proper size drill bit and secure in chuck. 2.4 Demagnetize drill and align bit with punch mark on material to be drilled. 2.5 Magnetize drill. 2.6 Start drill motor. 2.7 Advance drill bit by manually pulling lever. 2.8 When finished with drill, return drill motor to upper most position, turn power

off, loosen chuck and remove drill bit. 2.9 When using coolant during this operation, never allow coolant to accumulate

on floor or any area that could endanger you of electrical shock. 2.10 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Iron Workers

J.W.

SOP # 64 (9)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Make sure ram is clear of all objects. 2.2 When shearing, remove punch and forming dies. When punching, remove

forming dies. When forming, remove punching dies. When shearing, use hold down device.

2.3 Material strippers must be in place when punching. 2.4 Make sure foot guard is always on. 2.5 Push start button. 2.6 Place job in die of operation that you are doing. 2.7 Operate with foot pedal, keeping hands free of moving parts. Line work up

and apply pressure to foot pedal and hold down until ram has lowered and is back up.

2.8 Remove work, push stop button. 2.9 In an emergency, hit emergency stop button and leave area. 2.10 The following personal protective equipment should be worn during this



TMS / Specialties

Title: CNC Plate Roll (1” x 10”)

J.W.

SOP # 65 (14.1)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Make sure all rolls are functioning properly. 2.2 Always roll in center of machine when permissible. 2.3 Place material in the machine by hand or crane if needed. 2.4 Square material using a frame square or by raising roll on the far side and

line material up with it. 2.5 Never stand under material while rolling. 2.6 Before you start to roll, make sure you have the correct pinch pressure. 2.7 Make sure the yoke is closed and locked. 2.8 If a pre-bend is necessary, attain this by raising the trailing side roll enough to

bend material to required radius. 2.9 When pre-bend is attained, drop trailing side roll and raise receiving side roll

to start. 2.10 When job is finished remove material from the rolls. Be sure crane is vertical

with the load. 2.11 Close yoke and lower all rolls to the bottom and turn off power. 2.12 In an emergency, hit emergency stop button and leave are. 2.13 The following personal protective equipment should be worn during this



TMS / Specialties

Title: TSMC Plate Roll (1/2”x 8”)

J.W.

SOP # 66 (14.2)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Make sure there is nothing in the way of the opening and closing of the yoke. 2.2 Load the material, making sure yoke is closed correctly and that the proper

pinch pressure is applied. 2.3 Start machine. 2.4 When the material has been formed and needs to be unloaded by crane,

return bottom rolls to maximum bottom travel, make sure crane is vertical with load and no load is applied to top roll while removing the material.

2.5 Open yoke and remove material, close yoke and turn the power off. 2.6 In an emergency apply pressure to panic strips located on each side of the

roll, pull power disconnect leaver and leave area. 2.7 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Wysong Plate Roll

J.W.

SOP # 67 (14.3)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Turn power on. 2.2 Make sure all rolls are operating properly. 2.3 Set feed rolls for proper clearance for thickness of material to be formed. 2.4 Adjust back roll for desired setting to obtain radius. 2.5 Make sure material is square with feed rolls. 2.6 Push left pedal on floor to start machine. 2.7 When material is formed, take foot off of the pedal, unlock top roll release and

remove material. 2.8 In an emergency, hit emergency stop button and leave area. 2.9 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Roll (3/16”x 48”)

SOP # 68 (14.4)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Open feed rolls and adjust to thickness of material to be rolled. 2.2 Adjust back roll to desired setting to obtain radius. 2.3 Make sure material is square with rolls and pull start lever. 2.4 After material has been formed, stop machine by pushing lever. 2.5 Never roll any material beyond the capacity of the machine, which is 1/8”

thick by 4’ long. 2.6 In an emergency, apply pressure to the foot stop pedal located at the front of

the machine, pull disconnect lever and leave area. 2.7 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Electric Pipe Threader

J.W.

SOP # 69 (15)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Plug machine in to 110-volt power supply. 2.2 Select proper dies and install securely. 2.3 Place material in chuck and align material 4” to 10” from front of chuck

opening. 2.4 Lock both chucks if material is long enough to engage both. 2.5 Place power switch to forward and turn cutting oil pump on. 2.6 Advance feed slowly, manually feeding toward direction of cutting dies. 2.7 When dies start to thread, observe thread length and allow approximately 1 to

3 turns past dies to give you 1” of thread. 2.8 Stop machine by putting switch to the off position. 2.9 When motor stops, put switch to reverse position to remove pipe from dies. 2.10 When pipe comes out of dies, manually feed away from dies to further most

position, lift die assembly and engage reamer blade in to position. 2.11 Start motor in forward position, advance feed slowly and ream pipe. 2.12 When finished reaming, reverse feed to further most position and stop motor,

unlock chucks, remove pipe and turn off cutting oil pump. 2.13 Water must be used for stainless steel pipe only. 2.14 When job is finished, unplug AC power cord. 2.15 In an emergency, hit emergency stop button and leave area. 2.16 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Cut Off Saw (12”)

J.W.

SOP # 70 (17.3)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Check blade for size of material to be cut. 2.2 Plug saw into 110-volt power supply. 2.3 Place work in to clamp and secure material so that the blade will contact

material for required measurement. 2.4 Start saw and pull handle down. 2.5 Do not use excessive force as to damage or stall the blade. 2.6 When material has been cut, release finger switch and lift handle. 2.7 Wait for blade to stop and remove material. 2.8 In an emergency, unplug the saw and leave the area. 2.9 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Peerless Automatic Saw

J.W.

SOP # 71 (17.6)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Check coolant level. 2.2 Turn power on. 2.3 Set speed of blade for the type of material to be cut. 2.4 Set frame advance for the type of material to be cut. 2.5 Set height of frame to the material to be sawed allowing room under the

blade for material to advance. 2.6 Turn coolant on. 2.7 Set front and back clamps to width of material. 2.8 Set manual-automatic select switch to desired setting. 2.9 Start saw. 2.10 When cut is finished, turn off saw and remove part. 2.11 In an emergency, hit emergency stop button and leave the area. 2.12 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Sand Blasters

J.W.

SOP # 72 (18)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Fill with sand as needed. 2.2 Make sure main air is off. 2.3 Make sure the bleed off valve; pot valve and headset valves are closed. 2.4 Open main air valve (100# psi). 2.5 Check headset valve (6-10# psi). 2.6 Hold nozzle with both hands while in operation. 2.7 With head set on, turn pot pressure on proceed. When finished, turn pot valve

off and open bleed off valve, take off headset and close headset air valve. 2.8 In an emergency, turn off all valves and leave area. 2.9 The following personal protective equipment should be worn during this

operation: A. Safety Glasses and Sand blaster headset. B. Steel Toe Safety Shoes. C. Close fitting clothing, nothing loose, sleeves rolled up or buttoned, apron

strings tied in back, and shirttail tucked in. D. Respirator.

TMS / Specialties

Title: 12’ Columbia Shear

J.W.

SOP # 73 (19.1)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Never shear round bar. 2.2 Maximum capacity is 10-gauge stainless steel or 3/16” aluminum. 2.3 Place material on the table and measure what length you need to cut. 2.4 When ready step on foot pedal. 2.5 When you are through cutting, push stop button. 2.6 In an emergency, hit emergency stop button and leave are. 2.7 The following personal protective equipment should be worn during this



TMS / Specialties

Title: 10-1/2’ Hydraulic Shear

J.W.

SOP # 74 (19.2)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Never shear round bar. 2.2 Never shear over the capacity, which is ½” hot rolled plate. 2.3 Set stops to desired length of cut, set rake to desired setting which is low for

plate up to ¼” and high for plate over ¼” to ½”. 2.4 Set blade direction to desired setting which is IN for plate ¼” – ½” and OUT

for plate up to ¼”. 2.5 Make sure the material being cut is under one or more of the hold down

devices. 2.6 When ready step on foot pedal and make cut. 2.7 In an emergency, hit emergency stop button and leave area. 2.8 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Steam Cleaner

SOP # 75 (21)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Check fuel level and fill as needed. 2.2 Check cleaning solution and fill as needed. 2.3 Never operate this equipment in the rain or leave exposed to the rain. 2.4 Check condition of AC power cord and make sure it is properly grounded. 2.5 Hold nozzle firmly and start pump. 2.6 Allow pump to run long enough to fill nozzle. 2.7 Hold nozzle down to allow ceramic metering device in nozzle to go forward to

maximum pressure position. 2.8 Turn knob from pump to burner position. If the burner does not start, do not

operate. 2.9 When using soap solution feed hose should be placed in solution. If soap is

not used place feed hose in water tank. 2.10 Hold nozzle about 14” to 18” from surface to be cleaned. 2.11 When job is finished, place switch to pump position and burner will stop. 2.12 Wait until all hot water is pumped out and then turn power off. 2.13 In an emergency shut down steam cleaner, unplug AC power cord and leave

area. 2.14 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Water Table

J.W.

SOP #76 (23)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Do not load this table beyond its capacity. 2.2 Never burn on water table without raising the water level to the minimum

required for oxy-fuel burning. 2.3 To raise water level, turn selector switch to high. 2.4 To lower water level, turn selector switch to low. 2.5 To raise water to intermediate level turn switch to inter. 2.6 Do not use water for plasma cutting aluminum or magnesium. 2.7 In an emergency, hit emergency stop button and leave area. 2.8 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Heli-Arc Tig Welder

J.W.

SOP # 77 (24.1)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Turn power switch on. 2.2 Turn water on and then turn gas on slowly until pressure on gauge reaches

maximum. 2.3 Check for proper tungsten that is to be used with the type of metal to be

welded. 2.4 Check for proper rod that is to be used with the type of metal to be welded. 2.5 Apply rod holder to the metal being welded and proceed. 2.6 Operate the rod with thumb or foot control. 2.7 When job is complete, turn power switch off, close valve on gas bottle and

turn water off. 2.8 In an emergency turn power switch off and leave area. 2.9 The following personal protective equipment should be worn during this

operation: A. Full face welding hood. B. Steel Toe Safety Shoes. C. Close fitting clothing, nothing loose, sleeves rolled up or buttoned, apron

strings tied in back, and shirttail tucked in. D. Welding gloves.

TMS / Specialties

Title: Spot Welder

J.W.

SOP # 78 (24.2)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Turn power on. 2.2 Turn water on. 2.3 Adjust desired temperature with cycle control for the thickness of metal. 2.4 Place job between negative and positive electrodes and push foot pedal to

weld. 2.5 When job is finished, turn power and water off. 2.6 In an emergency, turn water and power off and leave area. 2.7 The following personal protective equipment should be worn during this

operation: A. Dark Safety Glasses. B. Steel Toe Safety Shoes. C. Close fitting clothing, nothing loose, sleeves rolled up or buttoned, apron


TMS / Specialties

Title: Punch

J.W.

SOP # 79 (27)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Select correct top and bottom dies. 2.2 Check dies for excessive wear, cracks or chipped areas. 2.3 Advance ram with foot pedal to desired clearance to install dies. 2.4 Install dies, advance ram to snug dies and tighten. 2.5 Place material in dies and advance ram with foot pedal until punch is

achieved. 2.6 When job is complete, turn power off. 2.7 In an emergency, hit emergency stop button and leave area. 2.8 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Inside & Outside Calipers

J.W.

SOP # 80 (29.4)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Take an as found reading of the calipers. 2.2 Thoroughly clean the calipers. 2.3 Visually inspect for obvious damage. 2.4 Repair any damage found or take out of service if not repairable. 2.5 Check that the mechanical actions move freely through the full travel of the

calipers. 2.6 Close caliper to 0” setting, check dial indicator and set if needed. 2.7 Gage calipers to 1-1/2” and check dial indicator. 2.8 Gage calipers to 4-1/4” and check dial indicator. 2.9 If gage readings and dial readings do not match adjust till they do or replace

calipers. 2.10 Calipers must be recalibrated if off .001”.

TMS / Specialties

Title: Paint Gun Cleaner

J.W.

SOP # 81

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 After each use, pour excess paint in to proper container. 2.2 Put cups and lids over jets in bottom of the machine. 2.3 Use locking spring to lock trigger in the on position, put gun over jet and

follow instructions on the machine. 2.4 Close lid, set timer and start the machine. 2.5 When the machine stops, remove paint gun and reassemble. 2.6 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Paint Pot

SOP # 82

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Pour paint into pot, make sure hose is connected to gun then begin spraying. 2.2 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Paint Shaker

J.W.

SOP # 83

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Put paint in the machine, put the can in shaker and tighten until it stops, close

door and turn it on, when it stops remove can and close door. 2.2 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Paint Thinner Recycler

J.W.

SOP # 84

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Open lid and put in waste bag, be sure to lock it in place. 2.2 Pour used thinner in to machine. 2.3 Turn machine on and set the timer. 2.4 The next day, remove waste bag and pour recycled thinner in to can outside. 2.5 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Cincinatti Brake Press

J.W.

SOP # 85 (1.2)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Turn machine on. 2.2 Select proper top and bottom dies for the thickness of metal to be formed. 2.3 Check dies for excessive wear, cracks or chipped areas. 2.4 With the ram adjust lever locked, engage ram by flipping reverse –off-

forward switch to the correct selection in order to obtain the proper clearance to install dies.

2.5 Install correct bottom die, next install correct top die. 2.6 When dies are installed, adjust ram for proper clearance of dies to form the

correct angle of material being formed. 2.7 When the ram is not level, it can be adjusted by unlocking the ram adjust

lever on the front of the machine and level one side with the other. 2.8 CAUTION- any time this machine is started up, the depth of the ram should

be checked before completing a complete cycle. This is done by advancing ram with foot pedal in small increments. Until the ram is all the way down with proper clearance to bend material at correct degree angle.

2.9 Place job in dies, using extreme caution, advance ram slowly until part is formed.

2.10 When job is complete, turn machine off. 2.11 In an emergency, hit emergency stop button and leave the area. 2.12 The following personal protective equipment should be worn during this



TMS / Specialties

Title: 48” Chicago Brake Press

J.W.

SOP # 85 (1.1)

Revision: 3/1/06


1 RESPONSIBILITY


2 PROCEDURE

2.1 Turn on main power 2.2 Push start button 2.3 Select correct top and bottom dies for thickness of material to be formed. 2.4 Check dies for excessive wear, cracks, or chipped areas. Do not use

damaged dies. 2.5 Advance ram with foot pedal to desired clearance to install dies. 2.6 Install dies, advance ram to snug dies and tighten. 2.7 Adjust ram with wheel on right side of machine to proper degree angle of

material to be formed. 2.8 Never bend beyond the capacity of this machine. 2.9 Place material in dies and advance ram with foot pedal until bend is

achieved. 2.10 When job is complete, turn power off. 2.11 In an emergency, hit emergency stop bottom and leave the area. 2.12 The following personal protective equipment should be worn during this



TMS / Specialties

Title: CNC Laser Cutter

J.W.

SOP # 86

Revision: 10/29/08


1 RESPONSIBILITY


2 PROCEDURE

2.1 Turn on power breaker on back of machine. 2.2 Turn on green button and key on CNC control panel. When CNC is booted

up turn on laser on button. 2.3 Zero all axis on laser by moving cutting head any where on table and

pressing safety and all zero return at the same time. 2.4 Turn on power breaker on MSC Controller and press the green button on

controller. 2.5 Zero elevator by moving to load/unload position. 2.6 Turn on Ncell program on PC. 2.7 Select correct program to be cut and turn online tab on. 2.8 When job is finished, machine will unload part to the unload carts. Identify

with job number. Identify unused portion of material and put back in rack. 2.9 In an emergency, hit emergency stop button and leave area. 2.10 The following personal protective equipment should be worn during this



TMS / Specialties

Title: Inspection Tolerances

J.T.

SOP # 87

Revision: 4/15/09


1 RESPONSIBILITY

1.1 The Supervisor is responsible for the training of the Standard Operation Procedure (SOP) of this operation / process.

2 PROCEDURE

2.1 Copies of engineering drawings and customer-supplied drawings are made and sent to planning by engineering. 2.2 Relevant standards and codes are to be kept in the Customer files and issued to the departments involved. 2.3 Operator should examine drawing before starting machining operations to determine that he has a readable print and that he has all reverent paperwork. 2.4 Unless otherwise specified tolerances are to be per Title Block. 2.5 Non-tolerance Dimensions may be specified as:

2.6.1 X.XX (2) PLACES +/-.015”. Two place decimals will be considered as if dimensions are fractional. These dimensions should be checked during the initial setup and periodically through out the machining process. Depending on the quantity 10 percent should be sufficient. 2.6.2 X.XXX (3) PLACES +/-.005. Three places decimal should be checked closely during the machining process but again does not need to be checked every time as long as the dimension checked is held to the middle of the tolerance. Depending on the quantity of parts one out of three parts will be sufficient.

2.6 Tolerance Dimensions

2.7.1 X.XXX/X.XXX AS SPECIFIED. As specified dimensions are to be held to the specified tolerance. These dimensions are to be checked on each part to prevent deviation.

2.7 The following Personal Protective Equipment should be worn during this operation:

A. Safety Glasses.

B. Steel Toe Safety Shoes. C. Work gloves. D. Close fitting clothing, nothing loose, sleeves rolled up or buttoned, apron strings

tied in back, and shirttail tucked in.

TMS / Specialties

Title: Inspection Tolerances

J.T.

SOP # 87

Revision: 4/15/09


TMS / Specialties Title: TD Williamson Work Instruction

J.T.

SOP# 88

Revision: 6/30/09


1 RESPONSIBILITY

1.1 The Supervisor is responsible for the training of the Work Instruction of this operation.

2 PROCEDURE

2.1 Upon entering the routing into the E2 manufacturing software, the operator

shall indicate the Heat Number for the material in the job traveler comments. 2.2 If the Heat Number is not available at the time the job traveler is printed, an

area shall be accessible for the Heat Number to be added on the traveler once the material arrives at TMS.

2.3 If raw material is supplied by TMS, it must be purchased for each TD Williamson order.

2.4 If material is supplied by TD Williamson, receiving shall verify mill test reports received and properly label heat numbers on the job traveler and customer supplied material.

2.5 Once the material arrives at TMS the mill test reports shall be placed behind the order and a copy sent to the Quality Manager. The Heat Number shall be written on the raw material and job traveler when the material is received.

2.6 If the mill test reports are not included with the shipment, the material will be rejected or quarantined until the mill test reports are obtained.

2.7 After each operation is complete (burn table or machining), the Heat Number shall be stamped to each blank immediately after the operation is complete. The job will not continue until the Department Supervisor or Quality has signed off of the operation.

2.8 After the first article is completed, the inspection data will be gathered and maintained by a Quality Inspector assigned to the project.

2.9 If the Heat Number is machined off the part, the operator is responsible to communicate with Quality and stamp the Heat Numbers before each part is taken off the machine. The job will not continue until the Department Supervisor or Quality has signed off of the operation.

3.0 In-process inspection is added to the job traveler routing using the E2 Manufacturing Software. An inspection process will follow each level of operations accordingly.

3.1 If a non-conformance is found in process, a rework traveler shall be initiated

TMS / Specialties Title: TD Williamson Work Instruction

J.T.

SOP# 88

Revision: 6/30/09


for the item and a non-conformance/Corrective Action completed by Quality. A notation shall be made on the original traveler reflecting the heat number(s) of the piece(s) scrapped. Once the non-conformance paperwork has been processed, please reference procedure 2.1 thru 3.2 accordingly.

3.2 Quality shall gather and verify all appropriate inspection data, bubbled drawings and mill test reports prior to shipping.

3.3 Shipping is responsible for properly crating the items. The customers purchase order number, part number and heat number shall be listed on the outside of the crate and correlate with the customer’s purchase order. Inspection data, bubbled drawings and mill test reports shall accompany all shipments.

TMS / Specialties

Title: Process Control Expedited Orders “Normal Business Hours”

J.T.

SOP# 89

Revision: 2/1/10


1 RESPONSIBILITY


2 PROCEDURE

2.1 Sales receive the following order information from the customer prior to the

customer placing the rush order: Part #, Drawing / PDF Format Preferred, Sample (if required), Quantity, Description, Special Instructions (Finish, Paint, etc.), Requested/Required Delivery, Shipping (Delivery, Freight Line, UPS, etc.), Pricing (Approximate, Cost Plus, Time/Material, To Be Determined), Purchase Order (Verbal, Email or Faxed).

2.2 Sales and/or Engineering are responsible for drawings: If existing or repeat drawings, the Sales Person and/or Engineering shall; Exchange if Revised, Make Copy, Stamp “Copy”, Initial and Date, Check Reference Information. If the drawing(s) are new, the Salesperson and/or Engineering shall assign number and log in, Stamp “Original”, Make Copy, Stamp “Copy”, Initial and Date.

2.3 Once the drawing(s) information has been completed a production and sales

review “Initial Meeting” will take place.

2.4 Responsible Parties: Salesperson, Production Manager, Job Manager and Required Production Team. The responsibilities of the team are to: Determine Process, Materials and Delivery; Determine Plan of Attack and Required Action.

2.5 Once the initial review meeting has been completed, a Job Manager will be

appointed. The Job Manager Team consists of Kenny Smith, Matt Hendrix, Darrell Burlison, and Greg Parton.

2.6 After the Job Manager has been appointed, the order shall be sent to

Routing/Quote. The responsible personnel are as follows: Kevin Hurst, Dexter Browning, Darrell Burlison, Kenny Smith or Matt Hendrix.

TMS / Specialties


J.T.

SOP# 89

Revision: 2/1/10


2.7 Following the Routing/Quotation, the Salesperson is responsible for contacting the customer to follow-up and give status.

2.8 Once the customer is contacted, it is the Salespersons responsibility to finalize

the order and the order write-up is completed.

2.9 After the order is written up, the routing is reviewed to verify the requirements. Responsible personnel include: Kevin Hurst, Dexter Browning, Darrell Burlison, Kenny Smith or Matt Hendrix.

2.10 Following Routing Review, Order Entry into E2 (Print Travelers). The order

entry person shall mark the order and traveler with appropriate indicator (Blue Sticker) and sign the Job Managers name on the sticker. Responsible personnel for entering orders: Sandra Thornton, Kevin Hurst, Darrell Burlison or Matt Hendrix.

2.11 Once the travelers are printed, the Engineering Review Process takes place.

Additional drawings are pulled (if required), make additional copies (if required), verify correct drawings with traveler, write job number, initial and date the drawing.

2.12 Production and Sales Review Secondary Meeting. Responsible parties:

Salesperson, Production Manager, Job Manager and required Production Team. The team shall review the process, materials and delivery and review the plan of attack and required action.

2.13 Manufacture/Produce Required Parts and/or Services. Responsible

Personnel: Manufacturing Group.

2.14 Inspection Process. Responsible Personnel: Steve Caswell, Arlen Otwell and Jeff Taylor.

2.15 Shipment/Delivery. Salesperson is responsible to determine method of

shipment. (Deliver, Motor Freight, UPS, etc.)

2.16 Post Manufacturing Review Meeting: Responsible parties: Salesperson, Production Manager, Job Manager and required Production Team. The Team shall review the process, Materials, Delivery and Cost, review plan attack and

TMS / Specialties


J.T.

SOP# 89

Revision: 2/1/10


required actions and discuss and document needed corrections.

TMS / Specialties

Title: Process Control Expedited Orders “After Hours”

J.T.

SOP# 90

Revision: 2/1/10


1 RESPONSIBILITY


2 PROCEDURE

2.1 Sales receive the following order information from the customer prior to the

customer placing the rush order: Part #, Drawing / PDF Format Preferred, Sample (if required), Quantity, Description, Special Instructions (Finish, Paint, etc.), Requested/Required Delivery, Shipping (Delivery, Freight Line, UPS, etc.), Pricing (Approximate, Cost Plus, Time/Material, To Be Determined), Purchase Order (Verbal, Email or Faxed).

2.2 Sales and/or Engineering are responsible for drawings: If existing or repeat drawings, the Sales Person and/or Engineering shall; Exchange if Revised, Make Copy, Stamp “Copy”, Initial and Date, Check Reference Information. If the drawing(s) are new, the Salesperson and/or Engineering shall assign number and log in, Stamp “Original”, Make Copy, Stamp “Copy”, Initial and Date.

2.3 On Call Personnel: Team #1: Phillip Hart/Dewayne Ferguson, Team#2: Greg

Parton/Matt Hendrix. Team#3: Robert Brasher/Stanley Wade. Team Rebuild: Mark Haynes/Bubba Cooper. Each team will be on rotation per job and other resources can be used. Team Leader is Darrell Burlison.

2.4 Once the Team Leader has been notified and the appropriate team contacted,

it is the salespersons responsibility to contact the customer, follow-up and give status.

2.5 Manufacture/Produce Required Parts and/or Services. Responsible Personnel:

Manufacturing Group. Manufacturing time shall be gathered on Time Card.

2.6 Inspection Process. Responsible Personnel: On call Supervisor.

2.7 Shipment/Delivery. Salesperson is responsible to schedule method of shipment. (Hand Ticket Required)

TMS / Specialties

Title: Process Control Expedited Orders “After Hours”

J.T.

SOP# 90

Revision: 2/1/10


2.8 Routing Review: Verify Requirements. Required Personnel: Kevin Hurst,

Dexter Browning, Darrell Burlison, Kenny Smith or Matt Hendrix.

2.9 Enter Order (Print Travelers). Following Routing Review, Order Entry into E2 (Print Travelers). The order entry person shall mark the order and traveler with appropriate indicator (Blue Sticker) and sign the Job Managers name on the sticker. Responsible personnel for entering orders: Sandra Thornton, Kevin Hurst, Darrell Burlison or Matt Hendrix.

2.10 Material and Time Transfer. Transfer time from Hand Ticket to routing.

Capture all material, all time, and all expenses, indicate machine(s) operated and review all cost.

2.11 Following the Time Transfer, the Salesperson is responsible for contacting

the customer to indicate pricing, review job and express appreciation.

2.12 Bill Out in E2. Create Packing Slip and Process Invoicing. Responsible Personnel: Shipping Department and Salesperson.

2.13 Post Manufacturing Review Meeting: Responsible parties: Salesperson,

Production Manager, Job Manager and required Production Team. The Team shall review the process, Materials, Delivery and Cost, review plan attack and required actions and discuss and document needed corrections.

Documents

TMS/SPECIALTIES SOP LIST - tmsco.com · TMS/SPECIALTIES SOP LIST ... remove the job and flip off switch. ... All maintenance performed on that machine will be compliance to the Lock