Eagle Machining, Inc.

Transcription

1 Company Manual REVISIONS DATE DESCRIPTION REVIEWED APPROVED REVISION 04/04/2014 Update machine capacities JV, HL, JN JV Rev. C 01/25/2014 Update procedures & equipment JV, HL JV Rev. B 01/29/2010 Modification/Formatting JV, HL, DN JV Rev. A

2 Table of Contents I. THE COMPANY... 3 A. ABOUT US... 3 B. CONTACT INFORMATION... 3 II. STATEMENT OF POLICY... 4 III. STATEMENT OF PROCEDURE... 4 A. PROCUREMENT OF MATERIAL Order Entry Purchase orders Acknowledgements... 4 B. MATERIAL RECEIVING CONTROL Document Control Procedures Material Verification Control... 4 C. ORDER ACCEPTANCE... 5 D. ORDER PROCEDURES... 5 E. ORDER PROCESS... 6 IV. INSPECTION EQUIPMENT... 7 A. CALIPERS... 7 B. GAGES... 7 C. MICROMETERS... 7 D. MISCELLANEOUS... 7 V. EQUIPMENT... 8 A. CNC LATHES... 8 B. CNC MILLS C. MANUAL MILLS Page 2 of 11 Date: 04/04/2014 Rev. C

3 I. THE COMPANY A. About Us specializes in the precision machining of a diverse range of critical components for the oilfield industry and specialty metal/plastic components. Most of these components are made from a variety of metals and plastic including: titanium, k-monel, stainless steel, carbon steel, copper, aluminum, cast iron, and plastic. Eagle Machining possesses a comprehensive range of state of the art CNC equipment and highly skilled craftsmen, creating an ideal setting for quality work and services. The Mission of is to provide quality products to our customers by working closely with our customers to meet their specifications and requirements. In addition, we are committed to the continuing improvement of our work processes and daily activities to meet the future requirements of the customers. B. Contact Information EAGLE MACHINING, INC Antoine Dr, Bldg D Houston, TX Tel: Fax: info@eagleminc.com Page 3 of 11 Date: 04/04/2014 Rev. C

4 II. STATEMENT OF POLICY The Manager of Manufacturing will designate those Quality Assurance or Quality Control personnel to receive raw materials for processing of customer orders. These designated Quality Assurance Quality or Control personnel will have the responsibility to keep a full and continuous record on all information and documentation pertaining to the area in which they have been assigned. The Quality Assurance or Quality Control personnel will have complete control of their particular area and will have full authority to reject any nonconforming materials. III. STATEMENT OF PROCEDURE This procedure is to describe all areas of acquisition, stocking, handling, processing, record keeping, inspection, shipping, and responsibility regarding processing of customer's orders by Eagle Machining. A. Procurement of Material Any material purchased by Eagle Machining for jobs will require the mill of origin to provide full certified specifications and the result of all designated testing and documentations or any other non-test specification be required in order to provide trace ability, the following procedure will be followed: 1. Order Entry Order will be placed according to specifications from Eagle Machining customers. Eagle Machining will assign a Work Order or Job Number for each item. 2. Purchase orders a) Eagle Machining place an order with a vendor or customer s approved vendors. b) A copy of the purchase order is scheduled for pick up or awaiting for delivery. 3. Acknowledgements Acknowledgement will be checked with the original purchase order for any discrepancy. The purchase order is then retained for three years or more. B. Material Receiving Control 1. Document Control Procedures a) Receiving tickets are prepared and process in accordance with an established practice. b) Receiving documents are checked for complete information such as material specifications references, quantities heat number identification, and any other identifications or information. c) Material is then tagged per Eagle Machining job number, matched with job card and put into production accordingly. d) A copy of the material test report is included with the job. e) A copy is also scanned into the computer for record. 2. Material Verification Control a) The unloading, receiving, and verification of all inbound merchandise are performed in Page 4 of 11 Date: 04/04/2014 Rev. C

5 accordance with an established practice. b) Receiver records the quantity received by noting the number of bundles, boxes, crates, and actual quantity on the packing slip. Extra caution is exercised during unloading to avoid in-house damage. c) A determination of received quantities is made by the receiving departments. d) Quality checks of received material are performed by receiving against established manufacturing standards, size, shape, or finish. e) Heat number and identification marks are tagged on the material. f) Upon receipt of heat controlled material for which certifications are required, receiving personnel checks for certifications and checks for proper heat number tags, etc... g) Receiving department determines that all received products are properly identified before placing into processing areas. C. Order Acceptance a) Customer orders are accepted by Eagle Machining Sales Department, in accordance with a standard, established practice, and are put in Work Order with all necessary information provided by customer such as quantity, special processing, details, or any other instructions or requirements. b) When an order is developed as the result of an inquiry and a formal written quotation, the customer s order requirements are verified by the conditions of the written quotation. c) All orders are assigned a sequentially registered number, which serves as the control reference for processing, shipping, invoicing, and documentation or respective orders. d) Customers confirming Purchase Orders are reviewed in accordance with procedures to establish conformance of the customer s order requirements with that of the entered telephone order. e) Customer's inquiries and orders involving critical requirement materials are reviewed by the quality Assurance Manager or his designated representative. f) Order changes will be processed when possible, in accordance with the practice used for a new order. D. Order Procedures a) Production receives a copy of assigned work order along with blue prints and specified material. b) Material is checked and inspected prior to machining or forming in accordance to assigned policy. c) The plant copy of the job order is routed to each step in the processing sequence. Material received, saw or shear, machine, or appropriate department. d) Inspection practices and responsibilities include the following: Refer to section II-C and II-D. e) Material is inspected as required by customers purchase order for condition, finish, and size, evaluated for conformance with purchase order and indicated customer order requirements and specifications. This includes verification of heat treat or any other specification, when applicable. f) Inspection performs control and assigned inspection to assure proper order processing. Refer tin Inspection Section VII. g) Customer requirement which involve extra testing outside processing; such as, paint, anodizing, act. Will be handled in accordance to customer's selection. (See back section). h) The machine operator makes certain that the heat number is retained on all resulting shorts and for storage purposes last job number tagged on material. i) Marking of parts is executed to customer purchase order; low stress stamps are to be employed, per customer specification. (See back Section). j) Loading and shipping control of orders is provided by documentation packaging with appropriate Page 5 of 11 Date: 04/04/2014 Rev. C

6 notations. k) Certification of processed orders is the responsibility of Quality Control personnel. Refer to Inspection Section VII E. Order Process 1. Phase I: Inspection Procedures a) Material inspection refer to Section VI b) Material processing sawing and shearing of material per ob is placed with job card in designated area for job assignment to machine. c) Material sent for special services, heat treat, act., are sent at this point to returned materials refer to Section V, I-G and section VI, 1-A-E. 2. Phase II: Job assignment a) 1 st operation, completion part is brought to inspection to be determined if necessary adjustment are to be incorporated. b) All threaded parts are gagged in machine before removing. 3. Phase III: Inspection Procedure a) All jobs are spot inspected throughout completion parts. This procedure is performed on all operations per customer specification. b) Every tenth part of ten or more quantity complete inspection is performed on all steps to assure control and determine any necessary adjustments. 4. Phase IV: Finishing c) Deburr; Threads, holes, slots, etc, determined by specific part. d) Cleaned and degreased and returned to inspection. e) Parts are 100% checked at this point. If so specified, parts are marked, stencils, and if outside process specified sent out for those services, (paint, anodizing, etc.) For returned parts refer to Section V-G and section VI step 1 A-E. f) Parts are then to be package per customer specifications or returned to another specified area if part of assembly. g) Data control forms are filed out on all non-title block dimensions. Page 6 of 11 Date: 04/04/2014 Rev. C

7 IV. INSPECTION EQUIPMENT A. CALIPERS 1. 0" 4" Mitutoyo Digital Caliper. 2. 0" 6" Mitutoyo Digital Caliper. 3. 0" 8" Mitutoyo Digital Caliper. 4. 0" 10" Mitutoyo Digital Caliper. 5. 0" 12" Mitutoyo Digital Caliper. 6. 0" 24" Mitutoyo Digital Caliper. 7. 0" 40" Mitutoyo Digital Caliper. B. GAGES 1. Brown & Sharp Tesa Micro Hite Plus M "/300mm Mitutoyo Digital-Mastic Height Gage. 3. 5/6 6" Mitutoyo Telescoping Gage. 4. 5/6" 6" General Telescoping Gage SPI Angle Gage. 6. 4" 80" Thread Gage mm 2.5mm Thread Gage " 0.5" Steel Plug Gage. 9. Starrett 29 Deg ACME Screw Thread Gage /64" 0.5" Starrett Radius gage sets (2 sets) " 0.045" Starrett Thickness Gage " 0.5" Starrett Dial Depth Gage " 0.5" Mitutoyo Dial Thickness Gage. 14. Pitch 12 Pitch Starrett ACME Crew Pitch Gage /8" 7/8" General Inspection Gage balls. C. MICROMETERS 1. 0" 6" Starrett outside Micrometer. 2. 0" 12" Mitutoyo outside Micrometers (2Sets). 3. 1" 8 " Starrett inside Micrometers (2sets). 4. 0" 6" Starrett Depth Micrometer. 5. 0" 8" Starrett Depth Micrometers (2Sets). 6. 0" 6" Mitutoyo Blade Micrometer. D. MISCELLANEOUS 1. 18" x 24" Starrett Crystal Pink Granite Surface Plate. 2. 2" x 4" x 2" Brown & Sharpe V-Blocks. 3. 3/8" 21/4" Brown & Sharpe Adjustable Parallels Set Precision Angle Blocks. 5. 7" Starrett Universal Bevel Protractor. 6. 4" Starrett Mechanics' Improved Levels " 6" Intrepid Dial Indicial. 8. SPI Surface Roughness Standards " 1" General Space Block Set " Mitutoyo Precision Square. Page 7 of 11 Date: 04/04/2014 Rev. C

8 V. EQUIPMENT A. CNC Lathes SAMSUNG SL-35/1500: Fanuc Oi-TD Control 15 Hydraulic Chuck X-Axis Travel: Z-Axis Travel: HP Spindle Motor 2,000 RPM Spindle 10 Turret Stations 4.63 Bar Capacity Spindle Nose A2-11 SAMSUNG SL-25/500: Fanuc Oi-TD Control 10 Hydraulic Chuck X-Axis Travel: 14.9 Z-Axis Travel: HP Spindle Motor 3,500 RPM Spindle 12 Turret Stations 3.0 Bar Capacity Spindle Nose A2-8 MORI SEIKI SL-300: Fanuc 18i Control 12 Hydraulic Chuck X-Axis Travel: 16.5 Z-Axis Travel: HP Spindle Motor 3,500 RPM Spindle 12 Turret Stations 2.9 Bar Capacity 3.4 Bore Spindle Nose A2-8 Page 8 of 11 Date: 04/04/2014 Rev. C

9 MORI SEIKI FRONTIER-L II: Control MSC 521 Fanuc 18i 10 Hydraulic Chuck X-Axis Travel: 14.9 Z-Axis Travel: HP Spindle Motor 3,500 RPM Spindle 10 Turret Stations 2.5 Bar Capacity 3.0 Bore Spindle Nose A2-8 DAEWOO LYNX-210L: Fanuc 21i Control 8 Hydraulic Chuck X-Axis Travel: 12.6 Z-Axis Travel: HP Spindle Motor 4,000 RPM Spindle 12 Turret Stations Bar Capacity 20.1 Over Bed DAEWOO PUMA 240C: Fanuc 21 i-tb Control 10 Hydraulic Chuck X-Axis Travel: 13.8 Z-Axis Travel: HP Spindle Motor 3,500 RPM Spindle 12 Turret Stations 3.0 Bar Capacity 20.7 Over Bed Page 9 of 11 Date: 04/04/2014 Rev. C

10 FEMCO WNCL-35 Fanuc OT Control 15 Hydraulic Chuck X-Axis Travel: Z-Axis Travel: /40 HP Spindle Motor 2,500 RPM Spindle 12 Turret Stations 4.5 Bar Capacity 24.4 Swing Over Bed B. CNC Mills (2) SAMSUNG MCV850S: Fanuc Oi-MD Control X-Axis Travel: 78.7 Y-Axis Travel: 33.5 Z-Axis Travel: HP Spindle Motor 6,000 RPM Spindle 8.0 Rotary Index Table 40 Tools Drum Type ATC CAT50 Taper Spindle 290 PSI Through Spindle Coolant Two machines DAEWOO DMV-3016Dl: Fanuc Control Oi-M X-Axis Travel: 32.2 Y-Axis Travel: 16.1 Z-Axis Travel: HP Spindle Motor 8000 RPM Spindle 7.0 Rotary Index Table 20 Tools Drum Type ATC CAT40 Taper Spindle 1200 PSI Through Spindle Coolant Page 10 of 11 Date: 04/04/2014 Rev. C

11 C. Manual Mills ACER 1054 Bed Mill: Fagor 8055i 3-axis CNC control X-Axis Travel: 31.5 Y-Axis Travel: 20.0 Z-Axis Travel: CAT40 Taper Spindle 5 HP Spindle Motor ACER Manual Mill w/dro X-Axis Travel: 28.0 Y-Axis Travel: 12.0 Z-Axis Travel: 16.0 R8 Taper Spindle 3 HP Spindle Motor Page 11 of 11 Date: 04/04/2014 Rev. C