Process Documents

[JParis]

I was wondering if anyone had a complete "Process Document" that they could share...

I am making a push into this direction now...

With 60 machines on the floor and growth imminent, more machines to start rolling in in 1st quarter 2025, it's long past time to take this next step.

Process Document, what am I talking about?

A document that details all the tooling, fixtures, cutting tools, holders any other required specific information...how is the part held, hold exactly is loaded, torque specifications...a manufacturing drawing detailing dimensions cut in each operation, dimensions to check, tools tool use, records of dimensions checked...a complete process document that can be stored electronically, access as required and use to check-off "Certify" that "said" individual is "signed-off" to run that job.

Simply put this isn't "job shop" level documentation.

[Newbeeee™]

Simply put this isn't "job shop" level documentation.

Yeh I did this for a couple of parts - one for the external ice and snow detection system used on every Sikorsky search and rescue 'copter.
And, I was a job shop 

[JParis]

Yeh I did this for a couple of parts - one for the external ice and snow detection system used on every Sikorsky search and rescue 'copter.
And, I was a job shop 

Yeah, there is a certain class of work that would do so...

[CNCAppsJames]

...

Process Document, what am I talking about?

A document that details all the tooling, fixtures, cutting tools, holders any other required specific information...how is the part held, hold exactly is loaded, torque specifications...a manufacturing drawing detailing dimensions cut in each operation, dimensions to check, tools tool use, records of dimensions checked...a complete process document that can be stored electronically, access as required and use to check-off "Certify" that "said" individual is "signed-off" to run that job.

Simply put this isn't "job shop" level documentation.

I've not seen anything like that out in the wild that wasn't generated though a PLM system. Both companies I'm thinking of had 1-2 people who's only job was to create documentation in support of machining. They used that position as Programmer Development. If they could get the documentation squared away with the necessary level of attention to detail, then they could probably be programmers when a position opened up.

Obviously you use Mastercam, but what CAD do you use?

[JParis]

Obviously you use Mastercam, but what CAD do you use?

Solidworks...

There is a push on to bring in PTC Windchill for a PLM system.

[CNCAppsJames]

Solidworks...

There is a push on to bring in PTC Windchill for a PLM system.

If your first post is any indication of the direction you need to go, you've basically got  3 choices; PTC, NX, or CATIA. If you stomach at least looking at a fringe system, Top Solid may be a viable solution.

[Newbeeee™]

Yeah, there is a certain class of work that would do so...

To elaborate John....Obviously Jobcard/Routecard/Traveller went with all jobs.
THIS controlled everything. THE master document, with its unique Job number.
Part number, rev number, description yada yada - all the normal stuff.
Material spec, size, and batch number written onto it.
Then it was populated per operation, but adding anything necessary and for more detail, an MPS (Manufacturing Process Sketch) would be added, which was the part number, but with a MPS prefix (Company drawing border, issue controlled, produced on Autocad.)
For the setup sheet, that was a PDF with the prog number prefix and "SetupSheet" suffix. So for this instance,
It would be called VMC-0804 SetupSheet.pdf
On this, was again part number, revision, and everything needed - tool manufacturer, stickout, holder size etc.
All info to make the part, in a Customer specific directory, with folder called by Part number and revision.
And within that, and OOI (Out of Issue) directory, where all info for previous revisions were kept (so we could make old versions if required).
EVERYTHING, to make the part, including important emails (drawing deviations etc) were within this specific folder.
And only the one prog in the control at a time.
And preferably no sub progs as they sometimes were forgotten to be saved....although we laterally went to internal subs on the odd job which done away with this problem.
Prog header also had
Customer
Part No
Rev No
Op No
Sub No's if applicable
All datums via G10
So everything locked down and controlled, but we were a small business....

Op No    Work Centre                                                       
10    Inspection                   
Release Job for Production (Sign & Date).                                                                       
Check & Verify Mtl (Sign & Date).                                       

20    CNC Mill    VMC-0804 (specific prog #)  HT-0301 (specific fixture #) 
4th Axis Fixture:                                                                                       
Load to Fixture & M/C inside as per MPSXXXXX .   
Part Rotates 180degrees & M/C Datum Face, 2.620" Dia, & M5 WTI Tapped Holes.                           
Deburr in Cycle 
                                 

30    CNC Mill            VMC-0805  HT-0301A                   
4th Axis Fixture:                                                                                       
Load to Fixture
M/C all Peripheral Faces as per MPSXXXXX.
Also Finish M/C Neck.                                                         
Deburr in Cycle
                                   

40    CNC Mill            VMC-0807  HT-0301B                   
Load to Fixture: 
Finish M/C Neck Radius & Bore. Bore to be 28.03/28.015 Pre-Plate.                                       
Deburr in Cycle                                   

50    Inspection                   
Inspect Prior to Treatments                                   

60    SubCon xxxx                   
Treat to drawing requirements                                                                           
CofC required                                   

70    Inspection                   
Verify Treatments                                                                           
Final View

                           

[Rstewart]

Last place I was at - acting as a Mfg Eng, we had an ERP software (Solumina).  My main job was to plan out the processes, document everything, (with nice Solidworks pictures) and sometimes manufacturing drawings.  Every machine/workspace had a computer on the network to check off on each step.  If they were complicated or tedious, the worker couldn't check through it without me also signing off on that specific step.
I have no idea how ya'll have gotten this far without ERP / PLM. 
You must hire only the finest operators.

[JParis]

Oh, we have an ERP system...it's currently a mess and a work in progress...

PLM has quickly become a necessity as we have so much that isn't connected to each other.

[Newbeeee™]

Oh, we have an ERP system...it's currently a mess and a work in progress...

PLM has quickly become a necessity as we have so much that isn't connected to each other.

You places that are "world class"
If only all y'all ran more like job shops....

[Zoffen]

Oh boy you are up for some pain!

If it were me and I were in your shoes this is what i'd do and how'd I'd do it. Take everything with a grain of salt as I am a 1 person job shop but still strives to document everything as I forget alot! + also just some guy on the internet.

The hardest part about where you are at is where to start. When you are staring up at the mountain from the bottom the task may seem insurmountable but just like eating an elephant, you do it one bite at a time. Regardless of what ERP/MRP system you go for you most likely will still have to generate the documents manually so you might as well start there.

First step is to define some process documentation templates. Essentially like newbee wrote out about you need to define what/why you need to document/manage. This is only the first draft and it will be refined over time.

Now that you have figured out what you need to document/manage try to identify the job/part that REALLY NEEDS the documentation. This the the low hanging fruit. Its the jobs that only guy A can run, or the jobs that have alot of scrap or the job that can only be run on Machine B for a certain reason. Those dumb frustrating jobs that everyone hates.

Now go through and document the shit out of this job.

Next time the job comes around you have a sweet "Test" you can run to see how effective your documentation was.

Opps missed this info, added this info from the operator that only they remember when running the parts, Better photos with more details yada yada yada

The goal is every time you run the job you refine the process docs until they are GOLDEN GODS OF PROCESS DOCUMENTATION.

Cool. Now move onto the next part. Now the next part. Now the next part. All the while refining the PROCESS of creating Process Document.

Then however you decide to store these documents you can figure out later. Possibly write your documents in a standard way that this info can be imported in your ERP/MRP automatically?


Since now the jobs hopefully start running smoother/faster/better, you should easily be able to track this data and use this ass ammo in your magazine when talking to management about spending money doing this stuff. It will most likely require a person full time to do this as well. But hey if they can keep the spindles turning 1% more they probably have paid for their salary 10x over.

Good luck!

[Newbeeee™]

^^^^adding to Zoffren (also +Big 1 at standardisation of templates)
Yes, digi photos were also a big thing. Picture says a thousand words. Digi photo into paintshop and a few notes added onto that, then paste into the setup sheet - we did this alot too.
And gotta remember 2x things.

#1 is beware of information overload.
#2 is people's eyes glaze over and hate reading info.

 

[Zoffen]

Powerpoint is the way! Every step is slide. Do whats on the slide and move on.

[JakeL]

Gonna rant for a minute...

Few weeks ago had an operator scrap a bunch of parts. Turns out he wasn't pushing the part against the bump stop in the second op. Furthermore, he wasn't checking the finish dimension I specifically put on the operation sheet to ensure the part was pushed against the bump stop. 

Long story short we had to write up a corrective action. One of our engineers came to me and asked me to put on the operation sheet "ensure part is against bump stop". And add a note to make sure that dimension was checked every part to ensure the part was loaded correctly.

I told the engineer I'd add the notes, but most of the guys on the shop floor are going to think I'm an idiot for writing that on the operation sheet because it's obvious.

Rant over.

All of this to add that just because a step is on the operation sheet doesn't mean it's going to happen. What's that saying about idiot proofing and always coming up with new idiots? 

[Zoffen]

new idiots? 

Replace this person with a robot.