SYSTEM PROCEDURE

Tooling Repair & Perishable Tooling

REVISION: 00 PROCEDURE NO.: PTR003 DATE EFFECTIVE: 02/26/01

1. PURPOSE

1.1. The purpose of this document is to define the process by which tooling is maintained and
repaired.

2. SCOPE

2.1. This procedure applies to the repair and maintenance of all production tooling, including
the controls for the identification and utilization of perishable tooling.

3. RESPONSIBILITY

3.1. The V.P./G.M. of Fabrication Division, and the Stamping Operations Manager have the
primary responsibility for ensuring compliance of this procedure and to ensure the necessary
resources for successful implementation are provided.

3.2. Tool Room, Quality Control, and Production personnel are responsible for complying with
this procedure.

4. REFERENCE DOCUMENTS

4.1. Quality System Manual

4.2. Control of (COMPANY) Part Master (PDE003)
4.3. Fabrication Division System Controls (PFD001)
4.4. Information Services (PIS001)
4.5. Production Planning & Scheduling (PMF003)
4.6. Purchasing (PPR002)
4.7. Advanced Product Quality Planning (PQC004)
4.8. Document & Data Control (PQC008)
4.9. First Article Inspection (PQC007)
4.10. First Piece Inspection (PQC012)
4.11. In-Process & Last Piece Inspection (PQC013)
4.12. Control of Quality Records (PQC020)
4.13. Tooling Management (PTR001)

5. REQUIRED DOCUMENTS/MATERIAL

5.1. Tooling Release – green tag (FTR007)

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Tooling Repair & Perishable Tooling

REVISION: 00 PROCEDURE NO.: PTR003 DATE EFFECTIVE: 02/26/01

5.2. Tooling Inspection Request – red tag (FTR006)

5.3. Die Maintenance Log (FTR001)
5.4. Die Repair Ticket (FTR002)
5.5. Perishable Tool Log
5.6. Die Repair Codes List (FTR008)

6. PROCEDURE

6.1. GENERAL REQUIREMENTS

6.1.1. Production Supervision in conjunction with Set Up Personnel shall be

primarily responsible for identifying maintenance needs for all production
tooling utilized during (COMPANY)’s Stamping and Fabrication
Operations.

6.1.1.1. In the case of Stamping Operations this responsibility shall

be extended to the Tool Room personnel who are
responsible for performing the tooling maintenance and
repair activities.

6.1.1.2. In the case of Fabrication Operations a procedure shall be

established for the maintenance and repair of (COMPANY)’s
Fabrication Tooling.

6.1.2. There shall be four primary ways to determine the maintenance & repair
requirements for tooling utilized during (COMPANY)’s Stamping
Operations.

6.1.2.1. The preventive maintenance requirements (if any)

established by the Production Planning Team shall be
established via the Set-Up Instructions on the Job Router for
those tools required for that operation. Typically the
instruction is to have the tool room perform some action
either before set up or after so many cycles of the press
during production.

6.1.2.2. Production Supervision or Set-Up Personnel shall identify

routine maintenance requirements during the teardown of a
production run (see The Red & Green Tag – Tool
Maintenance System below).

6.1.2.3. QC Personnel shall identify maintenance and/or repair

issues during First Piece, In-Process, & Last Piece
Inspection by generating and processing a Die Repair Ticket
(see applicable section below).

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Tooling Repair & Perishable Tooling

REVISION: 00 PROCEDURE NO.: PTR003 DATE EFFECTIVE: 02/26/01

6.1.2.4. Tool Room Personnel shall identify maintenance and/or

repair issues while performing maintenance and/or repair
per the above methods.

6.2. The Red & Green Tag - Tool Maintenance System

NOTE: This System shall primarily be utilized for Dies used in the Stamping
Operations. It shall also be utilized in the maintenance of Tooling and
Inspection Fixtures when scheduling the maintenance and repair is
crucial to meeting production requirements.

6.2.1. Production Supervision and Set-Up Personnel shall use the Red &
Green Tag - Tool Maintenance System during the teardown of production
jobs.

6.2.1.1. The Red Tag, Tooling Inspection Requested, shall be

generated when a maintenance concern is identified during
the teardown of the Production Job. Maintenance items are
typically determined either by a visual examination of the
tooling and/or a visual examination of the last production
part (strip in the case of progressive stamping dies).

6.2.1.1.1.The last production part shall be

submitted to QC for Last Piece Inspection
(see PQC013).

6.2.1.1.2.In the case of progressive stamping dies

the last production strip shall be kept with
the die until pulled for the next production
run.

6.2.1.2. The Red Tag shall be placed on the specified tool as a visual
maintenance status of the tool, to remind Production
Supervision that the tool needs to be evaluated and/or
worked on by the Tool Room prior to setting up for the next
production run.

6.2.1.3. The Green Tag, Tooling Release, shall be generated by

Production Supervision and/or Set-Up Personnel when the
visual examination of the tooling and last production piece
do not show any maintenance needs during the teardown of
the production job.

6.2.1.4. The Green Tag shall be placed on the specified tool as a

visual maintenance status of the tool, indicating that the tool
does not need to be evaluated by the Tool Room for
maintenance and/or repairs prior to the next Set-Up for
production.

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Tooling Repair & Perishable Tooling

REVISION: 00 PROCEDURE NO.: PTR003 DATE EFFECTIVE: 02/26/01

6.2.2. Tool Room Personnel shall use the Red & Green Tag – Tool
Maintenance System during their routine maintenance and repair
activities.

6.2.2.1. In the case where the tool is being inspected per the Red
Tag generated by Production Supervision and/or the Set-Up
Personnel, the Tool Room Personnel shall generate a Green
Tag indicating that the maintenance items have been
evaluated and the appropriate actions have been taken to
allow the tool to be utilized in production.

6.2.2.1.1.The Green Tag shall be placed on the

specified tool as a visual status of the
tool’s readiness for production.

6.2.2.1.2.If there are further maintenance issues

identified and they do not need to be
performed during this maintenance
and/or repair activity, then the Tool Room
Personnel shall make note of the
maintenance items to be worked on after
the production run.

6.3. The Die Repair Ticket – Tool Maintenance & Repair System

6.3.1. The Tool Room receives a Die Repair Ticket from Quality Control or
Production when either function determines that repair or maintenance
of the tool is required.

6.3.2. Die Repair Tickets are routed as follows:

White Copy  Inspector (QC)
Yellow Copy  Tool Room ((COMPANY) Die Repair Data when
completed)
Pink Copy  Production
Tan (Manila) Copy  With Last Piece or Sample,

6.3.3. When complete, all repair and maintenance work is recorded on the Die
Repair Ticket and in the Die Maintenance Log.

6.3.4. The Tool Maker shall complete the Die Repair Ticket by entering:
 A description of the Work Performed on Tool
 Die Repair Code #’s (Die Repair Codes List)

6.3.5. Initial and complete a Die Maintenance Log Record by entering:

 Date
 Work Done
 Reject Tag # (Die Repair Ticket #)

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Tooling Repair & Perishable Tooling

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 Reason Code (Die Repair Code)

 Initials
 Hours required for repair

6.4. REPAIR OF TOOLING/DIES IN PRODUCTION

6.4.1. The Tool Room shall receive a copy of the Die Repair Ticket.
NOTE: A part sample to illustrate the problem being experienced with
the die may accompany the ticket.

6.4.2. The Tool Maker shall decide whether to pull the die from the press for
repair, or to attempt to adjust the die in the press.

6.4.3. If the die will remain in the press:

6.4.3.1. Make adjustments to the die.

6.4.3.2. Run sample parts with the Set-Up Person under normal
operating conditions of the press.

6.4.3.3. Verify acceptability of the parts using the standard inspection

procedure.

6.4.3.4. Make further adjustments until acceptable parts are obtained, or

pull the die.

6.4.4. If the die is to be pulled from the press, alert a Production Supervisor
and/or Die Setter to bring the die to the Tool Room.

6.4.4.1. Repair and/or maintain the die as necessary.

6.4.4.2. Alert the Production Supervisor, or Die Setter. They will alert a
Jeep Driver to deliver the die to the appropriate press.

6.4.4.3. The Die Setter will reset the die in the press.

6.4.4.4. Run sample parts under normal operating conditions of the

press.

6.4.4.5. Determine acceptability of the parts using the standard

inspection procedures. NOTE: If necessary, the die may be
removed again for further repair, or may be adjusted while in the
press, until acceptable parts are obtained.

6.4.5. Complete the Die Repair Ticket and enter into the Die Maintenance Log.

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6.4.6. Place the Die Repair Ticket in the designated location in the Tool Room,
for the assigned person and/or function to collect and enter into the
(COMPANY) Die Repair Menu. NOTE: Any sample part accompanying
the repair ticket shall be scrapped.

6.5. REPAIR OF TOOLING/DIES OUT OF PRODUCTION (Backlog)

6.5.1. The Tool Room Supervisor and/or Lead Person shall coordinate with the
Production Control Manager and/or Stamping Operations Manager the
maintenance and repair activities for tooling/dies not in production (also
known as Backlog)

6.5.2. The Tool Room Supervisor and/or Lead Person shall assign the backlog
items to the appropriate Tool Maker and ensure that the Jeep Driver
retrieves the tooling from its designated location.

6.5.3. The Tool Maker shall perform the necessary repair and/or maintenance
work on the tooling/die (see Die Repair Ticket or Tool Maker’s notes on
die maintenance needed).

6.5.4. Completes the Die Repair Ticket and enters the activity in the Die
Maintenance Log, including the Tool Maker’s initials.

6.5.5. Places the Die Repair Ticket (yellow copy) in the designated location in
the Tool Room for the assigned person and/or function to collect and
enter into the (COMPANY) Die Repair Menu.

6.5.6. Have the die returned to its regular storage location, depending on the
scheduling of its next production run.

6.6. PERISHABLE TOOLING

6.6.1. The Tool Room Supervisor and/or Lead Person shall establish in the
Perishable Tool Log those Tools (e.g. punches, inserts, springs, etc.)
requiring unique control.

6.6.1.1. This unique control shall be based on those tooling items

that cannot be purchased or made in a timely manner in
order to meet production requirements.

6.6.2. The Tool Room Supervisor and/or Lead Person shall also determine
what levels of perishable tooling is necessary (if any) to meet current
production schedules.

6.6.3. Tool Room Personnel shall notify the Supervisor and/or Lead Person
when the levels of perishable tooling are low so they may be reordered
or made, as determined necessary.

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Tooling Repair & Perishable Tooling

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7. RECORDS

7.1. (COMPANY) Die Repair Menu (Data/Tickets)

7.2. Die Maintenance Log
7.3. Perishable Tool Log

8. REVISION HISTORY

REVISION DATE OF
SECTIONS DESCRIPTION OF CHANGE
LEVEL REVISION
Re-Issued Procedure to comply with Restructured Quality
System (Baseline with QS-9000 Registration) and PQC008
– Document & Data Control.
00 02/26/01 All Added more detail on the Red & Green Tag – Tooling
Maintenance System for clarification. Also gave further
clarification as to Perishable Tooling (versus the spare
tooling storage and retrieval system).

9. AUTHORIZATION

POSITION HELD BY AUTHORIZATION SIGNATURE OR INITIALS

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