Tool Repair & Tool Maintenance Process

1 PURPOSE
1.1 This procedure defines the process of tool repairs and/or maintenance performed to ensure tooling and product
quality is maintained.

2 SCOPE
2.1 This procedure applies to all maintenance and repairs for customer tooling used to manufacture the product.
2.2 This procedure applies to the stamping department where customer tools are used to manufacturer the product..

3 RESPONSIBILITY
3.1 Engineering is responsible for the effectiveness and maintenance of this procedure.
3.2 Production Scheduling is responsible for checking tool repair status when planning production orders.
3.3 Tooling Manager is responsible for scheduling repairs and/or maintenance in timely manner.
3.4 Tooling, Production Setup and Quality personnel are responsible for reviewing tool condition generally at time
of last-off in order to request for actions needed for repair and/or maintenance.
3.5 Quality personnel are responsible for checking last-off samples when tool repair requests are issued that may
require additional action to be included on repair tickets.
3.6 Tooling personnel are responsible for performing and documenting actions taken and labor hours on repair
tickets.
3.7 Tooling, Production and Quality personnel are responsible for verifying actions taken on tool repairs to ensure
product quality is maintained.

4 TERMS & DEFINITIONS

4.1 Setup – Request for repair at time of production setup and/or setup inspection related to product quality.
4.2 In Process – Request for repair during production run cycle related to the tools performance and/or inspection
results affected product quality.
4.3 Last Off – Request for action determined during the end production run cycle review and or last off inspection
that results effected product quality.
4.4 Other – Request for action needed on a tool determined at any other time not listed above. These are generally
changeover requests needed during production scheduling, etc.

5 ASSOCIATED DOCUMENTS AND REFERENCES

5.1 Larsen Quality Manual
5.2 Tool Repair Database
5.3 Production Scheduling Procedure
5.4 Manufacturing Operation Procedure
5.5 Control of Non-Conforming Product Procedure
5.6 Preventive & Corrective Action Procedure
5.7 Customer Supplied Products and Properties
5.8 Tool Repair Ticket Form

Document Name: Tool Repairs and Maintenance Process Printed copies of this document are not controlled Date: 01/24/2020
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 Tool Repair & Tool Maintenance Process

6 PROCEDURE
6.1 Management of production tooling and manufacturing, test, inspection tooling, and equipment

Larsen provides resources for tool and gauge design, fabrication, verification activities for production and
service materials and for bulk materials, as applicable.

Larsen establishes and implements a system for production tooling management, whether owned by Larsen’s
customer, including:

a) maintenance and repair facilities and personnel;

b) storage and recovery;
c) set-up;
d) tool-change programmes for perishable tools;
e) tool design modification documented, including engineering change level of the product;
f) tool modification and revision to documentation;
g) tool identification, such as serial and asset number; the status, such as production, repair or disposal;
ownership; and location.

Larsen verifies that customer-owned tools, manufacturing equipment, and test/inspection equipment are
permanently marked in a visible location so that the ownership and application of each item can be determined.
Larsen has a system implemented to monitor these activities if any work is outsourced.

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 Tool Repair & Tool Maintenance Process
6.2 The following diagram describes this process for tool repairs and/or maintenance required.
NOTE:
Product discrepancies found during
inspections are handled per Control of
Non-Conforming Product Procedure.
When QC finds things wrong with
sample check on In-Process tickets, they
must include those findings on the repair
ticket.
Ticket requests entered into the database
generates e-mail to send to departments
personnel for internal communication
purposes.
Setup & In Process tickets are returned
to production setup personnel when
tool is going back into the press.
Last Off and Other tickets are returned
to QC department.
Tool is setup in press, setup person
submits sample to QC along with
ticket for setup inspection.
Return ticket to tool room for further
actions until completed.
When more actions are taken, the
person must record the actions (use
back of form), initials, date and
record additional time spent.
Document Name: Tool Repairs and Maintenance Process
File ID: LAR-P-019 REV E
Action Action for tool repair may be requested by any
person in order to prevent or correct tools
Required
performance and/or product quality discrepancies.
Person completes section 1 on the tool repair
ticket form. May consult with department leaders
Request for correct information needed on ticket.
Action
Ticket is handed to QC to enter request in the tool
repair database. Person entering ticket in system,
makes check mark in section 1 and initials on
ticket form and returns to person requesting. Only
Index one ticket index # is open at a time in the
Ticket database. When additional requests or other
information is needed after ticket is submitted, A
supervisor will need to edit the repair ticket in the
data base and add the item to the open ticket.
Action is taken on the tooling. This may be done in
the press or out of the press as necessary to
Take perform the action needed. Person must record
Action action taken, initial, date and time spent on action
in section 2 and/or fill out the yellow PM sticker
that is placed on the back of the form, when needed
or when PM check is initiated.
Ticket is returned to production or quality
department based on when request was made.
Actions taken are updated in tool repair database.
Enter Actions Person entering ticket in system, makes check mark
in section 2 and initials on ticket form. Ticket is
Taken
placed in part folder for verification at next setup.
When additional actions are taken the person
updating ticket in database only enters the additional
actions and time spent.
Verify Actions performed are verified for effectiveness.
Action Production verifies the tool performance.
Quality verifies product quality.
Person initials/dates in section 3.
When verification is complete, the ticket is updated
NO Action/s
in database and ticket is closed. Person entering
ticket in system, makes check mark in section 3 and
OK? initials and dates on ticket form. When verification is
incomplete, action items will require review and
authorization from Tool Room, Production and/or
YES Quality before running. If action items can be
completed next run, Action items will then be
transferred to the next repair ticket index and note the
Close original index number request was made. Then the
Ticket tool repair ticket can be closed.
Tickets completed are turned in for filing per records
table.
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 Tool Repair & Tool Maintenance Process
NOTE: ELP Stamping
Two weeks in advance the tooling department is notified about the production planning and/or tooling needs. Production
works together with planning and program management to perform the necessary actions and complete the tool repair tickets
(including regular or last off tickets) for the upcoming tooling demand. As part of the semi-weekly tool planning, the
notification about tooling needs is made by program management and distributed to all involved teams via email.

7 RECORDS
7.1 The following table list the records maintenance established by this procedure.

Access
How Minimum Disposal
Record Dept Location Restriction
Organized Retention Authority
(if any)
Repair Tickets Front File Cabinet Date Closed None 2 Months Plant Manager
El Paso Office
Repair Tickets Production Desk Date Closed None 3 Months Production
Mundelein Office Control
Repair Database N/A Tool Repair Ticket None Active Life Engineering
Database Number of Tool plus Admin
one year or
as specified
by customer
of regulatory
agency
.

8 REVISION
8.1 The following table list the changes made to this document.

Rev Date Change

- 7/9/2012
- 7/16/2012
A 9/18/2012
B 2/6/2014
C 03/09/2017
D 10/28/2017
E 01/24/2020
Draft for review with affected departments.
Changed Doc ID was MUN-P-057, added QC responsibility on checking
samples, defined QC sample check on in-process tickets, updated records table.
Set to release for final committee review and approval.
Combined ELP-P-006 to LAR-P-057 to use for both locations based on same
process approach used. Agreed and approved for release during ISO Meeting.
Document ID was LAR-P-057_A. Updated per document control procedure to
LAR-P-019_B Tool Repair & Maintenance.
Update process to reflect current process and changes in the database.
Updated to meet requirements of ISO 9001:2015 and IATF 16949:2016.
Updated with note to clarify tool repair follow up process. Add a clarification
note about yellow PM sticker.

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 Appendix A – Tool Repair Ticket Form
BS
Repair Ticket Field Descriptions 1
T-INDEX: ____ JOB #____ Press # ___
1. Ticket Index number, Job# and Press# WHEN WAS THIS REQUESTED?
when entered in repair database. Person
2 (Check one box only)
entering data makes check mark in
request section and initials below. SETUP IN PROCESS LAST OFF OTHER BS

2. When was this requested? Person 3 4

entering data makes check mark in CUSTOMER: PART NO:
request section and initials below. 5 6
TOOL NO: COUNTER:
3. Customer listed on job traveler. LAST OFF ONLY
7 CHANGE OVER TO:
4. Part Number the tool is currently
set to run product for. AND/OR ACTION(S) REQUESTED
List any concerns with tool condition and/or last pieces at end of each run
5. Tool Number 8

6. Last Off strokes at the end of a production

run cycle only.

7. Change over, check box then write the

part number to change.

8. Actions requested to be taken on the tool. BS

9. Person requesting for action.
9 10
10. Date of request. Person entering data REQUESTED BY: DATE:
makes check mark in request section and For additional comments use the back of this form.
initials below.
ACTION(S) TAKEN
11. Action(s) taken by toolmaker against 11
request.

12. Initials of toolmaker(s) taken the actions.

13. Date the actions were taken.

14. Amount of time toolmaker spent on the

actions taken (1/4 hour intervals). Person PV
updating ticket makes check mark in
action section and initials. This is show
next person updating ticket that actions
taken, were entered. If more actions are REPAIRED BY: 12 DATE: 13 TIME: 14
taken then toolmaker writes on back of For additional comments use the back of this form.
form with hours.
VERIFY ACTION(S) OR LAST OFF OK
15. Were the actions taken accepted or 15 ACCEPTED REJECTED
rejected. When action cannot be
accepted then consult with tooling on next IF THE REPAIR IS NOT ACCEPTED CONSULT WITH DEPT MGR FOR DIRECTIONS
course of action required. WHEN COMPLETE REPLACE SHOP PACKET WITH NEW TICKET

16 LAST OFF OK – NO REPAIR REQUIRED

16. Used for last off inspection when results
of product quality were accepted and no 17 JB, YM 18
repair actions are needed. VERIFIED BY: DATE:

17. Initials of the person(s) that verified NOTES IF REQUIRED:__________________________________________

actions taken or last off OK by.

18. Date the verification was performed or

last off OK was done. Make check mark Tickets updated in the database are by section and/or event. If actions taken
in verify section to indicate ticket was were entered, then more actions taken after, the person updating the ticket
updated and closed. When verification is needs to know if all hours were entered. Using check marks in each section
incomplete action items will then be
transferred to the next repair index. Note
helps show others that this step was entered, therefore they should only enter
the original index number request was the additional actions taken and time spent and not include the previous entry.
made. Then the tool repair ticket can be
closed.

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