Manufacturingdemo

Setup steps:

1. Load material

   • Use soft jaws for finished surfaces
   • Torque to 45 Nm - no more (Dave's tip: "finger tight plus quarter turn")
   • Check runout with dial indicator - must be <0.02mm

2. Set work offset

   • Touch off X, Y from datum hole
   • Z from top of stock - LEAVE 0.5mm safety margin
   • Double-check G54 values before running

3. Speed and feed for 6061-T6

   Operation	Speed (RPM)	Feed (mm/min)	DOC (mm)
   Roughing	8000	2000	3.0
   Finishing	10000	1500	0.5
   Drilling	4000	800	-

4. Speed and feed for 7075-T6 (harder - reduce by 20%)

   Operation	Speed (RPM)	Feed (mm/min)	DOC (mm)
   Roughing	6500	1600	2.5
   Finishing	8000	1200	0.5
   Drilling	3200	650	-

5. First part checks

   • Run at 50% feed override first cycle
   • Stop after roughing, measure critical dims
   • Only go full speed after first part approved

Common mistakes:

• Running 7075 at 6061 speeds → tool breakage
• Forgetting coolant → surface finish issues
• Not checking runout → parts out of tolerance

1.2 Steel Setup (Haas VF-2)

Critical difference from aluminium: Lower speeds, higher rigidity needed

Setup steps:

1. Material check

   • Mild steel (1018/1020): Standard setup
   • 4140: Pre-heat treated? Check hardness first
   • Stainless (304/316): COMPLETELY different - see section 1.3

2. Speed and feed for mild steel

   Operation	Speed (RPM)	Feed (mm/min)	DOC (mm)
   Roughing	3000	800	2.0
   Finishing	4000	600	0.3
   Drilling	1500	200	-

3. Tooling notes

   • Use coated carbide (TiAlN) not HSS
   • Check insert condition - steel kills worn inserts fast
   • Minimum stickout on endmills

Dave's wisdom: "If it's squealing, you're going too fast. If it's rubbing, you're going too slow. Sweet spot is a nice consistent hiss."

2. Quality Control Procedures

2.1 Incoming Material Inspection

Every delivery must be checked before going to stock.

Step 1: Paperwork check

• Mill cert matches PO material spec
• Heat/batch numbers recorded
• Quantity matches delivery note

Step 2: Visual inspection

• No visible damage, corrosion, contamination
• Protective packaging intact
• Correct size/form (bar, plate, tube)

Step 3: Dimensional check (sample)

• Measure 3 pieces per batch (or 10% if <30 pieces)
• Check OD/thickness against spec
• Record on incoming inspection form

Step 4: Material verification (if critical)

• PMI test for stainless/alloy steel
• Hardness test if heat treatment specified
• Record results on cert

Reject if:

• Material doesn't match cert
• Dimensions outside tolerance
• Visible defects
• Missing paperwork (quarantine until resolved)

Where to log: Incoming Inspection Register (blue folder, QC office)

2.2 In-Process Inspection

First-off inspection (MANDATORY):

• 100% dimensional check against drawing
• Sign-off by setter AND operator
• Keep first-off part until batch complete

Patrol inspection:

• Every 20 parts OR every hour, whichever is sooner
• Check 3 critical dimensions (marked on drawing)
• Record on SPC chart if applicable

What to do if out of tolerance:

1. STOP machine immediately
2. Quarantine suspect parts (red bin)
3. Inform supervisor
4. Check last good part - when did drift start?
5. Measure tool wear
6. Adjust and re-validate with new first-off

2.3 Final Inspection

Before parts leave:

• All dimensions per drawing (CMM report for complex parts)
• Surface finish check (comparator or profilometer)
• Visual inspection - no burrs, scratches, handling marks
• Quantity count matches job card
• Parts cleaned and preserved
• Paperwork complete (job card, inspection report, any NCRs)

Sign-off required by: QC Inspector (or supervisor if QC unavailable)

3. Machine Error Codes

3.1 Haas VF-2 Common Errors

3.2 Before Calling Maintenance

Try these first:

1. Note exact error code and what machine was doing
2. Power cycle (off for 30 seconds, back on)
3. Check obvious things: coolant, air pressure, chip buildup
4. Check maintenance log - has this happened before?

Maintenance contact: Extension 247 (day shift) / Mobile: [number] (out of hours)

4. Daily Startup Procedure

4.1 Morning Checklist (All CNC Machines)

Before starting any machine:

• Visual walkaround - no leaks, damage, obstructions
• Check coolant level (top up if below MIN)
• Check way oil level (weekly or per OEM spec)
• Air pressure at 6-7 bar
• Swarf cleared from work area
• Guards in place and functional

Machine startup:

1. Main power ON
2. Wait for control to boot (30-60 sec)
3. Release E-stop
4. Home all axes (press HOME ALL)
5. Warm-up cycle: Run spindle 2000 RPM for 5 mins, rapid axes through full travel
6. Check ATC function (tool change test)

Log startup in machine logbook - time, operator name, any issues noted

4.2 End of Shift Procedure

Before you leave:

• Current job complete or safely paused at good point
• Parts counted and logged
• Machine in safe state (spindle stopped, coolant off)
• Work area clean - swarf removed, tools put away
• Job card updated with completed qty
• Issues noted in logbook for next shift

DO NOT leave machine running unattended overnight unless approved.

5. Safety Procedures

5.1 PPE Requirements

Minimum PPE on shop floor:

• Safety glasses (always)
• Safety boots (steel toe)
• No loose clothing, jewelry, or dangling items
• Long hair tied back

Additional PPE for specific tasks:

• Cutting fluid handling: Nitrile gloves, apron
• Grinding: Face shield, hearing protection
• Lifting >15kg: Back support belt available

5.2 Emergency Procedures

Fire:

1. Raise alarm (red break-glass points)
2. If safe, use extinguisher on small fires only
3. Evacuate via nearest exit
4. Assemble at car park (far end)
5. Do NOT re-enter until all-clear given

Injury:

1. Stop machine/process
2. First aid kit: QC office, goods-in, break room
3. First aiders: [Names - typically posted on notice board]
4. Serious injury: Call 999, then reception

Spillage:

• Coolant/oil: Use spill kit (yellow bin by goods-in)
• Contain, absorb, dispose in hazardous waste
• Report to supervisor

6. Troubleshooting Common Issues

6.1 Surface Finish Problems

6.2 Dimensional Problems

6.3 Tool Breakage

If a tool breaks:

1. STOP - do not run next tool over broken tool fragments
2. Remove workpiece carefully
3. Inspect for damage to part and machine
4. Find root cause before restarting:
   • Excessive load? Check program, speeds/feeds
   • Worn tool run too long? Check tool life tracking
   • Programming error? Check toolpath for gouges
   • Wrong tool for material? Verify tool selection

7. Key Contacts

8. Tribal Knowledge - Tips from the Team

From Dave (30 years on the floor):

"If the machine sounds wrong, it IS wrong. Stop and look before you make scrap."

"First part is free. Take your time. Second part is where you find out if you got it right."

"Write down what you changed. I don't care if it's on a napkin. Next week you won't remember."

From Sarah (Quality):

"Measure twice, cut once. Then measure again because the first measurement was probably wrong."

"If you're not sure, ask. Nobody ever got fired for double-checking."

From Mike (Maintenance):

"Clean machines break less. 5 minutes of cleaning saves 5 hours of breakdown."

"If the same fault happens three times, there's a root cause we haven't found. Don't just reset and hope."

Version History

This is a demonstration skill. In a real implementation, all content would be captured from YOUR team, YOUR equipment, YOUR procedures.