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DAE notice new guys zeroing off the vise jaw instead of the part and scraping 30 parts before anyone catches it?
Had a green operator last month set his G54 off the back jaw instead of the stock face, and every part came out 0.040 shallow until the inspector caught it on the 31st piece, so now I make all my trainees touch off on the actual face with a 0.0005 indicator before they hit cycle start, anybody else got a cheap trick to stop this before it costs a whole bar of material?
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torres.drew8d ago
Scrap happens in every shop and that 0.040 miss on a back jaw is a pretty normal mistake for a green operator, not some huge disaster. In my experience most stock that comes in is oversized enough that you can just face off the extra and rerun the parts, so you're not really eating a whole bar unless the print has a tight overall length callout. Checking with an indicator on the face is fine but it adds time to every setup and setups are where you make your money, so there's a tradeoff there. Your mileage may vary by material and part cost, but on cheap aluminum slugs I'd rather teach one guy to eyeball the face and check the first part than slow down every job with a touch off ritual. Take this with a grain of salt since every shop runs different tolerances, but the real fix is usually having the operator measure the first one and sign off, not adding steps to the setup.
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