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newSchoolWorks.com › VoTechWorks › Manufacturing & Marine › CNC Machining › Capstone Project: Full-Cycle CNC Part Production › Lesson 3
MFG-CNC14-08 · Lesson 3 · 90 clock hours · practice

Machine Setup, Production Run, and In-Process Inspection

Objective. The student performs a complete LOTO procedure, sets up the Haas mill and/or lathe per their own setup sheets, executes a single-block dry run, machines the part from raw stock through all operations, and records in-process measurements on an inspection log at each critical stage.

⚠ Pending professional review

This lesson, its worked examples and its practice questions has not yet been verified by a licensed engineer or certified journey-level tradesperson or by a certification or approval body. It is a study draft and may contain errors. Do not use it as instructions for work on a job site or on live equipment. Always follow your instructor, your supervising professional, and current official references and regulations.

VoTechWorks program approval and accreditation are still in progress. Credentials are issued only by the certifying bodies named in each program, after their own exams.

Machine Setup, Production Run, and In-Process Inspection

This lesson brings together every skill you have built in this program. You will set up a Haas mill and/or lathe from a blank piece of stock, run the program you created, and verify every critical dimension before moving to the next operation. Nothing in this lesson is optional — the sequence must be followed exactly.

Lockout/Tagout First — Every Time

Before you touch the machine for setup, LOTO is required. This is not a formality; it is the procedure that prevents stored energy from injuring you while your hands are inside the work envelope. Follow OSHA's Control of Hazardous Energy standard and your shop's written LOTO procedure in this order:

1. Notify anyone sharing the machine.

2. Identify every energy source: electrical main, pneumatic air supply, hydraulic pressure, and any gravity hazard (spindle or turret weight).

3. Shut the machine down using the normal stop procedure.

4. Open and lock the main disconnect with your personal lock; attach your tag with name and date.

5. Isolate air and hydraulic lines using their lockout devices.

6. Verify zero energy by pressing the cycle-start button and attempting spindle start — nothing must move.

7. Document every step on the LOTO Verification Form and hand it to your instructor for a signature before proceeding.

Failure to complete LOTO correctly stops you immediately. You must restart the entire procedure from step 1. Your instructor will not sign a partial form.

PPE for this lesson: ANSI-rated safety glasses, a chip/coolant shield when appropriate, and steel-toed footwear. Remove gloves before operating any rotating spindle.

Machine Setup

With energy locked out, install cutting tools in their holders and torque retention knobs or collet nuts to the value specified on your approved tooling list. Under-torque causes tool pull-out; over-torque damages the holder taper. Record the torque applied for each tool on your setup sheet.

Once tools are installed and the machine is energized under normal run conditions (LOTO removed after setup is complete in the work envelope), establish your work offset:

Enter all tool length offsets (TLO) using your tool-length measurement results. Double-check each H-number against the T-number on the program — a mismatch between tool number and offset number is one of the most common causes of a crash.

Dry Run and First Article

With the part program loaded, set the rapid override to 5% and execute a single-block dry run: press cycle start once per block, watch every move, and keep one hand on feed hold. Annotate any discrepancies — wrong coordinate value, missing M-code, unexpected arc — directly on your G-code printout in red pen. Do not run the part until your instructor clears the dry run.

After clearance, set feedrate override to 60% and machine the first operation. Stop the machine completely before opening the door. Measure every feature listed on the First-Article Checklist before starting the next operation. Use the correct instrument for each feature:

Record every reading on the Inspection Log: nominal value, actual reading, tolerance band, and in/out-of-tolerance status.

In-Process Inspection and Nonconformance

Inspection does not happen only at the end. You measure after each operation because catching an error early may allow you to recover the part; catching it at the end usually means scrap. If any measured feature falls outside the drawing tolerance, stop cutting and complete a Nonconformance Report (NCR) before touching the machine again. The NCR must include:

Your instructor must review and approve the corrective action. Only then may you re-enter the dimension offset, adjust the program, or take a cleanup pass.

Production Run and Final Cleanup

After the first article passes, you may increase feedrate override toward 100% for production operations as your instructor authorizes. Continue to record in-process measurements at each stage. When all operations are complete, the part goes to the instructor for independent final inspection using calibrated instruments. Every critical dimension must be within tolerance — there is no partial credit on critical features.

End-of-shift housekeeping is part of the grade: remove chips from the table, chip pan, and auger tray; wipe coolant from guideways and tool holders; return tools to storage; and verify the machine is in a safe, locked-off state before leaving the shop.

Why This Matters for Your Credentials

Haas Certification competencies require demonstrated machine setup and safe operation on Haas equipment — this lesson is your primary evidence. NIMS credentialing standards for Machining Level 1 and Level 2 cover measurement, inspection, and process control. Every form you complete today — LOTO Verification, Inspection Log, NCR — is a professional document the same as you would produce in an aerospace, marine, or precision manufacturing shop.

Key terms10

Lockout/Tagout (LOTO)A written procedure required by OSHA that isolates every hazardous energy source on a machine — electrical, pneumatic, hydraulic, and gravitational — and verifies zero energy before any worker enters the danger zone.
Work Offset (G54–G59)A coordinate value stored in the Haas control that defines where the part's program zero point is located in the machine's coordinate system; established with an edge finder or probe.
Tool Length Offset (TLO)The distance from the machine spindle gauge line to the tip of a specific tool, stored in the control and referenced by the H-number in the program so the control knows exactly where each tool tip is.
Single-Block Dry RunA test mode in which the control executes one G-code block at a time at greatly reduced rapid speed, allowing the operator to verify each move before committing to the next; feed hold is kept within reach throughout.
First-Article InspectionA complete dimensional verification of the first part produced, performed operation-by-operation before continuing, to confirm the setup, program, and tooling produce features within drawing tolerances.
Nonconformance Report (NCR)A written record documenting a dimension or feature that fails to meet drawing requirements; includes the actual vs. nominal value, probable cause, and an approved corrective action before machining resumes.
Feedrate OverrideA control knob or percentage setting on the Haas operator panel that multiplies the programmed feedrate by the selected percentage, allowing the operator to slow down or speed up the cut without editing the program.
Inspection LogA structured form on which every measured dimension is recorded during in-process and final inspection, showing nominal value, actual reading, tolerance, and pass/fail status for traceability.
Edge FinderA precision sensing tool spun in the spindle and brought into contact with a workpiece edge; the tip kicks off-center at the moment of contact, allowing the operator to identify the exact edge location and set the work offset.
Gage Blocks (Jo Blocks)Hardened and lapped steel blocks of certified thickness used as reference standards to verify measuring instrument accuracy before a measurement session begins.

Worked examples4

1. Your outside micrometer reads 1.2478 in on a turned diameter. The drawing calls for 1.2500 in ± 0.0010 in. Is the part in tolerance? If not, by how much is it out?
  1. Identify the tolerance band: lower limit = 1.2500 − 0.0010 = 1.2490 in; upper limit = 1.2500 + 0.0010 = 1.2510 in.
  2. Compare the actual reading (1.2478 in) to the lower limit (1.2490 in): 1.2478 < 1.2490, so the part is below the lower limit.
  3. Calculate the deviation: 1.2490 − 1.2478 = 0.0012 in below the lower limit.
  4. Conclusion: The diameter is out of tolerance by 0.0012 in on the low (undersize) side. A cleanup pass cannot restore undersize material; an NCR must be written and the instructor must determine whether the part is scrap or salvageable.
Answer: The part is out of tolerance. The diameter is 0.0012 in undersize relative to the lower limit. An NCR is required before any further machining.
2. You are using an edge finder (radius 0.100 in) to locate the left edge of a part along the X axis. When the tip kicks off, the machine's X-axis display reads X −6.3500. What value do you enter as the X work offset so that program zero is at the left edge of the part?
  1. The center of the edge finder is at X −6.3500 when the tip kicks.
  2. The tip kicked to the right of the part edge, meaning the part edge is 0.100 in to the right of the edge finder center: part edge X position = −6.3500 + 0.100 = −6.2500.
  3. To set this as program zero (X0), enter −6.2500 as the X value in the work offset register (e.g., G54 X).
  4. Verify by jogging to X0 and confirming the spindle centerline is directly over the part edge.
Answer: Enter X −6.2500 in the work offset register. Program zero is now at the left edge of the part.
3. Your program specifies a pocket depth of 0.750 in. You measure the finished pocket with a depth micrometer and get 0.762 in. The drawing tolerance is ±0.005 in. Calculate the deviation and complete the NCR deviation field.
  1. Tolerance band: lower limit = 0.750 − 0.005 = 0.745 in; upper limit = 0.750 + 0.005 = 0.755 in.
  2. Actual reading is 0.762 in. Compare: 0.762 > 0.755, so the pocket is deeper than the upper limit.
  3. Deviation = 0.762 − 0.755 = 0.007 in oversize (too deep).
  4. NCR deviation field entry: 'Nominal 0.750 in, Actual 0.762 in, Tolerance ±0.005 in, Deviation 0.007 in over upper limit — oversize/too deep. Material cannot be added back; part is candidate for scrap. Probable cause: Z-axis tool length offset entered as a positive value instead of negative, causing tool to cut deeper than programmed.'
Answer: The pocket is 0.007 in deeper than the upper tolerance limit. The deviation field reads: actual 0.762 in vs. upper limit 0.755 in, out by 0.007 in. The part is likely scrap; the NCR must be completed and instructor-approved before any decision is made.
4. A tooling list specifies a retention knob torque of 20 ft·lb. Your torque wrench is calibrated in in·lb. What in·lb value do you set on the wrench?
  1. Conversion factor: 1 ft·lb = 12 in·lb.
  2. Calculate: 20 ft·lb × 12 in·lb per ft·lb = 240 in·lb.
  3. Set the torque wrench to 240 in·lb before tightening the retention knob.
Answer: Set the torque wrench to 240 in·lb.
In class: Before touching any machine: perform and document full lockout/tagout in writing on the LOTO Verification Form, don correct PPE (safety glasses, chip shield, steel-toed footwear), load tools in correct holders to torque spec, establish work offset using an edge finder or probe, and enter all tool length offsets; instructor observes and signs the LOTO form — failure to complete LOTO correctly stops the student and requires a full restart · Execute a single-block dry run at 5% rapid override with hands on feed-hold; annotate any discrepancies on the G-code printout; once cleared by instructor, run first article at reduced feedrate override (60%), stop after each operation, and measure all features called out on the First-Article Checklist before proceeding; record all readings on the Inspection Log using the correct instrument (micrometer, caliper, height gage, CMM if available) and note any out-of-tolerance conditions immediately · Complete remaining operations; if an out-of-tolerance condition is found during in-process inspection, the student completes a Nonconformance Report (NCR) identifying the dimension, actual vs. nominal, probable cause, and proposed corrective action before cutting resumes; instructor must approve the corrective action; all chips and coolant are cleaned up per shop housekeeping SOP at the end of each shift
Materials: Haas CNC mill and/or lathe, approved raw stock (aluminum 6061 or 1018 steel per drawing), LOTO locks and tags, LOTO Verification Form, cutting tools per approved tooling list, edge finder or Renishaw probe, digital calipers (0.0005 in resolution), outside micrometers (0.0001 in), depth micrometer, height gage, surface plate, gage blocks, Inspection Log form, Nonconformance Report form, shop safety glasses, chip shield, PPE station, Haas Certification competency checklist
Check: All critical dimensions on the finished part are measured by the instructor independently using calibrated instruments; each critical dimension must be within the drawing tolerance — zero critical dimensions out of tolerance for a passing part; LOTO Verification Form must be complete and signed; Nonconformance Reports (if any) must be complete and logical; any student who bypasses LOTO or removes a guard receives an automatic fail and must restart after a remediation session

Practice check8

Answer each question, then check it. Nothing is recorded; this is your own practice.

Workplace Safety / LOTO
1. During the LOTO procedure, a student locks the main electrical disconnect but does not attempt to press cycle start to verify zero energy. The instructor should:
Haas Certification / Machine Setup
2. When setting up tools for a Haas milling operation, which consequence is most likely if a retention knob is tightened to significantly less than the specified torque?
NIMS Machining / Work Holding and Setup
3. You are using a 0.200 in diameter edge finder. The tip kicks when the machine X-axis reads X −4.1000 and the edge finder is to the left of the workpiece. What X value represents the left edge of the part?
NIMS Machining / CNC Programming and Operation
4. During a single-block dry run at 5% rapid override, you notice the tool moves to Z +2.0000 instead of Z −0.5000 for the first drilling cycle. The most likely cause is:
NIMS Machining / Quality Control and Inspection
5. Which measuring instrument is most appropriate for verifying a precision turned diameter with a drawing tolerance of ±0.0005 in?
NIMS Machining / Quality Control and Inspection
6. A student measures a milled slot width at 0.6285 in. The drawing specifies 0.625 in +0.003/−0.000. Which statement is correct?
NIMS Machining / Quality Control and Inspection
7. A Nonconformance Report (NCR) must be completed and approved before machining resumes when:
Workplace Safety / Shop Housekeeping
8. At the end of a machining shift, a student leaves chips piled in the machine's chip pan and coolant pooled on the table, planning to clean up 'next class.' This is a problem primarily because:
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