First published in the August 1997 issue of Cutting Tool
Engineering magazine.
Educate Your People
The increase in CNC utilization that can be achieved by improving the
proficiency of your people will outperform any other single improvement you can
make in the CNC environment. It should go without saying that a well
trained programmer will be able to prepare efficient, safe, workable programs.
A well trained setup person will be able to efficiently make good, safe setups.
A well trained operator will efficiently run good parts and never cause a
crash. Truly, the quality of your CNC environment is directly related to the
proficiency of your people.
Levels of CNC proficiency
There are five levels of CNC proficiency, though most CNC users must only
train at one or two of these levels.
Ability to communicate intelligently - Even if they will not be
working with the CNC machines on a regular basis everyone in the CNC
environment should have a working knowledge of CNC. This includes people you
would normally not consider sending to a machine tool builder’s CNC
course. Managers, foremen, design engineers, manufacturing engineers, quality
engineers, inspectors, and tool setters are among the people who should have
the ability to communicate with CNC using people. While they may never actually
program or operate a CNC machine tool, they must understand the basics of how
CNC machines are used.
Ability to operate CNC machines - By sheer numbers alone, CNC
operators make up the bulk of people in the CNC environment. A CNC-using
company might have five CNC machines. They might have one or two programmers,
two or three setup people, and fifteen operators (one for each shift on all
five machines). This, coupled with the fact that it can be difficult to hire
new operators into the company that already possess CNC operation experience,
makes this level of proficiency the one of highest concern to most companies.
CNC operators should have a good grasp of basic machining practice (blueprint
reading, measuring tools, shop math, etc.). Operator responsibilities commonly
include workpiece load/unload, program activation, workpiece measurement, SPC
reporting, offset adjustment, and tool maintenance.
Ability to setup CNC machines - Though many companies expect their
CNC operators to make their own setups, most do have a special level of person
designated for making setups. Responsibilities include all related to operation
as well as making work holding setups, cutting tool assembly, measurement, and
offset entry, program zero assignment, program loading and saving, program
verification, and running the first workpiece.
Ability to program CNC machines - A good programmer should have a
firm understanding of all responsibilities related to operation and setup.
Additional abilities include developing a sequence of machining operations
(process), planning for cutting tools and fixturing, developing setup and
program running documentation, developing the CNC program, and help with
verification/running of program if questions arise.
Ability to teach CNC - If your company will be training its own
people, of course you’ll need an instructor. The instructor should be
patient and willing to relate information freely, should have a firm
understanding of the material to present, and should be able to work with a
wide variety of people.
Evaluate your training alternatives
CNC training is available from several sources.
Use your machine tool suppliers - All machine tool suppliers provide
training for the products they sell. However, these courses tend to be quite
condensed, and assume the attendees already have a firm understanding of the
machines being discussed. These courses tend to be very good for your CNC
programmers/setup people, but most do not stay basic enough for entry level
operators.
Check out local technical schools - Most technical schools have
excellent CNC curriculums. They provide a cost-effective training alternative,
even for entry level operators. Many schools will even custom-tailor a course
to your needs, and some will even teach on your own premises.
Seek the help of outside training suppliers - Organizations like The
Society of Manufacturing Engineers provide regular public seminars related to
CNC. Most also provide in-plant versions of the seminars as well. Additionally,
many training consultants offer custom training to address your specific needs.
Use training videos and computer based training - There are many
excellent videos for teaching CNC basics as well as more advanced topics.
Develop your own in-plant training program - Unfortunately, none of
the resources just mentioned will allow the level of fine-tuning you may need
in your training program. You may, for example, wish to combine some basic
machining practice skills along with your CNC operator training. Developing
your own in-plant training program will give you the ability to tailor the
curriculum to your needs.
