Work Instruction

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{
  "template_id": "tmpl_your_template_id",
  "format": "pdf",
  "data": {
    "company_name": "Ellerby Precision Engineering",
    "doc_id": "WI-CNC-07",
    "doc_title": "Setting and running the CNC lathe, cell 3",
    "revision": "4",
    "effective_date": "1 September 2026",
    "supersedes": "Revision 3 of 14 February 2025",
    "department": "Machining",
    "workstation": "Cell 3, CNC lathe LT-220",
    "process_owner": "Cell Leader, Machining",
    "approved_by": "Verity Ashgate, Production Manager",
    "approval_date": "28 August 2026",
    "purpose": "Set and run the CNC lathe in cell 3 so that every part leaves the machine within drawing, and so that anybody on any shift sets it the same way.",
    "scope": "Turned parts made on the LT-220 in cell 3, from the setting sheet to the first part being passed. It does not cover programming, tool grinding or the yearly machine service.",
    "competence_required": "Trained on the LT-220 and signed off on the training record by the cell leader. An apprentice may set the machine only with a signed off operator at the cell.",
    "safety_notice": "The door interlock is never bypassed. The spindle is stopped and the isolator locked before anybody reaches into the work area. Swarf is cleared with the hook and the brush, never by hand.",
    "protective_equipment": [
      {
        "protective_equipment": "Safety glasses",
        "when": "At all times in the cell"
      },
      {
        "protective_equipment": "Cut resistant gloves",
        "when": "Handling bar stock and clearing swarf, never with the spindle running"
      },
      {
        "protective_equipment": "Safety boots",
        "when": "At all times in the cell"
      },
      {
        "protective_equipment": "Ear defenders",
        "when": "While the bar feeder is running"
      }
    ],
    "equipment": [
      {
        "equipment_or_material": "CNC lathe",
        "identifier": "LT-220, asset 3114",
        "check_before_use": "Daily check card signed, guards and interlock working"
      },
      {
        "equipment_or_material": "Tool holder set",
        "identifier": "TH-3 to TH-9",
        "check_before_use": "Inserts free of chips, clamp screws to 4 Nm"
      },
      {
        "equipment_or_material": "Digital micrometer",
        "identifier": "MIC-0442",
        "check_before_use": "In calibration date, reads zero on the standard"
      },
      {
        "equipment_or_material": "Bar stock",
        "identifier": "As the works order",
        "check_before_use": "Grade and heat number match the order"
      }
    ],
    "steps": [
      {
        "action": "Read the works order and the drawing, and take the setting sheet for the part number.",
        "done_by": "Operator",
        "checked_against": "Setting sheet matches the drawing issue"
      },
      {
        "action": "Load the program from the cell folder and check the program number against the setting sheet.",
        "done_by": "Operator",
        "checked_against": "Program number and issue agree"
      },
      {
        "action": "Fit the tools listed on the setting sheet and set the offsets.",
        "done_by": "Operator",
        "checked_against": "Offsets written on the setting sheet"
      },
      {
        "action": "Load the bar, set the stop and run one part in single block at 25 per cent feed.",
        "done_by": "Operator",
        "checked_against": "No alarm, no rub, chips breaking"
      },
      {
        "action": "Measure the first part on all drawing dimensions and record them on the first off sheet.",
        "done_by": "Operator",
        "checked_against": "Every dimension inside the drawing limits"
      },
      {
        "action": "Have the first part passed before the run starts.",
        "done_by": "Cell leader or inspector",
        "checked_against": "First off sheet signed"
      },
      {
        "action": "Run the batch, measuring one part in ten and writing it on the run chart.",
        "done_by": "Operator",
        "checked_against": "Run chart inside the limits"
      },
      {
        "action": "Stop the machine and tell the cell leader if any reading moves outside the limits.",
        "done_by": "Operator",
        "checked_against": "Machine stopped, parts held"
      }
    ],
    "records": [
      {
        "record": "First off sheet",
        "form": "F-QA-12",
        "kept_for": "3 years"
      },
      {
        "record": "Run chart",
        "form": "F-QA-15",
        "kept_for": "3 years"
      },
      {
        "record": "Daily machine check card",
        "form": "F-MA-02",
        "kept_for": "1 year"
      }
    ],
    "related_documents": "Drawing DR-4471 issue C, setting sheet SS-4471, the calibration schedule, and the procedure for output that does not meet the requirement.",
    "revisions": [
      {
        "revision": "2",
        "date": "3 June 2024",
        "change": "Bar feeder added to the equipment list.",
        "approved_by": "V. Ashgate"
      },
      {
        "revision": "3",
        "date": "14 February 2025",
        "change": "Measuring rate changed from one in twenty to one in ten.",
        "approved_by": "V. Ashgate"
      },
      {
        "revision": "4",
        "date": "28 August 2026",
        "change": "First part now passed by the cell leader, and the wording brought to plain words.",
        "approved_by": "V. Ashgate"
      }
    ]
  }
}
JSON