CNCSetup - MNMUK Setup Sheet Generator

Purpose: Standardized setup documentation to reduce setup time, prevent errors, and capture tribal knowledge.

When to Activate

"Create a setup sheet for [part/job]"
"Setup for [machine name]"
"New job setup on the NLX2500"
"Tooling list for [operation]"
"Document the setup for [part number]"

Setup Sheet Templates by Machine Type

DMG MORI 5-AXIS MILLS (NMV3000, DMU50, NHX500)

SETUP SHEET - 5-AXIS MILLING

Job Information

Field	Value
Part Number
Part Name
Customer
Operation
Machine	[ ] NMV3000 [ ] DMU50 [ ] NHX500
Program Number
Setup By
Date

Workholding

Item	Details
Fixture ID
Fixture Location
Clamping Method
Clamping Torque	Nm
Pallet Number
Datum/WCS	G54 / G55 / Other:

Work Offset Setup

Axis	Value	Method
X		Probe / Edge finder / Indicator
Y		Probe / Edge finder / Indicator
Z		Probe / Tool setter
A
B/C

Tool List

T#	Description	Diameter	Length	Offset	Notes
T1				H1 D1
T2				H2 D2
T3				H3 D3
T4				H4 D4
T5				H5 D5

CELOS Settings

Parameter	Value
Spindle Warm-up	[ ] Required [ ] Not Required
Coolant Type	[ ] Flood [ ] Through-spindle [ ] Mist
Coolant Pressure	bar
Chip Conveyor	[ ] On [ ] Off

Critical Dimensions (First-Off Check)

Feature	Nominal	Tolerance	Actual	OK
		±		[ ]
		±		[ ]
		±		[ ]

Safety & Notes

Guards in place
Correct PPE worn
Program proven at reduced feed

Special Instructions:

Known Issues / Tips:

DMG MORI TURNING CENTRES (NLX2500, ALX2000)

SETUP SHEET - CNC TURNING

Job Information

Field	Value
Part Number
Part Name
Customer
Operation	OP10 / OP20 / Complete
Machine	[ ] NLX2500 Twin [ ] NLX2500 Single [ ] ALX2000
Program Number
Setup By
Date

Material & Stock

Item	Details
Material
Stock Type	[ ] Bar [ ] Billet [ ] Forging [ ] Casting
Stock Size	Ø x L mm
Bar Feeder	[ ] Yes [ ] No
Bar Stop Position	mm from chuck face

Workholding - Main Spindle

Item	Details
Chuck Type	[ ] 3-jaw [ ] Collet [ ] Special
Chuck ID/Size
Jaw Type	[ ] Hard [ ] Soft [ ] Pie jaws
Jaw Bore	Ø mm
Grip Length	mm
Clamping Pressure	bar

Workholding - Sub Spindle (if applicable)

Item	Details
Chuck Type	[ ] 3-jaw [ ] Collet
Jaw Type	[ ] Hard [ ] Soft
Grip Length	mm
Part-off Position	mm
Transfer Method

Work Offset Setup

Offset	Value	Method
Z (Face)		Touch-off / Probe
X (Diameter)		Test cut / Probe

Tool List - Turret

T#	Station	Description	Insert	Orientation	Offset	Notes
T1
T2
T3
T4

Live Tooling (if applicable)

T#	Station	Description	RPM	Notes

Cutting Parameters Reference

Operation	Speed (m/min)	Feed (mm/rev)	DOC (mm)
Rough OD
Finish OD
Rough ID
Finish ID
Thread
Part-off

Coolant Settings

Parameter	Value
Coolant Type	[ ] Flood [ ] High-pressure
HP Coolant Pressure	bar
Chip Conveyor	[ ] On Direction:

Critical Dimensions (First-Off)

Feature	Nominal	Tolerance	OK
OD 1	Ø	±	[ ]
OD 2	Ø	±	[ ]
Length		±	[ ]
Thread		Class	[ ]

Cycle Time

Phase	Time
Load	sec
Cut Cycle	sec
Unload	sec
Total	sec

Special Instructions:

Known Issues / Tips:

HARDINGE TWIN SPINDLE TURNING

SETUP SHEET - HARDINGE TURNING

Job Information

Field	Value
Part Number
Part Name
Operation
Program Number
Setup By
Date

Stock

Item	Details
Material
Stock Size	Ø x L mm
Bar Feed	[ ] Yes [ ] No

Workholding

Spindle	Chuck	Collet/Jaw	Grip	Pressure
Main			mm	bar
Sub			mm	bar

Precision Notes (±0.003mm capability)

Parameter	Setting
Warm-up Cycle	[ ] Required - Run time: min
Temperature Stability	[ ] Verified
Probe Calibration	[ ] Verified

Tool List

T#	Description	Insert	Offset	Notes

Critical Dimensions

Feature	Nominal	Tol	Gage	Method
		±0.003

Precision Tips:

Allow 20-min spindle warm-up for best tolerance
Verify coolant temperature stable
Use in-process gauging for critical features

CITIZEN SWISS-TYPE (Sliding Head)

SETUP SHEET - CITIZEN SWISS

Job Information

Field	Value
Part Number
Part Name
Machine	[ ] Citizen Laser Head [ ] Citizen LFV
Program Number
Setup By
Date

Material & Bar Stock

Item	Details
Material
Bar Diameter	Ø mm (max Ø38.1mm)
Bar Length	mm
Bar Supplier/Heat

Guide Bushing Setup

Parameter	Value
Guide Bushing Size	Ø mm
Bushing Type	[ ] Rotating [ ] Fixed
Bushing Material	[ ] Carbide [ ] Bronze
Z-axis Reference	mm

Main Spindle Collet

Parameter	Value
Collet Size	Ø mm
Clamping Pressure	bar
Stock Stick-out	mm

Sub Spindle Setup

Parameter	Value
Collet Size	Ø mm
Pickup Position	Z = mm
Grip Length	mm

Tool List - Gang Slide

Position	Tool	Insert/Size	Offset	Notes

Tool List - Back Working

Position	Tool	Insert/Size	Notes

LFV Settings (if LFV machine)

Parameter	Value
LFV Mode	[ ] On [ ] Off
Oscillation Frequency	Hz
Amplitude	mm
Applied To	[ ] OD [ ] ID [ ] Drilling

Laser Head Settings (if Laser machine)

Parameter	Value
Laser Operation	[ ] Marking [ ] Cutting [ ] N/A
Power	W
Program

Coolant

Type	Setting
Oil Type
Pressure	bar
Mist	[ ] On [ ] Off

Critical Dimensions (±0.003mm capability)

Feature	Nominal	Tol	Method
		±
		±

Cycle Time Target

	Time
Cycle	sec
Parts/Hour

Swiss-Specific Tips:

Verify guide bushing alignment before production
Check oil level and filtration
LFV excellent for 316SS and titanium chip breaking
Monitor bar remnant length

MITSUBISHI EDM (Wire & Spark)

SETUP SHEET - EDM

Job Information

Field	Value
Part Number
Part Name
Machine	[ ] Wire EDM [ ] Spark EDM
Program Number
Setup By
Date

Workpiece

Item	Details
Material
Hardness	HRC
Dimensions	L x W x H mm
Weight	kg

WIRE EDM SETUP

Wire Settings

Parameter	Value
Wire Type	[ ] Brass [ ] Coated [ ] Other:
Wire Diameter	mm
Wire Tension	g
Wire Speed	m/min

Workholding

Item	Details
Fixture Type
Leveling	[ ] Verified
Start Hole	X: Y: (if applicable)

Cutting Parameters

Pass	On-Time	Off-Time	Wire Speed	Offset
Rough	μs	μs	m/min	mm
Semi	μs	μs	m/min	mm
Finish	μs	μs	m/min	mm
Skim	μs	μs	m/min	mm

Flushing

Parameter	Value
Upper Nozzle	mm gap
Lower Nozzle	mm gap
Flushing Pressure	bar
Submerged	[ ] Yes [ ] No

SPARK EDM (SINKER) SETUP

Electrode

Parameter	Value
Electrode Material	[ ] Copper [ ] Graphite
Electrode ID
Undersize	mm
Polarity	[ ] + [ ] -

Cutting Parameters

Phase	Current	On-Time	Off-Time	Depth
Rough	A	μs	μs	mm
Semi	A	μs	μs	mm
Finish	A	μs	μs	mm

Flushing

Method	Setting
Type	[ ] Jet [ ] Suction [ ] Orbital
Pressure	bar
Retract Height	mm
Jump Frequency

Dielectric

Parameter	Value
Type
Level	[ ] Verified
Filter Status	[ ] OK
Conductivity	μS

Critical Dimensions (Wire: ±0.004mm, Spark: ±0.050mm)

Feature	Nominal	Tol	Actual	OK
		±		[ ]

EDM Tips:

Wire: Check wire path and guides before start
Spark: Verify electrode alignment with workpiece
Monitor dielectric condition
Log electrode wear for repeat jobs

HAAS FAST RESPONSE CELL (Mini Mill & Tool Room Lathe)

SETUP SHEET - HAAS FAST RESPONSE

Job Information

Field	Value
Part Number
Part Name
Machine	[ ] Mini Mill [ ] Tool Room Lathe
Program Number
Setup By
Date
Priority	[ ] Urgent [ ] Standard

Purpose

[ ] Prototype [ ] First Article [ ] Repair [ ] One-off [ ] Prove-out

MINI MILL SETUP

Workholding

Item	Details
Vice/Fixture
Parallels	Height: mm
Stop Position
WCS	G54

Tool List

T#	Description	Diameter	Length	Notes
T1
T2
T3

Work Offsets

Axis	Value	Method
X		Edge finder
Y		Edge finder
Z		Tool touch

TOOL ROOM LATHE SETUP

Workholding

Item	Details
Chuck	[ ] 3-jaw [ ] Collet [ ] Other
Stock	Ø x L mm
Stick-out	mm

Tool List

T#	Description	Offset	Notes
T1
T2
T3

Notes (±0.050mm typical tolerance)

Special Instructions:

For Production Transfer:

Machine recommended: Key learnings from prototype:

Setup Sheet Best Practices

Before Setup

Review drawing and previous setup sheets
Gather all tooling, fixtures, gages
Verify program revision matches drawing
Check raw material matches specification

During Setup

Follow setup sheet step-by-step
Document any deviations
Verify tool lengths and offsets
Run first part at reduced feed (50%)

After Setup

First-off inspection - all critical dimensions
Update setup sheet with any changes
Record actual cycle time
Note any issues or improvements

Continuous Improvement

Add "Tips" from experienced operators
Update tooling recommendations based on results
Photo key setup steps for complex jobs
Track setup time for benchmarking

Output Format

When generating a setup sheet, I will:

Ask which machine/job if not specified
Generate appropriate template
Pre-fill known information
Highlight fields requiring operator input
Include relevant tips from tribal knowledge

Integration with Other Skills

PlantCapability: Verify machine selection before setup
AutomotiveManufacturing: Link setup sheets to work instructions
TribalKnowledge: Pull tips and known issues into setup sheets

cncsetup

Safety Notice

Copy this and send it to your AI assistant to learn

SETUP SHEET - 5-AXIS MILLING

Job Information

Workholding

Work Offset Setup

Tool List

CELOS Settings

Critical Dimensions (First-Off Check)

Safety & Notes

Special Instructions:

Known Issues / Tips:

SETUP SHEET - CNC TURNING

Job Information

Material & Stock

Workholding - Main Spindle

Workholding - Sub Spindle (if applicable)

Work Offset Setup

Tool List - Turret

Live Tooling (if applicable)

Cutting Parameters Reference

Coolant Settings

Critical Dimensions (First-Off)

Cycle Time

Special Instructions:

Known Issues / Tips:

SETUP SHEET - HARDINGE TURNING

Job Information

Stock

Workholding

Precision Notes (±0.003mm capability)

Tool List

Critical Dimensions

Precision Tips:

SETUP SHEET - CITIZEN SWISS

Job Information

Material & Bar Stock

Guide Bushing Setup

Main Spindle Collet

Sub Spindle Setup

Tool List - Gang Slide

Tool List - Back Working

LFV Settings (if LFV machine)

Laser Head Settings (if Laser machine)

Coolant

Critical Dimensions (±0.003mm capability)

Cycle Time Target

Swiss-Specific Tips:

SETUP SHEET - EDM

Job Information

Workpiece

WIRE EDM SETUP

Wire Settings

Workholding

Cutting Parameters

Flushing

SPARK EDM (SINKER) SETUP

Electrode

Cutting Parameters

Flushing

Dielectric

Critical Dimensions (Wire: ±0.004mm, Spark: ±0.050mm)

EDM Tips:

SETUP SHEET - HAAS FAST RESPONSE

Job Information

Purpose

MINI MILL SETUP

Workholding

Tool List

Work Offsets

TOOL ROOM LATHE SETUP

Workholding

Tool List

Notes (±0.050mm typical tolerance)

Special Instructions:

For Production Transfer:

Source Transparency

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