CNC Setup Verification Checklist (Free, PDF)

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14 critical items still open - these are the highest-risk gaps.

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Job and documentation

Work order or traveler matches the part number and drawing revisionCRITICALSetup sheet is the current released revisionCRITICALMaterial on the table matches the material on the traveler, with certification if requiredCRITICALRequired quantity, lot number and serial numbers are confirmedInspection plan and gauges for first piece are availablePrevious job and fixtures have been cleared from the machine area

Program and control

Program number and revision comment match the setup sheetCRITICALSafe start line cancels compensation and canned cyclesCorrect work offsets (G54 and others) are active and loadedCRITICALSpindle speed and feed override are at 100 percent or below the setup sheet limitRapid override is reduced for the first runCRITICALProgram has been reviewed or simulated after the last editMacro variables and counters are reset where needed

Tools and offsets

Every tool in the program is in the magazine in the correct pocketCRITICALTool length and diameter offsets are measured and enteredCRITICALTool holders are clean, the pull studs are tight and runout is acceptableInserts are indexed and not worn past the life limitTool stickout is within the program assumptionTool life counters are reset for new toolsCoolant nozzles are aimed and the coolant level and concentration are acceptable

Workholding and clearance

Vise, chuck or fixture is clean, torqued and seated on locating surfacesCRITICALClamping force and jaw pressure match the setup sheetCRITICALPart is seated against stops with no chips under itClamps, bolts and fixtures clear the tool path and the tool holderCRITICALStock height and Z zero have been checked against the programSoft jaws are bored or ground to the correct sizeProbe or touch-off setter is calibrated and a probe cycle has been tested

First piece and release

First cycle was run in single block with feed and rapid reducedCRITICALDoor is closed and chip guards are in place before cycle startCRITICALFirst piece is inspected against the drawing for critical dimensionsCRITICALOffsets are adjusted and recorded after first pieceInspector or supervisor has approved first piece releaseTool and program changes are logged for revision control

Every item should be answered yes before the first cycle start. Items marked critical are safety or scrap risks and must never be skipped.

Digitize shop floor checklists

Optional: a review of how setup checks could be captured and linked to work orders.

Optional. The tool and every export work without this. No spam.

How to use the checklist

Work down the groups in order, ticking each item after you have physically checked it, not from memory. Items marked critical are those where a miss causes a crash, injury or scrapped batch. Export the finished list to PDF or Excel as a record that goes with the job.

Why this order

Paperwork comes first because running the wrong revision wastes the whole setup. Program and control follow, then tools and offsets, since a good program with a wrong offset still crashes. Workholding and clearance come last before the first cycle because they depend on everything above, and first piece release is the final gate.

Adapting it to your shop

Add machine specific items such as pallet changer checks, bar feeder alignment, four axis or tombstone verifications, and any customer or standard requirement like AS9100 first article. Many shops keep a short version for repeat jobs and the full list for new parts and changed revisions.

Common mistakes

Skipping the checklist on repeat jobs, because the last run was fine, is the largest cause of problems, since fixtures, offsets or tools may have been changed in between. Also avoid ticking everything at the end of the shift, and make sure critical items are done before cycle start.

Frequently Asked Questions

How long should a setup checklist take?

A well designed checklist for a repeat job takes a few minutes. A new part or changed revision may take longer since it includes program review and first piece inspection. The time is small next to the cost of a crash or scrapped lot.

Who signs off the checklist?

The setup person or operator completes it, and the supervisor or quality inspector approves first piece release. In regulated work the checklist and first piece record may need to be retained with the job record.

Should every job use the same checklist?

Use a common core and add items by machine type and part family. A lathe with a bar feeder needs different checks than a five axis mill, so keep one checklist per process type to keep it short.

Does this replace the setup sheet?

No. The setup sheet describes how to set up the job, and the checklist confirms that it was done. They work together, and the checklist should reference the setup sheet revision.

If you want setup status, program revisions and first piece results visible from your ERP, we can walk through how that data could be captured and queried.

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