Swiss Lathe Setup and First Piece Checklist

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Paperwork and readiness

Traveler, drawing revision and program revision matchCRITICALCustomer special requirements and inspection plan reviewedMaterial certificate on hand and lot number recordedCRITICALGages and fixtures listed on the plan are present and in calibrationCRITICALSetup sheet or previous setup photos availableRequired secondary operations and outside processes confirmed

Bar stock, feeder and collet

Bar diameter and grade checked against the travelerCRITICALBar checked for straightness and burrs before loadingFeeder channel, pusher and bar support match the bar sizeCRITICALCollet and guide bushing match the bar diameter and are cleanCRITICALBar end stub length set so the last part is not lost to a bad gripCoolant type, concentration and level confirmed

Tooling and offsets

Tool list matches the program and all tools are the correct gradeCRITICALInserts and cutoff blade are new or within planned lifeTool offsets set and verified, with spindle and sub-spindle references checkedCRITICALGuide bushing clearance and tool stick-out checked for collisionsChip control and coolant nozzle positions checkedSpare tools and gages for the run staged at the machine

Program proving

Program dry run with feed override reduced and no collisionsCRITICALCut the first part in single block mode and measure before cyclingCRITICALPart transfer to the sub-spindle and ejection into the catcher testedCutoff and facing clean with acceptable burrCycle time recorded and compared with the quoted cycle timePart counter and bar-end signal tested

First piece inspection

All drawing dimensions measured on the first piece, including critical characteristicsCRITICALSurface finish and thread fit checked with the right gageVisual check for burrs, tool marks and damageSecond piece measured after thermal stabilizationFirst piece approved and signed by quality or the leadCRITICALFirst piece retained and tagged with job and date

Handoff to run

Inspection frequency, sample size and reaction plan explained to the operatorCRITICALTool change interval and offset adjustment limits written on the travelerChip conveyor, coolant and bar stock supply confirmed for the shiftSetup time and issues recorded for the next setupProgram changes saved with a new revision and noted

All critical items must be complete before the first piece is approved and the operator takes over. Record any skipped item and the reason on the traveler.

Digitize setup and first piece records

Optional: we can show how to capture setup checklists against ERP jobs and trend setup time and first piece failures.

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How to use the checklist

Work through the groups in order and tick each item as it is done. Items marked critical must be complete before the first piece is approved and the machine is released to production. Export the checklist as a record, and attach it to the job traveler. If an item does not apply, note why rather than leaving it blank, since blanks cannot be told apart from skipped steps. Review the checklist after problem jobs and add the item that would have caught the problem.

What it covers

The first group confirms the paperwork matches: drawing revision, program revision and material certificate. The second covers the bar, feeder, collet and guide bushing, which cause many Swiss problems when mismatched. The third covers tools and offsets. Program proving uses a dry run and single block cut before cycle start. First piece inspection covers all dimensions and a second piece after thermal stabilization. The last group hands off inspection frequency and reaction limits.

Linking it to your quality system

A setup checklist supports the control of production processes expected by quality systems such as ISO 9001 and AS9100, where first article or first piece verification is part of the process. It is not a replacement for a formal first article inspection when a customer requires one, such as AS9102 for aerospace. Keep the completed checklist with the job record so you can show what was checked on the day.

Common mistakes

The most expensive mistake is releasing the machine after one good part and no second check, because thermal growth and tool wear show up after the machine warms up. Another is changing the program at the machine without saving a new revision. A third is leaving the reaction plan vague, so the operator does not know when to adjust and when to stop. If your ERP tracks setup time, record the actual setup so future quotes use real numbers.

Frequently Asked Questions

What is the difference between first piece and first article inspection?

First piece inspection is an internal check that a setup makes good parts. First article inspection is a formal, documented verification, often required by the customer, such as AS9102 in aerospace. A first piece check may feed into an FAI but does not replace it.

How many parts should be measured at first piece?

At least one part for all dimensions, and preferably a second after the machine stabilizes. Many shops measure a short run of parts for critical features to confirm the process is stable before releasing it.

Why check the guide bushing and collet?

A worn or wrong-size guide bushing or collet causes taper, chatter, bar marks and size drift on Swiss machines. They are a common hidden cause of size problems that look like tool wear.

Can I customize the checklist?

Yes. Treat it as a starting point and add machine-specific steps, customer requirements and lessons from past scrap. Remove steps that do not apply to your machines rather than skipping them each time.

If setup and first piece records live on paper, Netray can help bring them into your ERP job record so they can be searched and trended.

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