CNC Setup Sheet Application
This customizable CNC Setup Sheet App/software is developed to reduce production time with detailed, standardized instructions for each step of the part/machine setup process. This app eliminates manual methods and spreadsheets with automatic digital setup sheets, reduces machine setup time, improves efficiency, eliminates downtime, and provides required tools and information on a single platform.
Meet CAMCO Manufacturing Inc.
CAMCO Manufacturing (A Machine Shop in Sayre, PA, United States) uses CNC Lathe machines to manufacture parts/components for satellites, army tanks, medical devices, etc. They own over 30 CNC lathes, 20 CNC mills, and a large variety of grinders, gearshapers, hobs, and CNC Coordinate Measuring Machines. They were having trouble setting up these machines because they were using manual instructions, paper instructions, and Excel sheets to do it.
The CNC Setup Sheet Problem
The machinists or the floor guys often had to consult multiple sources such as engineering drawings, programming books, handwritten notes, and even separate spreadsheets to gather the data to set up machines and do a single job.
This approach raised manual errors, production delays, and inefficiencies as the information was not centralized, which made troubleshooting difficult. The production process takes too much time, involves manual machine setup, calculation errors, setup sheet changes, tooling information, and other difficulties.
The Setup Sheet as a Solution
To tackle these difficulties, CAMCO partnered with Zuggo Custom Apps to develop a custom web application that centralizes information and helps to create digital setup sheets that are fully customizable according to each job/setup. Also, Zuggo developed CAMCO a Tool Crib (Tools inventory management application) to manage tools related information, for tracking and reporting on tool usage to optimize tool life and maintenance schedules.
And integrated Tool Crib with the setup sheet app for the automatic synchronization of tooling information. This integration eliminates the need for manual data input and reduces the risk of errors. Note: This integration is not mandatory; we have integrated it for quick and error-free tool selection and information regarding each part setup.
Setup Sheet Application Development Process
CAMCO reached out to Zuggo experts to develop custom applications according to their needs. The Zuggo team scheduled a demo meeting with the CAMCO Champion (e.g. Rich Arnold) and discussed the requirements to develop a CNC setup sheet Application. CAMCO appointed a Champion to lead the app development and ensure alignment with their goals. Throughout the development process, the Champion led the development with our App Coordinator to develop it using the .NET technology stack.
Development & Integration
Zuggo’s developers developed the Setup Sheet App to fit CAMCO’s unique manufacturing processes/setup requirements. We utilized .NET, C#.NET Core, SQL Server, Blazor, and Entity Framework. We integrated Tool Crib application, which helps to get exact data from the ToolCrib App to provide operators with accurate tool information, such as GRNs (tool identification numbers), tool descriptions, maintenance, and availability.
Weekly Progress Meetings
Throughout the entire development process, we held regular meetings via Skype with the Champion, App Coordinator, and Programmers to discuss progress, features, and project metrics. For Project tracking, we used Zuggo’s custom project tracking IT Ticketing application (EMMA) to monitor progress and organize features
What does the CNC Setup Sheet App do?
The setup sheet application centralizes the information so that the machinist can get the necessary information at their fingertips without any error/difficulty. It helps to improve efficiency, eliminate downtime, and provide easy access to all data and tool information on a single platform. The app offers insights into tool life and enables the manufacturing of complex parts with high precision.
- Customizable setup sheet structure for various machining operationsCentralized access to all production tools and their data on a single platform Provide detailed tooling information, including images, GRNs (part numbers), and offsets.
- The app consolidates all relevant data, including part numbers, operation sequences, tooling details (with images), machine specifications, and program instructions.
- Provides a built-in speed and feed chart to eliminate the need for external references/resources.
- The app tracks all changes made to set up sheets and provides a history of modifications and who made them, facilitating troubleshooting and accountability.
- Integrated functionality to add operation or move stops to indicate points where the machine pauses for operator intervention.
- Managers Section to track and analyze setup performance and to identify improvement and cost savings areas.
Examples of CNC Setup Sheet App Features
The CNC setup sheet app can significantly improve the efficiency and accuracy of CNC job setup by providing a centralized, organized, and easily accessible platform for all relevant information and instructions to organize and track all the necessary information, tools, and parameters for each job.
A section to list all tools required for a specific job, including tool numbers, diameters, and speeds/feeds.
A section to specify the material type, dimensions, and any relevant properties.
A section to document the machine-specific parameters, such as coordinate systems, offsets, and coolant settings.
A section to describe how the workpiece should be clamped and any special fixtures required.
A section to specify the program file name and location.
A checklist to ensure that all steps of the setup process have been completed.
Core CNC Setup Sheet Functionality/Features
This CNC software can be customized to fit individual machine setups and manufacturing operations. No two shops are the same. That’s why the Setup Sheet App creates highly customizable setup sheets (instead of relying on CNC Excel setup sheet/spreadsheets) for specific CNC machining requirements and manufacturing processes. We’re not talking about a generic, manual approach (the custom CNC machine setup sheet template that you can customize according to each job/shop setup). We’re talking about an app that molds itself, defines operation sequences, specifies tools, and provides detailed instructions for each step. Supports various part types and complexities.
Machinist Calculator
The Application offers a machinist calculator with built-in formulas to help a machinist make quick calculations like angles in inch, MM, or angle conversion, bolt circle diameter, chord geometry, etc. It can be used for a variety of tasks (depending on setup sheet and shop requirement), including Calculate Feed & Speed, Tool Diameter for Production, and Depth of Cuts for Each Part.
Speed & Feed Chart
The speed and feed chart in this App accurately defines the product cutting parameters and tool information required for production. Speed and feed chart built in to eliminate the need for external references and access to pre-calculated optimal speed and feed rates for different materials and tools.
Tooling Information
The setup sheet provides detailed tooling information, including tool numbers (GRNs), descriptions, images, turret positions, offset values, and special instructions. You don’t have to waste time searching for the right tools. Simply select the tool holder you need, and the Setup Sheet App instantly pulls data from the Tool Crib App and shows you only the compatible inserts that are currently available in your inventory.
ODS and Engineering Drawing
The Setup Sheet App lets you store and retrieve ODS (Operational Data Sheets) and engineering drawings for each part, directly within the relevant setup sheet. The setup sheet saves the Engineering Drawing for a part, which is a complete drawing that covers the technical domains of the product, such as product dimensions, drawing visuals (1st angle, 2nd angle, 3rd angle), and more.
Setup Sheet Changes
The setup sheet can store all the changes made in the specific part. It stores a complete history of changes made including date, time, user, and description of changes to provide control and transparency over your setup processes. This detailed history allows you to quickly identify any issues, understand the changes done during the setups, and maintain accountability across your team.
Manufacturing Check Sheet
The App allows you to create and store custom check sheets for each part/setup. It provides a standard way to confirm that all critical parameters, dimensions, and visual aspects (as per the ODS drawing) are met before the job goes into production. It’s a built-in quality control system that helps you catch errors early and maintain high standards. It ensures that the production dimensions, visuals, and cuts are accurately checked and then put into operation.
Special Notes
The Special Notes feature allows users to add customized notes for individual tools or the entire setup process. This provides a space for detailed instructions, warnings, or tips for operators to have all the necessary information to perform tasks accurately and efficiently.
Move Stops
The Move Stops feature defines specific points in the machining process where the machine should pause for operator intervention. This facilitates operator intervention for manual part loading, tool changes, or quality checks.
Manager Section
The Manager Section is designed to provide comprehensive insights and control over the entire setup process. This section lets managers monitor, analyze, improve setup performance, and monitor your shop insights. The Manager Section provides a comprehensive dashboard with insights into job status, machine utilization, tooling usage, and overall machinist performance.
Reports and Analytics
The Reports and Analytics Section provides detailed insights about the daily added setup sheets, fixed tooling, approved QRNs, saved sheet reports, setup time by purchase order, etc., to make informed decisions and optimize machining operations. These tools give managers and operators the information they need to work faster, reduce downtime, and make their work better.
Customize this Setup Sheet Application With Our Experts
Creating Custom Setup Sheets
The setup sheet app helps to create custom, unique setup sheets for each setup. Whenever we have to set up a new job, we can create a custom setup sheet according to machine requirements. For example, we can select the individual part number from the database, operations, material requirements, turret, cycle time, machine selection, etc.
During the setup sheet manager/programmer/machinist can make changes and everyone can see who, when, and what changed. The main feature includes operation description such as 1st angle, 2nd angle, 3rd angle, fin face & turn, groove etc., turret position, offset, tooling QRN (QRN is a custom number to represent each tool), tooling description, and special notes for addition instruction/information for that particular operation/setup.
Setup Sheet Application Customizations
The application is fully customizable and scaleable as it’s built using .NET, C#, SQL Server, Blazor, and Entity Framework. You can customize it according to your machine requirements and you can use it with together ToolCrib or separately depending on your own choice. Each time you set a new job, you can make a custom setup sheet by using the in built feature/CNC machine setup sheet template in which you define the necessary details/instructions.
Machine Profiles
The application allows for the creation of machine profiles. Each profile defines the specific capabilities and limitations of a particular CNC machine (e.g., chuck size, tool capacity, and available tooling).
Tooling Libraries
The application can integrate with your existing tooling database, or a new one can be built. This ensures that only tools available on a specific machine are selectable for setup sheets associated with that machine profile.
Conditional Logic
The application can leverage conditional logic to adjust the setup sheet dynamically based on machine selection, material, or other parameters. For example, different tooling might be recommended based on the chosen material.
Customizable Operations
The operation sequences are fully customizable. Zuggo works with you to define standard operating procedures (SOPs) for different part types and machines as required.
Achievements/Results After Integration at CAMCO
The Setup sheet software enhanced CAMCO machining setup/operations after successfully integrating the setup sheet into their machines. According to CAMCO machinists (Camden) and managers (Rich Arnold), they have experienced approximately a 32% increase in overall production. The machinist’s output improved by 30% using a centralized set of instructions. This saved them 33% time. It used to take them 3 hours, but now they only require 2 hours.
- Reduced Setup Time: By 30-40% through standardized procedures and automated calculations.
- Increased Machine Utilization: By 10-15% due to optimized setup times and minimized downtime.
- Improved Product Quality: Reduced defects and rework by 10-15% through consistent setup procedures and quality control checks.
- Enhanced Employee Training: Speed up operator training by 30-40% through clear, concise instructions and interactive training modules.
- Decision Making: Improved decision-making capabilities through real-time data and analytics and reports.
Trusted Excellence
Multi-Platform CNC Setup Sheet Application
The setup sheet app is built using .NET, C#, SQL Server, Blazor, and Entity Framework. It is a fully customizable and scalable application that can be easily customized to fit your CNC machines/shop. The application is integrated with the ToolCrib app (it’s a custom tool management system that we use to manage all tooling related data) and when we make a custom setup sheet for each operation/setup it helps us to locate tool data by just putting tool required QRN or ID number. It imports the tool data and stores it in the sheets automatically, resulting in high tool life and reduced manual error/risk.
This app is a web based application that users can access through the cloud and web browsers. It’s a multi-platform system, accessible on computers, laptops, tablets devices, etc. It provides automatic updates, scalable performance, and remote accessibility to keep your operations running smoothly from anywhere.
Customize and install our Setup Sheet Application on-premises for direct control over your setup instructions and data security. This allows for deep customization to meet your specific operational requirements. It’s the perfect choice for shops with strict data governance policies or unique infrastructure needs.
Let’s Customize & Set up the Application Into Your CNC Machines
Don’t wait any longer. This CNC machine setup sheet can significantly increase your production efficiency with standardized, detailed instructions. It can minimize errors, reduce setup time, and ensure consistency in the machining process. This ultimately allows for faster production and machining progress with less downtime between part production and adjustments.
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