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What Was Your Mentally Exhausting Program??

cheesiechanman
The reason I ask is because of the program I am working on right now. I have 3 fixtures with 4 parts that I have been working on. All of them have complicated Datums / Poor design. The fixture that holds two parts is the most complex of course. The gage is the only one built to hold the part vertically. It has a hole in the back of the gage to probe the bottom of the part through. So the part sits with the rear surface in the CMM's +x direction. The part sits on the net pads for datum A about 120mm from the back surface of the gage (where the hole is) There are 18 small clips spaced around the outside edge of the part that I need to touch in the -x direction. This means I need to articulate my probe to, at times, an angle of A-115B35. This shortens the distance from the end of the probe to the Z axis column. Most of the time I am less than 2mm from crashing into the gage.

The part also only has one tiny slot to control rotation on one side of the part. So when placing the part on the gage it can rock, roll and slide everywhere. So that means I need to create local alignments on each clip to ensure that they hit correctly which means dancing around that almost crashing point the entire time. And I need to create alignment after alignment to ensure that I am hitting it correctly and then be sure that I recall a fixture alignment before proceeding because if I forget to revert back to the fixture and the next part changes in size/ location/ rotation by a mm or 2 I am guaranteed to crash. And this doesn't include the complexity of some of the dimensions and the callouts. For example a profile without datums with a unequal tolerance called out..... or a position on a single plane.....

So with all that being said I have been programming these parts for a couple weeks now and my head at the end of the day is just mush. That's where the Forum comes in. So I want to thank all of you for giving me a source of relief from my mental torture chamber over here.

Also, What are you more exhausting program memories. What is that one job that really kicked your butt?


Parents
  • I started at a new facility and they brought me on a little late. But the facility wasn't near completion either. So in short, I had to used a portable air compressor for my first couple weeks. Said facility had moved the CMM (Horizontal Arm) from a shuttered plant. They planned well and had a pit made to recess it so we could walk right onto the plate. Cool, my first horizontal. They were a Teir 1 to one specific GM facility. All was good except for the floor plan. It was the rear section, from the front of the back seat to the rear bumper. Around 60 stampings, 1300 welds, 70 weld studs and we have not even started talking about the profile requirements. And I had to measure something from all 6 directions. My fixture was a plate with 4 risers only to allow access and they were still in the way. I worked my first 43 of 45 days straight and I still hadn't got the program totally done. Originally I was leapfrogging the measurement routine so I would measure one half, spin the fixture and measure the other side. This was my first sheet metal facility so I learned the hard way about the need for the NI probe body. I think it was 3 months before I had the program finally proven out. Then I found out after the fact that the arm they moved was originally a dual arm setup. The sad thing was they ended up purchasing a refurbished dual arm a couple years later. And it took them 4 years to put in a hoist. That part neve got above a 70% pass rate, shoot the main stamping from GM never got above a 50% pass rating. Start with crap, don't expect a diamond in return. In the end, I had to reprogram it after receiving the dual arm machine. Which was another first for me.
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  • I started at a new facility and they brought me on a little late. But the facility wasn't near completion either. So in short, I had to used a portable air compressor for my first couple weeks. Said facility had moved the CMM (Horizontal Arm) from a shuttered plant. They planned well and had a pit made to recess it so we could walk right onto the plate. Cool, my first horizontal. They were a Teir 1 to one specific GM facility. All was good except for the floor plan. It was the rear section, from the front of the back seat to the rear bumper. Around 60 stampings, 1300 welds, 70 weld studs and we have not even started talking about the profile requirements. And I had to measure something from all 6 directions. My fixture was a plate with 4 risers only to allow access and they were still in the way. I worked my first 43 of 45 days straight and I still hadn't got the program totally done. Originally I was leapfrogging the measurement routine so I would measure one half, spin the fixture and measure the other side. This was my first sheet metal facility so I learned the hard way about the need for the NI probe body. I think it was 3 months before I had the program finally proven out. Then I found out after the fact that the arm they moved was originally a dual arm setup. The sad thing was they ended up purchasing a refurbished dual arm a couple years later. And it took them 4 years to put in a hoist. That part neve got above a 70% pass rate, shoot the main stamping from GM never got above a 50% pass rating. Start with crap, don't expect a diamond in return. In the end, I had to reprogram it after receiving the dual arm machine. Which was another first for me.
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