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How long does it take you to program?

Let’s say someone gives you a metal part with 150 dimensions. How long would it take you to study the print, figure out fixturing, create a setup sheet, and program it? You’ve never seen this part before and it’s somewhat complex. Assume the print makes complete sense to you after studying the print—so you don’t need to ask the designer any questions.

Also, would the program run perfectly the first time? If not, how long would “proving out” the program (making adjustments) take you?

I ask these questions because I get them a lot being the only programmer at a significantly large company with 3 machines. I’m curious what other people’s experiences are, and I’m open to any tips. I will state my answers to these questions in one week. Hopefully I get a lot of responses.

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  • Let's assume that the part has been machined on all sides too, and that you won't be interrupted whilst programming. (oh how I miss machined parts!)
    I guess also assume you can check it all with one setup... anyhoo... 

    My typical process: (I program exclusively offline)
    1. Look over the drawing and start figuring out if I can rest against any datums. Consult feature sizes to find the largest probe that will check the most features.
    2. Open up the model and spin it around on the computer screen for about 30 minutes thinking about how to fixture it (probably makes me look like very silly, but has saved me enough times I keep doing it)
    3. Load up the model of my CMM's table and import the part model, then open my tooling library and build it all in the computer. Since the tooling is already "on the table" I know everything will fit perfectly.
    4. Armed with my part/fixture/table combo model I start it up in PCDMIS and get to programming. Figure out the alignment, then slam out a bunch of features, run collision detection, fix anything that needs it, repeat and repeat until its finished. Then start dimensioning. Game soundtracks and caffeine help with this process.

    150 dimensions, probably 1.5x that many features would probably take 2-3 days with how I do things. Due to starting the program to include all the tooling and table I am very confident when I run the first time that there won't be any issues proving out the program. I keep a note pad and jot down any adjustments that need made, normally adjusting prehit/retracts to increase speed. 

    When I worked at a machine shop and most of my parts could fit in your hand, I used clearance planes and avoidance moves exclusively.
    Now I work mostly with large fabricated parts, my machine is 26' long so clearance planes have been replaced with move points and avoidance moves. Speed is less of a concern, the DEA isn't going anywhere very fast, at least compared to your average sized CMM. (also takes longer to prove out programs now, have to get up and walk around inside the machine to follow the probe around)

    Having a library that includes all your available tooling really helps out the process, they do not need to be fancy to be effective. For my current machine we use a tooling table, for my old machine I used the machine to create a DXF file of the actual stone with tooling holes and travel limits, then used it to model a plate perfectly matched the machine.

    This is one that I did today to update a program to this decade. Everything including the C-clamps I may or may not use are included and pass collision detection. (part is model hidden)

  • We aren't allowed to listen to any music at my job. You are so lucky you have that option.

  • You can't use headphones while sitting at a computer?

  • Not unless we are in a meeting, or taking a phone call that is via software on the computer. We have personal phones so we typically do not need headphones/headsets

  • Wow, pretty sure it's been proven to increase productivity in tasks that require great focus. 
    Maybe slip in an earbud and ask for forgiveness later Innocent

  • The rules here are quite odd honestly, and I completely agree that it increases productivity. Apparently there were issues in the past with previous employees that ruined it for everyone. I would love to, though.

Reply Children
  • Technically, that is the rule where I work.  The rule was originally meant for just the shop floor, for safety purposes, but it was applied across the company to keep things fair.  They were really strict about it when I started 5 years ago, but slowly over time they have become more lax about it. 

    At first, some people like me would keep one small earbud in one ear and just try not to be obvious about it.  Some people on the shop floor would try to inconspicuously wear Bluetooth hearing protection earmuffs - I don't think they were fooling anyone, but it slid past the radar.  Little by little people got more bold about it.  Now, there are people walking around with earbuds all the time as if the rule doesn't exist. 

    I'm a little concerned that they will put the smack down on that sometime soon.  I sure hope not.  I enjoy listening to podcasts and audiobooks when working on tedious stuff. 

  • If only we could just be treated like responsible adults... In the machine shop they mostly stuck to the one earbud, one earplug rule. However, if the boss walked up behind you, and you couldn't hear him speak in a normal voice it was a problem.