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SETUP SHEET

Tool 1: Ø63 Face Mill — Sandvik R245

Tool 2: Ø20 End Mill — Carbide 4-flute

Tool 3: Ø10.2 Drill — Through coolant

Tool 4: M12×1.75 Tap — Spiral flute

Fixture: Kurt D688 Vise + Soft Jaws #SJ-FL01

Program: O2700 (Ver 3.2 — 14 Mar 2026)

IN-PROCESS INSPECTION RECORD

Balloon	Feature	Nominal	Tol +	Tol −	Part 1	Part 5
①	OD Ø150	150.000	+0.025	−0.000	150.012	150.018
②	Bore Ø80 H7	80.000	+0.030	−0.000	80.015
③	Bolt PCD Ø120	120.000	+0.050	−0.050	120.022
④	M12 Tap Depth	25.000	+1.000	−0.000

Measure at Part 1, 5, 10 then every 10th part · Record actual values · Flag if outside tolerance

M1 JOB TRAVELLER

Job ID: 27001-0001-001

Customer: BAE Systems

Part: FLANGE MOUNT ASSEMBLY

Customer PO: PO-BAE-2026-0412

Qty: 12

Due: 25 Mar 2026

Material: AL 6061-T6 Ø150×80

Rev: C (14 Feb 2026)

Operation Routing

Op	Process	Machine	Setup Std	Run Std	Status
10	CNC Milling — Op1 (Fixture Side A)	CNC01	0:45	1:15/pc	CURRENT
20	CNC Milling — Op2 (Flip Side B)	CNC01	0:30	0:50/pc	QUEUED
30	Deburr & Clean	NONCNC	—	0:05/pc	QUEUED
40	CMM Inspection	CMM1	0:15	0:20/pc	QUEUED

WHS: Standard PPE required. Aluminium swarf — no gloves near spindle. Coolant: Castrol Hysol SL35 (SDS on file). Lifting assist required for raw billet (12kg).

WORK INSTRUCTIONS — Op 10

Load raw billet into Kurt D688 vise with soft jaws #SJ-FL01. Torque to 45 Nm.
Set work offset G54 — touch off Z on top face, X/Y on vise datum pins.
Load program O2700 — verify tool table matches setup sheet (6 tools).
Run first part with feed override at 80% through first roughing pass.
After first part: check dims ①②③ per in-process record. Adjust offsets if needed.
Run remaining parts. Check dims at part 5 and every 10th part thereafter.
Deburr all edges (hand file or deburr tool). Remove all sharp edges.
Blow out all tapped holes with air gun. Verify thread with M12 go/no-go gauge.
Stack finished parts on pallet with interleave paper. Label: Job 27001, Qty, Operator.
Log parts made + any scrap on kiosk. Notify foreman if CMM queue > 4 jobs.

⚠️ CRITICAL NOTE: Bore Ø80 H7 is a press-fit for the bearing. If dimension is out of tolerance, DO NOT attempt to rework — notify Quality immediately. Scrap code: DIM-OOT.

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