GlossaryKind of term: Manufacturing termSetup sheet
What is a setup sheet?
A setup sheet describes per setup how the machine is made ready: workholding, part orientation, work origin, tools, program and the checks on the first part.
The sheet is written for the operator and gives the detail behind each item: how the workpiece sits in the workholding, how the work origin is established, the pocket number and overhang of each tool, the program name and which dimensions to check on the first part. A photo or sketch of the clamped part and the known pitfalls are often added.
Where does a setup sheet come from?
Part of the setup sheet comes from the CAM system, which can generate a tool list or a full setup sheet with images of the setup. The rest, such as experience with clamping or a known deviation, is added by the manufacturing engineer or the operator. A setup sheet is only useful when it matches the right revision of drawing and program; after a change it has to change with them.
How does a setup sheet work in practice?
On one-offs and small batches, setup time is often a large share of the cost per piece, and part of that time is searching: which jaws, where the origin, which cutter at what overhang. A complete setup sheet can cut that search on a repeat order, especially when a different operator runs the batch. Building the setup, probing and measuring the first part remain. Whether you cost a repeat order with a shorter setup time is an estimating choice that depends on the setup sheet, stored workholding and a proven program.
What is a setup sheet often confused with?
A setup sheet is not a process plan: the process plan describes the route of the whole part, the setup sheet one setup on one machine. Nor is it the NC program: the program drives the machine, the setup sheet guides the operator.
Frequently asked questions
What goes on a setup sheet?
Per setup: workholding and orientation of the part, work origin and how to establish it, tools with pocket and overhang, program name, the dimensions to check on the first part, and any notes. A photo of the clamped part often saves the most explaining.
Does a setup sheet save setup time on a repeat order?
Often, especially when a different operator runs the batch or the last run was long ago. Searching for workholding, origin and tools gets shorter; building the setup, probing and measuring the first part remain.
Who keeps the setup sheet up to date?
Usually the manufacturing engineer or CNC programmer, with additions from the operator. What matters is that it belongs to the revision of drawing and program, and that a change made on the floor finds its way back into the sheet.