Manufacturingdemo

What this skill does

# Manufacturing Operations Knowledge Base

**Company:** Demo Manufacturing Ltd (Example)
**Last Updated:** 2026-01-11
**Knowledge Source:** Captured from shop floor experts
**Powered by:** Taylored Systems — turning tribal knowledge into queryable AI

This demonstrates how **Taylored Systems** turns expert experience into queryable, AI-accessible tribal knowledge — your team's know-how, instantly searchable. Taylored Systems captures the unwritten expertise that lives in your team's heads and makes it available to every operator, every shift, instantly.

---

## Workflow Routing

This skill answers queries directly from its embedded knowledge base. Route to the relevant section based on query type:

| Query Type | Keywords | Section |
|------------|----------|---------|
| **CNC Setup** | "set up", "speeds", "feeds", "aluminium", "steel", "tooling" | §1: CNC Machine Setup |
| **Quality Control** | "inspection", "first-off", "CMM", "tolerance", "reject", "incoming" | §2: Quality Control |
| **Machine Errors** | "error code", "E-47", "alarm", "fault", "not working" | §3: Machine Error Codes |
| **Startup/Shutdown** | "morning", "startup", "checklist", "end of shift", "daily" | §4: Daily Startup |
| **Safety** | "PPE", "safety", "emergency", "fire", "injury", "accident" | §5: Safety |
| **Troubleshooting** | "problem", "chatter", "oversize", "rough finish", "tool breakage" | §6: Troubleshooting |

## Examples

**Example 1: New operator setup question**
```
User: "How do I set up the CNC for aluminium?"
→ Routes to §1.1 (Aluminium Setup, Haas VF-2)
→ Returns step-by-step: torque spec (45 Nm), work offset procedure, speed/feed tables
→ Includes Dave's tribal tip: 7075 needs 20% speed reduction vs 6061
```

**Example 2: Machine fault diagnosis**
```
User: "Machine 3 is showing error code E-47, what do I do?"
→ Routes to §3.1 (Haas VF-2 Error Codes)
→ Returns: Spindle overload — stop program, check chip pack/dull tool/excessive DOC
→ Includes escalation path: Maintenance Ext 247
```

**Example 3: Client demo of the system**
```
User: "Show me how this works — I'm a potential customer"
→ Presents knowledge base overview and "How To Use This Skill" section
→ Demonstrates how expert knowledge (Dave's 30 years, Sarah's QC insight) is captured and searchable
→ Explains: in your real system, all content comes from YOUR team's actual procedures
```

---

## How To Use This Skill

This demonstrates how Taylored Systems captures and structures manufacturing knowledge. Staff can ask natural questions like:

- "How do I set up the CNC for aluminium?"
- "What's the inspection process for incoming materials?"
- "Machine 3 is showing error code E-47, what do I do?"
- "New starter here - what's the morning startup procedure?"

The AI returns YOUR company's actual procedures, not generic internet answers.

---

## 1. CNC Machine Setup Procedures

### 1.1 Aluminium Setup (Haas VF-2)

**Before you start:**
- Check job card for material spec (6061-T6 vs 7075 - DIFFERENT SPEEDS)
- Verify tooling is correct for the job
- Ensure coolant level is above MIN line

**Setup steps:**

1. **Load material**
   - Use soft jaws for finished surfaces
   - Torque to 45 Nm - no more (Dave's tip: "finger tight plus quarter turn")
   - Check runout with dial indicator - must be <0.02mm

2. **Set work offset**
   - Touch off X, Y from datum hole
   - Z from top of stock - LEAVE 0.5mm safety margin
   - Double-check G54 values before running

3. **Speed and feed for 6061-T6**
   | Operation | Speed (RPM) | Feed (mm/min) | DOC (mm) |
   |-----------|-------------|---------------|----------|
   | Roughing | 8000 | 2000 | 3.0 |
   | Finishing | 10000 | 1500 | 0.5 |
   | Drilling | 4000 | 800 | - |

4. **Speed and feed for 7075-T6** (harder - reduce by 20%)
   | Operation | Speed (RPM) | Feed (mm/min) | DOC (mm) |
   |-----------|-------------|---------------|----------|
   | Roughing | 6500 | 1600 | 2.5 |
   | Finishing | 8000 | 1200 | 0.5 |
   | Drilling | 3200 | 650 | - |

5. **First part checks**
   - Run at 50% feed override first cycle
   - Stop after roughing, measure critical dims
   - Only go full speed after first part approved

**Common mistakes:**
- Running 7075 at 6061 speeds → tool breakage
- Forgetting coolant → surface finish issues
- Not checking runout → parts out of tolerance

---

### 1.2 Steel Setup (Haas VF-2)

**Critical difference from aluminium:** Lower speeds, higher rigidity needed

**Setup steps:**

1. **Material check**
   - Mild steel (1018/1020): Standard setup
   - 4140: Pre-heat treated? Check hardness first
   - Stainless (304/316): COMPLETELY different - see section 1.3

2. **Speed and feed for mild steel**
   | Operation | Speed (RPM) | Feed (mm/min) | DOC (mm) |
   |-----------|-------------|---------------|----------|
   | Roughing | 3000 | 800 | 2.0 |
   | Finishing | 4000 | 600 | 0.3 |
   | Drilling | 1500 | 200 | - |

3. **Tooling notes**
   - Use coated carbide (TiAlN) not HSS
   - Check insert condition - steel kills worn inserts fast
   - Minimum stickout on endmills

**Dave's wisdom:** "If it's squealing, you're going too fast. If it's rubbing, you're going too slow. Sweet spot is a nice consistent hiss."

---

## 2. Quality Control Procedures

### 2.1 Incoming Material Inspection

**Every delivery must be checked before going to stock.**

**Step 1: Paperwork check**
- [ ] Mill cert matches PO material spec
- [ ] Heat/batch numbers recorded
- [ ] Quantity matches delivery note

**Step 2: Visual inspection**
- [ ] No visible damage, corrosion, contamination
- [ ] Protective packaging intact
- [ ] Correct size/form (bar, plate, tube)

**Step 3: Dimensional check (sample)**
- Measure 3 pieces per batch (or 10% if <30 pieces)
- Check OD/thickness against spec
- Record on incoming inspection form

**Step 4: Material verification (if critical)**
- PMI test for stainless/alloy steel
- Hardness test if heat treatment specified
- Record results on cert

**Reject if:**
- Material doesn't match cert
- Dimensions outside tolerance
- Visible defects
- Missing paperwork (quarantine until resolved)

**Where to log:** Incoming Inspection Register (blue folder, QC office)

---

### 2.2 In-Process Inspection

**First-off inspection (MANDATORY):**
- 100% dimensional check against drawing
- Sign-off by setter AND operator
- Keep first-off part until batch complete

**Patrol inspection:**
- Every 20 parts OR every hour, whichever is sooner
- Check 3 critical dimensions (marked on drawing)
- Record on SPC chart if applicable

**What to do if out of tolerance:**
1. STOP machine immediately
2. Quarantine suspect parts (red bin)
3. Inform supervisor
4. Check last good part - when did drift start?
5. Measure tool wear
6. Adjust and re-validate with new first-off

---

### 2.3 Final Inspection

**Before parts leave:**

- [ ] All dimensions per drawing (CMM report for complex parts)
- [ ] Surface finish check (comparator or profilometer)
- [ ] Visual inspection - no burrs, scratches, handling marks
- [ ] Quantity count matches job card
- [ ] Parts cleaned and preserved
- [ ] Paperwork complete (job card, inspection report, any NCRs)

**Sign-off required by:** QC Inspector (or supervisor if QC unavailable)

---

## 3. Machine Error Codes

### 3.1 Haas VF-2 Common Errors

| Code | Meaning | What To Do |
|------|---------|------------|
| **E-47** | Spindle overload | Stop program. Check for chip pack, dull tool, or excessive DOC. Reduce load and restart. |
| **E-52** | Servo overload (axis) | Check for crash or obstruction. Power cycle. If persists, call maintenance. |
| **E-91** | Low coolant | Top up coolant tank. Check for leaks. |
| **E-102** | Tool not clamped | Clean taper, check drawbar. Try re-clamping. If persists, check retention knob. |
| **E-200** | Emergency stop | Check all E-stops. Reset and restart. |
| **E-310** | Encoder error | Power cycle machine. If persists, call Haas service. |

### 3.2 Before Calling Maintenance

Try these first:
1. Note exact error code and w