# Standard Operating Procedure: [MACHINE / PROCESS NAME, e.g. CNC Mill Setup and First-Article Inspection]

## Document Control

| Field | Entry |
|---|---|
| SOP ID | [SOP-MFG-001] |
| Version | [1.0] |
| Effective Date | [YYYY-MM-DD] |
| Owner | [PRODUCTION SUPERVISOR NAME] |
| Approver | [PLANT MANAGER / QUALITY MANAGER NAME] |
| Next Review Date | [YYYY-MM-DD] |
| Work Center / Line | [MACHINE ID, e.g. Mill-03, Cell B] |

## 1. Purpose

Standardize [OPERATION, e.g. job setup and first-article inspection on Mill-03] so that every changeover produces conforming parts from the first accepted piece, scrap stays under [TARGET %], and setups complete within [TARGET MINUTES].

## 2. Scope

- **Applies to:** [ROLES, e.g. machine operators and setup technicians] on [MACHINE/LINE] at [PLANT], all shifts.
- **Does not apply to:** [e.g. "maintenance and repair work, covered by the maintenance work-order system; programming changes, covered by SOP-ENG-002"].

## 3. Definitions

| Term | Definition |
|---|---|
| First article | The first part produced after any setup or change, inspected against the full drawing before the run continues |
| LOTO | Lockout/Tagout — isolating machine energy sources per 29 CFR 1910.147 before service or unjamming |
| Traveler | The routing document that follows the job: part number, revision, operations, quantities, sign-offs |
| Nonconforming product | Any part that fails a drawing or spec requirement; must be tagged and segregated |

## 4. Responsibilities

| Role | Responsibility |
|---|---|
| Operator | Runs setup per this SOP; performs in-process checks every [N PARTS/MINUTES]; stops the machine on any out-of-spec reading |
| Setup Technician | [IF SEPARATE ROLE] Performs tool changes and offsets; signs the setup section of the traveler |
| Quality Inspector | Approves the first article; no production run starts without a signed first-article check |
| Supervisor | Assigns jobs, resolves andon/stop-line calls within [15 MINUTES], audits this SOP [MONTHLY] |

## 5. Required Materials, Equipment, and Documents

- Job traveler and current-revision drawing [REV CONTROL SYSTEM — confirm rev letter matches the traveler]
- Tooling per the setup sheet [SETUP SHEET ID]; pre-set tools from the tool crib
- Calibrated measurement instruments: [e.g. 0–1" micrometer, calipers, thread gauge] — check the calibration sticker is in date **before** use
- PPE: safety glasses ([ANSI Z87.1]), hearing protection in [AREA], cut-resistant gloves for handling sharp stock (never near rotating spindles)
- Raw material verified against the traveler: [MATERIAL SPEC, HEAT/LOT NUMBER]

## 6. Procedure

Example steps below describe a milling changeover; adapt to your operation.

1. **Verify the paperwork.** Match part number and revision on the traveler, drawing, and program header. If any of the three disagree, stop and call [QUALITY/ENGINEERING]. Do not run "what's probably right."
2. **Clear the machine.** Remove all parts, fixtures, and tools from the previous job. Confirm the previous job's traveler is signed off and its remaining material is returned or tagged.
3. **Load the program and fixture.** Install fixture [FIXTURE ID] per the setup sheet; torque clamps to [SPEC]. Load program [PROGRAM ID]; verify the program number and last-edited date on screen match the setup sheet.
4. **Set offsets and dry run.** Touch off tools, set work offsets, then run the program in [SINGLE-BLOCK / DRY-RUN] mode above the part with rapid override at [25%]. Watch the first full cycle — hands off the door interlock.
5. **Cut the first article.** Run one part at programmed feeds. Deburr, clean, and measure **every drawing dimension**, recording actuals on [FIRST-ARTICLE FORM ID].
6. **Get first-article approval.** Present part + form to the Quality Inspector. Production starts only after the inspector signs. If rejected, correct offsets/tooling and repeat from step 5.
7. **Run production with in-process checks.** Check [KEY DIMENSIONS] every [N] parts or [N] minutes, logging on the SPC chart [CHART ID]. If a reading trends toward a limit, adjust per [REACTION PLAN]; if out of spec, stop and quarantine everything since the last good check.
8. **Handle nonconforming parts.** Tag red, record quantity and reason on [NCR FORM], move to the quarantine cage. Never return untagged suspect parts to the flow.
9. **Close out the job.** Count and record final quantities on the traveler, sign your operations, clean the work area to [5S STANDARD], and stage the job for the next operation.

## 7. Safety and Compliance Notes

- **LOTO (29 CFR 1910.147):** any reach past a guard, jam clearing, or tool change on [ENERGY-DRIVEN EQUIPMENT] requires your personal lock. One lock per person — never work under someone else's lock.
- **Machine guarding (29 CFR 1910.212):** interlocks must never be bypassed; report damaged guards immediately and take the machine out of service.
- Chips are sharp and hot: use a chip hook, never hands or compressed air toward the body (>30 psi cleaning prohibited per [1910.242(b)]).
- Quality records (first-article forms, SPC charts, NCRs) are retained [PERIOD] per [ISO 9001 / IATF 16949 / CUSTOMER] requirements.

## 8. Related Documents

- [SOP-ENG-002 — Program Change Control]
- [SOP-QA-010 — Nonconforming Material]
- [FORM FA-01 — First Article Inspection Report]
- [SETUP SHEET SS-XXX]

## 9. Revision History

| Version | Date | Author | Summary of Changes | Approved By |
|---|---|---|---|---|
| [1.0] | [YYYY-MM-DD] | [NAME] | Initial release | [NAME] |
| [ ] | [ ] | [ ] | [ ] | [ ] |

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Template by Pellucida (pellucida.ai) — turn this SOP into a training video at pellucida.ai/solutions/sop-to-training-video