A good setup sheet eliminates setup errors and lets any operator run any job. Here is the template.
Required Sections
1. Job Header
- Customer name + part number
- Drawing revision
- Quantity ordered
- Due date
- Material spec (with mill cert if aerospace/medical)
2. Machine + Program
- Machine number
- NC program file name + revision
- Estimated cycle time
- Estimated setup time
3. Workholding
- Fixture/vise number (if dedicated fixture, photo of mounted)
- Soft jaw set ID (if used)
- Work coordinate origin location (corner, center, etc.)
- Clamping torque value
4. Tool List
| Tool# | Description | Diameter | Length | Offset H | Offset D |
|---|---|---|---|---|---|
| T1 | 10mm 3-flute carbide end mill | 10.000 | 50.0 | H1=125.450 | D1=5.000 |
| T2 | 6mm carbide drill | 6.000 | 40.0 | H2=130.250 | D2=3.000 |
5. First Article Inspection
- Critical dimensions list with tolerances
- Inspection method per dimension (caliper, micrometer, gauge)
- Sign-off for first article
6. Notes
- Special instructions (preheat, deburr, special handling)
- Known issues from previous runs
- Lessons learned
Photo Documentation
Photos save 5-10 minutes per setup:
- Fixture mounted on machine
- Part loaded in fixture (showing orientation)
- Tool list visible
- Critical dimensions on drawing
Digital Alternatives
- Paperless Parts — Web-based setup docs
- MachineMetrics — Setup tracking + analytics
- Tablet at machine — iPad with PDF + photo viewer
- Simple shared drive — Google Drive folder per part number
Standardize Format
Same template for every job, every operator. Reduces cognitive load. Operators find what they need instantly.
Update After Every Run
Did anything go wrong? Add to notes. Did you find a faster setup method? Update the sheet. Living document.
Setup Reduction Techniques
See our SMED guide for cutting setup time 50-80% on existing jobs.
