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Ran the same job wrong for 8 months until a new guy spotted it
Honestly, I've been milling these brackets for over 200 parts with the same offset, and I never questioned it because the parts always fit. Then last Tuesday, a temp kid sets up the next run and asks why I'm using the tool wear number from the previous insert. Tbh, I had been carrying over a -0.0025 offset in the control forever, thinking it was just part of the program. He zeroed it out and the finish pass cut perfectly. Has anyone else had a habit like that where you just trust an old setting without ever checking where it came from?
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richardknight18d ago
Did the temp kid explain why he even looked at that offset in the first place, or was he just poking around the control? Because there's a big gap between spotting a weird number and knowing it doesn't belong there. How many inserts had you run through during those 8 months without resetting? If the finish pass held size the whole time, that offset was likely masking something else, like a slightly off tool holder or thermal drift. Curious what the first part looked like after he zeroed it, did the size shift right away or stay put?
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