| name | Manufacturingdemo |
| description | Demo manufacturing knowledge base for Taylored Systems. Shows how tribal knowledge gets captured and made queryable. USE WHEN user wants a manufacturing demo OR demonstrating to potential clients OR asks about CNC setup, machine error codes, quality inspection, startup procedures, troubleshooting, or safety OR says 'manufacturing demo', 'show me an example', 'how does it work', 'Taylored Systems demo'. |
| effort | medium |
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:
-
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
-
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
-
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 | - |
-
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 | - |
-
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:
-
Material check
- Mild steel (1018/1020): Standard setup
- 4140: Pre-heat treated? Check hardness first
- Stainless (304/316): COMPLETELY different - see section 1.3
-
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 | - |
-
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
Step 2: Visual inspection
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:
- STOP machine immediately
- Quarantine suspect parts (red bin)
- Inform supervisor
- Check last good part - when did drift start?
- Measure tool wear
- Adjust and re-validate with new first-off
2.3 Final Inspection
Before parts leave:
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:
- Note exact error code and what machine was doing
- Power cycle (off for 30 seconds, back on)
- Check obvious things: coolant, air pressure, chip buildup
- Check maintenance log - has this happened before?
Maintenance contact: Extension 247 (day shift) / Mobile: [number] (out of hours)
4. Daily Startup Procedure
4.1 Morning Checklist (All CNC Machines)
Before starting any machine:
Machine startup:
- Main power ON
- Wait for control to boot (30-60 sec)
- Release E-stop
- Home all axes (press HOME ALL)
- Warm-up cycle: Run spindle 2000 RPM for 5 mins, rapid axes through full travel
- Check ATC function (tool change test)
Log startup in machine logbook - time, operator name, any issues noted
4.2 End of Shift Procedure
Before you leave:
DO NOT leave machine running unattended overnight unless approved.
5. Safety Procedures
5.1 PPE Requirements
Minimum PPE on shop floor:
- Safety glasses (always)
- Safety boots (steel toe)
- No loose clothing, jewelry, or dangling items
- Long hair tied back
Additional PPE for specific tasks:
- Cutting fluid handling: Nitrile gloves, apron
- Grinding: Face shield, hearing protection
- Lifting >15kg: Back support belt available
5.2 Emergency Procedures
Fire:
- Raise alarm (red break-glass points)
- If safe, use extinguisher on small fires only
- Evacuate via nearest exit
- Assemble at car park (far end)
- Do NOT re-enter until all-clear given
Injury:
- Stop machine/process
- First aid kit: QC office, goods-in, break room
- First aiders: [Names - typically posted on notice board]
- Serious injury: Call 999, then reception
Spillage:
- Coolant/oil: Use spill kit (yellow bin by goods-in)
- Contain, absorb, dispose in hazardous waste
- Report to supervisor
6. Troubleshooting Common Issues
6.1 Surface Finish Problems
| Symptom | Likely Cause | Fix |
|---|
| Chatter marks | Too much stickout / speed too high | Reduce stickout, reduce speed 20% |
| Rough finish | Dull tool / wrong feed | Change insert, check feed rate |
| Built-up edge | Speed too low (aluminium) | Increase speed, check coolant flow |
| Burn marks | Speed too high / no coolant | Reduce speed, check coolant aimed at cut |
| Tearing (aluminium) | Wrong tool geometry | Use sharper tool, higher rake angle |
6.2 Dimensional Problems
| Symptom | Likely Cause | Fix |
|---|
| Consistent oversize | Tool wear compensation wrong | Re-measure tool, update offset |
| Random variation | Loose workholding / thermal | Check clamp torque, allow warm-up |
| Taper on diameter | Tailstock alignment (lathe) | Check and adjust alignment |
| Parts growing over run | Thermal expansion | Let machine warm up, check more frequently |
6.3 Tool Breakage
If a tool breaks:
- STOP - do not run next tool over broken tool fragments
- Remove workpiece carefully
- Inspect for damage to part and machine
- Find root cause before restarting:
- Excessive load? Check program, speeds/feeds
- Worn tool run too long? Check tool life tracking
- Programming error? Check toolpath for gouges
- Wrong tool for material? Verify tool selection
7. Key Contacts
| Role | Name | Contact |
|---|
| Shift Supervisor (Days) | [Name] | Ext 201 |
| Shift Supervisor (Nights) | [Name] | Ext 202 |
| Maintenance | [Name] | Ext 247 / Mobile |
| Quality Manager | [Name] | Ext 215 |
| Health & Safety | [Name] | Ext 220 |
| Goods In | [Name] | Ext 230 |
8. Tribal Knowledge - Tips from the Team
From Dave (30 years on the floor):
"If the machine sounds wrong, it IS wrong. Stop and look before you make scrap."
"First part is free. Take your time. Second part is where you find out if you got it right."
"Write down what you changed. I don't care if it's on a napkin. Next week you won't remember."
From Sarah (Quality):
"Measure twice, cut once. Then measure again because the first measurement was probably wrong."
"If you're not sure, ask. Nobody ever got fired for double-checking."
From Mike (Maintenance):
"Clean machines break less. 5 minutes of cleaning saves 5 hours of breakdown."
"If the same fault happens three times, there's a root cause we haven't found. Don't just reset and hope."
Version History
| Version | Date | Changes | Author |
|---|
| 1.0 | 2026-01-11 | Initial demo version | Taylored Systems |
This is a Taylored Systems demonstration skill. In a real implementation, all content would be captured from YOUR team, YOUR equipment, YOUR procedures — structured and delivered by Taylored Systems so your tribal knowledge is never lost.
