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Machine Operation for a New Order

Setup knowledge at the machine instead of on paper.

🏭 PRODUCTION
New order, new parameters, new configuration - and the machine operator is holding paper notes or calling the foreman.
-30%
training time on new orders
3-7
instructions per machine
60
critical minutes after changeover

With inexperienced operators or rare orders, every changeover costs time and produces scrap during ramp-up. Each machine typically needs 3-7 instructions: loading the CNC program and setting the zero point, configuring clamping fixtures per order, material change with material parameters, first-article inspection after setup, ramp-up and release.

⚠️
The trigger - how do you recognize it?
  • The first 30-60 minutes after a changeover are the most error-prone
  • Experienced colleagues get called for every setup change
  • The order documentation is paper that disappears somewhere on the shop floor
  • For rare orders, the setup gets "reinvented" every single time
ℹ️
How it works with GIRI

QR code on the machine or the order sheet - the operator scans before the setup. One clip per step with arrows pointing at the right spot, first inspection parts as a photo at the end of the instruction.

Bootcamp tip: This exact use case is the typical choice for Phase 1 · Prove It.

💡
The value
  • -30% training time on new orders
  • Less scrap during ramp-up - first parts are right sooner
  • Experienced staff are relieved instead of being called constantly
  • Knowledge stays in-house - even when the foreman leaves
💡
Typical users
  • Contract manufacturing with high variant diversity
  • Machine building (single and small series)
  • Automotive suppliers
  • Precision manufacturing
⚠️
What you want to avoid
  • Packing all variants into 1 instruction - better 5 short ones than 1 monster
  • Waiting for the foreman to write it down someday - he never has time
  • Text-only documents - nobody reads 4 pages of Word while the machine is down
KPI figures are industry benchmarks (SwipeGuide, POKA), not a GIRI guarantee.
Verwandte Artikel
Tool Change & Setup (SMED) → Quality Control → Getting Started