Lesson 1Basic CNC programme structure and common G-code/M-code elements relevant for verificationThis part introduces the basic setup of CNC programmes, essential G and M codes, and reading blocks, notes, and tool calls, enabling operators to check programmes for safety, proper movement, and fit with the machine setup.
Program header, safety lines, and commentsTool call, spindle speed, and coolant commandsLinear and circular motion G-code essentialsWork coordinate systems and tool length offsetsCommon M codes for spindle, coolant, and program endLesson 2Actions for abnormal conditions found during pre-start (tagging, notifying, isolating, initiating maintenance)This part outlines correct responses to unusual findings before starting, such as tagging, separating, informing key staff, and starting repairs, while avoiding risky shortcuts or unapproved fixes.
Recognizing critical versus minor abnormalitiesApplying tags and documenting out-of-service statusIsolating energy sources when hazards are presentNotifying supervisors and maintenance promptlyRecording issues in logs or digital systemsLesson 3Mandatory PPE for CNC work and rationale (eye protection, hearing protection, cut-resistant gloves, aprons, safety shoes)This part lists required protective gear for CNC milling, explains why each is vital, and guides on choosing, checking, and using it properly, connecting risks like flying bits, noise, and sharp parts to specific protections.
Eye and face protection for chips and coolant splashHearing protection selection for shop noise levelsCut-resistant gloves for handling tools and stockProtective clothing, aprons, and sleeves near rotating partsSafety footwear for impact and slip protectionLesson 4Common lockout/tagout procedure steps applied to CNC machines (isolation, verification, documentation)This part describes standard lockout/tagout steps for CNC machines, including cutting off energy, releasing it, confirming safety, and recording, with emphasis on teamwork with repair teams and following site rules.
Identifying all CNC energy sources and pointsShutting down machine using normal stop sequenceApplying locks, tags, and group lockout devicesVerifying zero energy and tryout of controlsRestoring energy and removing locks safelyLesson 5CNC milling machine components and control interface (spindle, axis drives, tool changer, coolant, PLC/HMI)This part explains key parts of CNC milling machines and the control panel, illustrating how the spindle, axes, tool swapper, coolant, PLC, and HMI work together, and how operators safely use screens, buttons, and modes.
Spindle assembly, drive, and speed controlLinear axes, ball screws, and feedback systemsAutomatic tool changer and tool magazine basicsCoolant delivery, chip evacuation, and guardingHMI screens, soft keys, and mode selectionPLC safety logic, interlocks, and status lightsLesson 6Machine-specific safety hazards (entanglement, flying chips, tool breakage, coolant exposure, electrical risks)This part examines specific CNC risks like getting caught, flying chips, tool snapping, coolant splashes, and electrical dangers, linking each to prevention steps and safe working practices.
Entanglement risks from rotating tools and partsFlying chips and high-velocity particle hazardsTool breakage causes and containment methodsCoolant mist, skin contact, and ventilation needsElectrical shock and arc risks around CNC cabinetsLesson 7Daily and shift inspection items for CNC (tool wear, spindle runout, coolant level, chip evacuation)This part specifies daily and shift checks like tool wear, spindle wobble, coolant levels, and chip removal, demonstrating how regular inspections avoid breakdowns, enhance finishes, and ensure steady output.
Visual inspection of guards, doors, and panelsChecking tool wear, chipping, and pull stud conditionMonitoring spindle noise, heat, and basic runoutCoolant level, concentration, and contamination checksChip conveyor, augers, and filter cleanlinessLesson 8Verifying guards, interlocks, and emergency stops on CNC machinesThis part concentrates on checking guards, interlocks, and emergency stops, covering test methods, pass criteria, and records so operators ensure safety features work before and while using the machine.
Types of fixed, movable, and interlocked guardsTesting door interlocks and safety switchesVerifying emergency stop buttons and circuitsConfirming light curtains or area scannersDocumenting safety device tests and findingsLesson 9CNC pre-start checklist: mechanical, electrical, tooling, workholding and coolant system checksThis part presents a systematic pre-start checklist for CNC, covering mechanical, electrical, tooling, holding, and coolant systems, stressing records, consistency, and spotting unsafe or odd conditions early.
Visual walkaround and housekeeping verificationMechanical axis travel and limit stop checksElectrical panels, indicators, and cable conditionTooling integrity, clamping, and offset confirmationWorkholding security and part location verificationCoolant level, concentration, and flow path checks
