Lesson 1Basic CNC programme structure and common G-code/M-code elements relevant for verificationThis section introduces fundamental CNC programme structure, essential G and M codes, and interpreting blocks, comments, and tool calls, enabling operators to check programmes for safety, accurate movement, and compatibility with setups in New Zealand manufacturing environments.
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 section outlines appropriate responses to unusual pre-start findings, covering tagging, isolating, alerting key personnel, and starting maintenance, while avoiding risky shortcuts or unauthorised fixes to ensure compliance with NZ safety regulations.
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 section specifies required personal protective equipment for CNC milling, explains the need for each item, and covers selection, inspection, and proper use, connecting hazards like flying chips, noise, and sharp edges to targeted protection in local operations.
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 section describes standard lockout/tagout steps for CNC machines, including energy isolation, dissipation, verification, and record-keeping, highlighting teamwork with maintenance and adherence to site-specific procedures under New Zealand guidelines.
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 section describes primary CNC milling components and the control interface, illustrating interactions between spindle, axes, tool changer, coolant, PLC, and HMI, and safe use of screens, buttons, and modes for operators in NZ facilities.
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 section examines CNC-specific hazards like entanglement, flying chips, tool breakage, coolant splashes, and electrical dangers, linking each to prevention strategies and safe practices suitable for New Zealand industrial settings.
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 section lists daily and shift inspections such as tool wear, spindle runout, coolant levels, and chip removal, demonstrating how regular checks avert breakdowns, enhance finishes, and sustain reliable production in Kiwi plants.
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 section emphasises verifying guards, interlocks, and emergency stops, detailing test methods, pass criteria, and logging to ensure operators confirm safety systems work before and during machine use in compliance with NZ standards.
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 section provides a systematic CNC pre-start checklist, encompassing mechanical, electrical, tooling, workholding, and coolant verifications, stressing documentation, consistency, and spotting unsafe or irregular conditions early in New Zealand operations.
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
