Production Line Setup Checklist

Pull the work order from the ERP queue and print or stage the traveler, routing, and current-rev drawing. Cross-check the print rev against PLM (SolidWorks PDM, Arena, Windchill) — running an obsolete rev because an ECN cascade missed the floor is one of the most common scrap causes at changeover.

Verify raw stock, hardware, and sub-assemblies match the kit list quantity and part number. Capture lot or heat numbers per the traceability requirement on the traveler — for AS9100 and IATF 16949 jobs this is non-negotiable. Confirm shelf-life-controlled material (adhesives, sealants, resin) is within date.

Check tool numbers against the setup sheet. Inspect cutting tools, inserts, dies, and fixtures for wear or damage. Confirm any required gauges are signed out from the crib and that calibration stickers are current — past-due gauges get red-tagged, not used.

Follow the machine-specific lockout/tagout procedure per 29 CFR 1910.147 before any setup task that requires reaching into the point of operation. Each authorized person applies their own lock. LOTO violations are an OSHA top-10 citation and the most common cause of amputation injuries on a production line.

Verify machine guarding per 1910.212 is in place and undamaged. Function-test E-stops on each station and confirm light curtains and interlocks trip the machine. Document the test result on the daily safety check.

If any safety device failed the function check, red-tag the affected station, open a work order in the CMMS (Fiix, eMaint, Limble, MaintainX), and hold the line until maintenance clears the issue. Do not bypass an interlock to keep the schedule.

PPE per the JSA for this work center — safety glasses, hearing protection in 85+ dBA areas, cut-resistant gloves at the rates specified, steel toe, hi-vis where required. Confirm the SDS binder is current for any chemicals introduced since the last setup.

Load the CNC program or PLC recipe per the setup sheet. Set offsets, work coordinates, and speeds/feeds. Confirm the program revision matches the drawing rev called out on the traveler.

Run a single piece. Quality measures all critical and major dimensions on the inspection sheet — CMM, calipers, micrometers, or pin gauges per the control plan. For aerospace, complete the AS9102 FAI form. Do not release to run until FAI is signed off.

If FAI failed, identify the out-of-spec dimension, adjust tooling or offsets, and run another first piece. Repeat until FAI passes. Do not release to production while any critical dimension is out — running 200 parts before catching it is a six-figure scrap event.

Verify the operator knows the sampling frequency from the control plan — every Nth piece, or per ANSI Z1.4 sampling. Confirm the SPC chart is staged at the station and the operator knows the reaction plan if a point goes out of control.

Cover takt time, hourly target, and the andon trigger thresholds — defect rate, downtime, or material short. Reinforce stop-the-line authority. Note any deviations from standard setup that the next shift needs to know about.

Production supervisor and quality both sign off. The traveler captures the setup actuals — setup time, crew, FAI part serial — for variance analysis at end of shift.