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I finally quit touching up my finish passes by hand and the parts look better for it
Everyone on the floor told me you always sneak in a light manual pass at the end to make the part look pretty, and I did that for almost four years. Around March I got moved to a job at our shop in Dayton running 4140 blocks with a 0.005 finish pass, and the inspector kept flagging tiny witness marks on the side walls. My lead told me to trust the program and pull my hands off the handwheel, and I thought he was nuts because that felt like cutting corners. Turns out my little touch-up passes were loading the insert unevenly and pushing the wall out a hair, and letting the machine do the whole thing held size within 0.0008 on 40 parts straight. I still keep the feed and speed dial in the same spot every run so it repeats, and I check the first part and then leave it be. My scrap rate on that job went from about 6 parts a week down to zero, and I feel a little silly about arguing with the lead over it. Has anyone else had hand touch-ups bite them like this, or is it still standard where you work?
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