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Evaluate the current product or part design for manufacturability (DFM review). Analyze machining strategy, toolpaths, materials, and tolerances to identify improvement opportunities. Review CAM programs and setup sheets for inefficiencies or unnecessary steps. Recommend design changes that reduce machining time, scrap rate, tool wear, or complexity. Provide alternate machining strategies, tooling options, or fixture concepts. Perform cycle time analysis and propose optimization targets. Identify potential cost reduction areas (material usage, tool selection, process order). Validate tolerance stack-ups and confirm which can be relaxed without affecting function. Deliver optimized CAD/CAM recommendations or updated files (if applicable). Provide a roadmap for implementing improvements across future production runs

Assess current workflows across machining, programming, QC, quoting, and shipping. Conduct virtual interviews with key personnel (operators, QC tech, programmer, supervisor). Identify undocumented or tribal-knowledge processes that require formal SOP creation. Review existing documents, job travelers, work instructions, inspection sheets, and checklists. Develop complete, step-by-step SOPs for critical processes such as: Machine setup & teardown Tooling selection & presetting CAM programming & revision control First Article Inspection (FAI) Calibration & gage handling Material receiving & traceability Nonconformance handling Quality checks during production Create visual SOPs including diagrams, photos, and process flow. Ensure alignment with industry standards (ISO 9001 / AS9100 if applicable). Deliver master SOP template + shop-specific customized versions. Provide a version control and document management plan.

Assess current shop layout, workflow, tooling storage, and workcell organization. Conduct virtual walkthroughs of production areas (3-axis, 5-axis, QC, tool crib, materials area). Develop a complete 5S framework tailored to a CNC job shop environment. Create step-by-step procedures for: Sort (Seiri): removing unnecessary tools/materials Set in Order (Seiton): layout optimization Shine (Seiso): cleaning standards & schedules Standardize (Seiketsu): visual controls, labeling, standardized setups Sustain (Shitsuke): audits, ownership, KPIs Develop a 30/60/90-day implementation plan. Recommend tools, layout improvements, color coding, floor markings, and shadow boards. Create templates for 5S audits, checklists, and workstation standards. Train supervisors on how to maintain and enforce 5S systems. Produce a final “5S Program Package” ready for deployment.

Project Goal: Reduce cycle time on five existing CNC production parts by 20–30% without compromising quality, dimensional accuracy, or tool life.Requirements: Analyze Current Setup & ProcessesReview existing CAM toolpaths, strategies, and sequence flow Evaluate spindle speeds, feedrates, stepdown/stepover, coolant strategy Assess tool selection, tool life, and tool change strategy Examine workholding and machine setup efficiency Review current G-code if necessary Optimization OpportunitiesRecommend high-efficiency machining (HEM) strategies Introduce adaptive/trochoidal roughing Optimize entry/exit moves, linking, and retracts Propose better tool geometry or coatings Recommend workholding improvements (quick change, modular, vises vs fixtures) Implement ImprovementsProvide updated CAM toolpaths or alternative strategies Suggest optimized cutting parameters (SFM, chipload, stepovers) Recommend new tools or holders if needed Identify bottlenecks and remove wasted motion

Review existing QMS documents (procedures, work instructions, forms, records). Assess compliance against AS9100 Rev D (or ISO9001:2015) clauses. Evaluate process interaction maps, quality manual (if applicable), and risk management documentation. Identify missing procedures, unclear workflows, or non-compliant documentation. Evaluate calibration, training records, NCR logs, corrective actions, supplier records, and traceability files. Assess documentation control, revision history, and approval workflow. Develop or improve required AS9100 procedures (e.g., NCR, CAPA, risk management, supplier evaluation, document control). Provide templates for forms, logs, checklists, and process maps. Create a prioritized gap list with recommendations for compliance. Outline next steps required before a Stage 1 or Stage 2 certification audit. Provide audit preparation guidance for internal audits and management review. Optional: Provide training material for shop personnel.