Program verification saved me after a 3am crash last Tuesday

I run a small shop outside Austin and last week one of my Haas mills decided to eat a tool holder during a roughing pass. The part was already 90 percent done and the customer needed it Thursday morning. I had to hand redo the offsets, change the insert, and rerun the same program from the middle. It took me about 4 hours to get everything dialed back in, and the whole time I kept wondering if the code had a bad line that caused the crash. Turned out the previous operator had left a manual override in the feed rate and nobody wrote it down on the setup sheet. I now check the program header and every override before I hit cycle start, especially on night shifts. Has anyone else had a crash traced back to an undocumented override that was just sitting in the control?

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mark_nguyen958m ago

Print out the program before you run it and go line by line with a highlighter. I do that every time now after a similar deal where someone left a 120% rapids override in and it cost me a spindle. Also make it a habit to zero out all overrides at the start of every shift, not just when you load a job. Takes 10 seconds and it saved my ass more than once.