Start with the job record, not the tool box
Begin with the parts that repeat every month or every quarter. Pull the drawing, setup sheet, previous programme notes and any scrap reports together before you choose tools. For shops in Germiston, Johannesburg or Pretoria, this matters even more when the same part moves between day shift and night shift. A clean tool list stops each setter from making small changes that later become big problems.
Write the list around the job, not around whatever happens to be on the shelf that morning. Include material grade, machine type, holder style, coolant method and the expected run quantity. If the job runs in aluminium on one contract and mild steel on the next, keep separate lists. That way tool choice, speeds and feeds stay tied to the material not guesswork.
- Part number and revision
- Machine name and spindle taper
- Material type and hardness
- Fixture or clamp notes
- Toolholder size and gauge length
Build the core cutting list for every repeat job
Most repeat jobs only need a small core set of tools. Keep that set tight and standardised so the operator can load the machine quickly and get back into production. A simple list often performs better than a long list with too many one off cutters, especially where tool room space is limited in Wadeville, Boksburg or Alberton.
For each operation, note the tool number, diameter, flute count, corner style, length of cut and overall length. Add the purpose of the tool in plain language, such as face mill, roughing cutter, finishing cutter, spot drill or holemaking drill. If a tool is only there for edge breaking or cleanup, say so. Small details save time later when the same programme is handed to another setter after load-shedding or a shift change.
- Op 10: spot, drill, tap or bore
- Op 20: roughing cutter for stock removal
- Op 30: finishing cutter for wall finish
- Op 40: drill for through holes or blind holes
- Op 50: chamfer or edge break tool
Match the tool to the material and machine limits
A tool list should match real machine limits, not catalogue theory. Check spindle speed, rigidity, coolant delivery and the holder you actually use. A long overhang on a light machine can chatter and shorten tool life fast, while the same cutter may run well on a heavier machining centre. That is why material matching is part of the list and not an afterthought.
For stainless steel, tool life often improves when you control cut length and maintain consistent chip evacuation. In aluminium, the list may need polished flute tools and higher chip clearance. In cast material, the right edge prep can reduce premature wear. If your shop works near the coast in Durban or Gqeberha, store cutting tools in a dry cabinet or sealed tote. Coastal humidity can cause corrosion on holders and packaging if the store room is left open.
- Confirm maximum spindle speed and feed range
- Check holder reach and clamping length
- Match flute count to material and chip load
- Record coolant type and delivery method
- Note any humidity or storage concerns
Set standard speeds, feeds and wear limits
A production tool list is stronger when it includes setting data that stays close to the machine. Keep the recommended speed, feed per tooth, axial depth and radial engagement for each tool. If the job is repeated on two machines, note whether one machine needs a slightly gentler cut due to spindle condition or fixturing. This is where tool life optimisation starts becoming useful in daily production.
Also record the wear limit for the tool before it is removed from service. A cutter that still makes chips is not always fit for a finish pass on a critical bore. Put the replacement point in writing, for example after a defined number of parts, visible edge wear, or when finish drifts out of spec. Shops in Centurion, Pretoria and Cape Town often use this to stop sudden rework on a busy Friday afternoon. It also helps with stock planning, because you can see when a cutter will need replacing before it holds up the next order.
- Recommended spindle speed
- Feed per tooth or feed rate
- Axial and radial depth of cut
- Tool wear limit or part count
- Replacement tool reference
Keep a spare stock plan for urgent runs
Once a job becomes repeat work, the tool list should link to stock planning. Keep at least one spare of every critical cutter and use a clear reorder trigger. If a tool is long lead or used in several recurring jobs, it should never be down to the last piece before you reorder. That is how late deliveries turn into machine downtime and extra overtime.
Mark the list with the items that must always be on hand for urgent tool supply. This is useful when a customer moves a deadline or when a machine comes back online after maintenance. Add the minimum stock level, preferred backup size and whether a sample tool trial has already been approved. The better the list, the less time your team spends checking shelves and phoning around.
- Minimum stock level per tool
- Preferred backup size or grade
- Lead time for replacement
- Tools needed for rush jobs
- Approved trial or alternate option
Review, standardise and keep the list alive
A production tool list is never finished after the first run. Review it after the first batch, then again after any tooling change, machine service or quality issue. Ask the setter, the operator and the inspection side what changed. If the part is now holding size more consistently, keep that version as the standard. If not, adjust one variable at a time so you can see what fixed the problem.
Use the same format for every repeat job across your shop in Germiston, Johannesburg, Pretoria, Cape Town, Durban and Gqeberha. Standardising the list makes it easier to train new staff, quote future work and avoid mixed notes in different books or spreadsheets. Keep the final approved version with the programme and store a copy in the job file so the next run starts with clear information, not a scramble.
- Review after first production run
- Log any tool changes or breakages
- Keep one approved version only
- Store with the programme and job file
- Update after supplier or process changes
