$200,000 Damage | EPIC FAIL… Machinist CRASHES TWO MACHINES at the Same Time 

How Is This Even Possible? Have You Seen Anything Like This? Not Just The Double CRASH… But The Attitude Of The Machinist Involved… and What Happens at the End? UNBELIEVABLE…

Worst crash I ever did was when I was still in technical college. Brand new Clausing lathe. I was the first student to program and machine a part on it, so I thought. I G0 to .500 in Z to the front of the part but I forgot the tool offset and I had also had Z in a positive number, not a negative. Turret went high-speed straight into the spindle. Machine was down 4 weeks for repairs and realignment. My teacher let me engrave my name in the spindle as the first student to run and crash the machine. I work with a guy who graduated from that school 2 years ago and he said my name is still on it. That was in 2001. Lol

This part about him getting promoted and getting a raise sounds so familiar. Same happened at the place where i did my apprenticeship, guy was breaking tools and crashing machine so very often and he got promoted, got a raise, but in return he was snitching to the employer whatever was happening in the company. Toxic place, glad i went out.

For anyone wondering if this was easily avoidable, yes this was insanely easy to avoid, the first time you run any tool you should turn the rapid down, wait for the tool to approach the part and just look at how far the tool has to go vs how close it actually is to the part

That company is going to get exactly what they deserve by keeping him. This was not a one time deal, he will do it again. A $200,000 crash would put my shop out of business.

Worked as a maint. machinist for Hughes Aircraft in the mid- 80's. Got to see lots of crashes big and small. The most impressive one was when one of the drive lugs on the spindle face of a horizontal machining center came off at speed. The screw apparently fractured and the harden steel block shot out, riccochetted off the door edge, hit the inside of the safety glass on the open door, cracking that, nailed a nearby steel post, and proceeded to strike the operator square in the forehead. He dropped like a sack of grain and had to be taken for some stitches, but otherwise he was okay. He had been warned to keep the door closed but who listens to reason? He was just lucky he wasn't the first or second stop on that little block's path. It would have brained him good. Earned him the nickname "Hammerhead".

I saw a guy make an offset change then press cycle start. Then turned around and was browsing on his phone not watching the machine. What he didn’t realize is put in the wrong number and that thing went 100 percent rapid into the chuck and cracked the whole machine all the way through. The machine got scrapped and he got fired cause it was all on camera.

Some of the most humble, effective, and powerful words I’ve learned for work are: “Hey, I fucked up, help me learn from this.”, right after “I’m not so sure about this, can you run through it with me and make sure I’m on the right track?”.

I'm a machinist who has encountered similar situations. In my current shop, I'm caught in a dilemma: if I take the time to review the program, it's considered time-wasting, but if I skip it, I risk jeopardizing the machine's safety. Despite the backlash, I choose to verify the program, which is frustrating, to say the least. I've been with this shop for five years, and I'm leaving for a new shop in just six days. The issue here primarily lies with the management.

The biggest crash that I’ve seen was of my own. I was employed by a well revered graphite machining company where I setup, programmed and operated a fryer ET-100 turning center capable of running 100” diameter parts (yeah… friggin huge!) while running a 10,000 lbs/85” dia rough-cast billet of graphite in my machine, the stock began to shift inside of the 6-jawed Chuck it sat in due to pressure loss in the tail stock. Eventually the part exceeded the ends of the jaws and the 5-ton mass of graphite dropped to the ways and into the tool post. I felt the ejection in the floor before I’d ever seen what had happened. Luckily no one was hurt and after inspection, and meraculously, neither was the machine other than a dented guard. Thank god graphite is a soft material! Although the company didn’t take any reprimanding action other than an expectable evaluation of the incident, I spent the following two days without sleep and was significantly depressed. It’s disheartening to hear of stories like in this video of operators who lack the understanding of what harm their negligence can result in. Of course the fiscal side but also that of safety. The manufacturing industry has come a long way in keeping employees safe, but it seems as though some have a hard time grasping the concept that when it’s you against steel/spindles/geared servos/cutting edges/lifting devices/gravity, the latter will always win void of safety.

The worst crash I've seen was some one running a 1 1/2 boring bar into chuck jaws turning around 3000 rpms rapid in x axis. The guy had been running parts that morning, apparently he hand jogged indexed turret to change insert. Pressed cycle start and first move was rapid in x axis. He didn't hand jog back in z enough for clearance. It was after lunch time if you know what I mean. Broke master jaws, mis aligned head stock, wedge, damaged turret. #1 tool pocket on turret could never be used again, tool holders wouldn't go in pocket. He was fired a couple of weeks later. I told him before that happened to not smoke pot with boys during lunch break.

Number one rule of running the first program in a CNC. Always watch it, slow the rapid down, and make sure you don't crash anything, doesn't matter if you wrote the program or not. If the programmer wrote in the wrong tool called up in the program, it's your responsibility to catch it. Rule around the shop I work for at least is always single block through the start of every operation.

I witnessed a CNC Lathe crash at a company in Chandler Az. Some idiot had mixed up 7/16 bolts with the 3/4 bolts. It wasn't the Machinist's fault, but he quit then and there. The floor began to shake as from an impending earthquake, I saw the door shoot across the room, one jaw went through the ceiling, one through the bay door, and the third was banging away in the Lathe. And the lathe was practically tap-dancing there. This poor man was just standing there afraid to move and hit the "big red button". He just walked out, and another family member came by 2 days later to pick up his tool chest. My boss, the owner, tried to get him to come back, but he refused. That was an "OH CRAP" day.

We face the exact same mentality everyday. Seriously where i live everyone tries to put the blame one someone else. I have only seen a handful of people that actually take pride and responsibility in their work. Being an owner of a small company that offers production machinery to other companies we see this each and everyday. The bad thing is those type of people actually pass down their negative mind to the new guys as well. So the stupidity continues. That is the most damaging thing in an industry. People who don't take pride in their work and take no responsibility. Great video.

Imagine colleagues that actually take pride in their work and put in the time to get better, see that person's promotion.

This sounds like an old videogame: you make a combo-crash and you level-up.

When I learned CNC machining we went through the whole process: Programming, Simulation, Tool setup, Machine check and setup, machining and QA. Now I know why. It's the machinists responsibility to cover for others mistakes before anything goes horribly wrong. That's why we dial down the Feed% and Spindle% to as slow as the tools allow so we can catch movements before they destroy the machine or the part. Sometimes you can even catch an error in the G-Code monitor before it gets executed.

While employed at a precision valve company in NJ, the front office made the decision to promote a bean counting contract efficiency expert to the head of manufacturing. This was a position that had ultimate say over setups, processes and tooling. Basically a god level " I know everything" position. During his orientation through the shop, he had a clipboard in one hand and a yellow highlighter in the other. White shirt, black tie and glasses. Standing next to the biggest Mazak CNC machining center we had, the operator called up the wrong tool and crashed the machine. The tool was a 10" diameter insert shell mill with about 100 inserts around the periphery. Spun to about 7000 RPM, this cutter was rapid moved into a 4 foot long 10" cast iron angle plate that was about 1 1/2" thick, full rapid speed. The angle plate was bolted to the table and fully loaded with castings. The crash was so violent, the counter torque from the crash shifted the machine well off its anchors in the concrete floor. This machine had a table you could lay a 4x8 sheet of plywood on with room to spare. The majority of the operators in the shop dove for cover, but our new savior never flinched because he thought it was supposed to sound like that. RIP B.G. you never had a chance after that. It literally sounded like a train hit the side of the building.

Always stand by your machine first run.... always!!!!

The largest crash that I have ever had happen to me was at work, I operate a large moriseki horizontal milling machine, I had ran the parts all weekend and everything was going great, when the tool change between tools 59 and 60 was going on the machine stopped, I came reset the machine and verified that the tools were going back to the right pots and then continued to run. I left my machine to load up some parts on our wire EDM and one of my coworkers had told me that my machine alarmed out, I though nothing of it, I suspected it was a +z over travel because I had zeroed out a tool prior. I walked to the machine to find the touch off probe had slammed into the part, ruining the probe and the part. It had turned out that between tool changes tools 59 and tool 60(probe) had gotten flipped in their pots. Tool 59 is a short pipe we use for washing the parts.

Best I've seen was on a huge cnc horizontal boring mill. Big component on the table and my buddy was lining up two bores to bore them to size. He had the spindle extended through the piece to reach the furthest bore with a dial. Having got it lined up he went to retract the spindle using rapid. Unfortunately he hit Y axis instead and the head of the machine went up with the spindle still inside the part. The machine tore all 4 t nuts through the cast table leaving 4 huge craters in the table. That machine had a lot of power!

CNC repairman here, worst crash ive ever been called to was when this company launch a 100h programme friday evening, the mold was aluminum so high spindle and soft cutters, (for who dont know usually big mold are cast aluminum with inox pipe inside for cooling), long story short the company who casted the aluminum misplaced an inox 1" tube by like 5 cm, machines saturday night exploded the cutters from the spindle, but anti-collision was disabled like the week before due to some elettrical issue (we were supposed to replace it like the week after). Monday morning the spindle was blu, the machine continue to mill with the spindle head, burning bearings, eletrical wiring, C and A axis where deformed (the screw of c and a in those machines is in bronze to reduce damage in situation like this), Z axis was ot of square about 1cm/1m. We ended up completly chaning Z,A,C axis, spindle, cooling unit (part of the spindle were been sucked into the cooling circuit), and remillling x and Y placing point for linear guide. i honestly didnt ask how much they paid for this work. But i know for facts the just the spindle is 35-45k$

I know of a lathe right now that is junk taking up floor space that a programmer mutilated in about 10 seconds. 12,000 rpms and a high rate of rapid into a part never ends well. When I had to teach myself CNC I always ran it with the machine axis locked and watched the program and verified tool changes. Still crashed a few times. Found out why the have frangible couplings the hard way. Not cheap, very stressful when dealing with high dollar tooling and machines. At first I hated doors on machines, eventually found out why they must have doors. :D

It's insane how lackadaisical some people can be in this industry. I've only been machining for about three years. I just took three hours to prove out a 25 minute program. I am completely okay with that, my boss is completely okay with that, my lead machinist is completely okay with that. Damaging a machine is bad, scrapping a part is bad, but I put my safety and the safety of people working around me and after me at the forefront of every decision I make. The worst crash I've ever had was when I first got into machining, and I thought the turret on the Mori Seiki SL-403 I was running was at home position. Indexed it right into the tail stock. I learned some new swear words that day, also spent a few hours with maintenance learning how to indicate a turret to tell if it's out of position.

I watch your channel and realise I am not the only one with problems in the workshop. It gives strength to see my losses are so many times smaller but still drive me crazy. My CNC is very very small. You have a very strong will

We had someone crash our Chiron 6000. Machine was down for roughly 2 months costing over $500,000 in repairs, not including lost production (each part is upwards $5000 each, and we can make 10 a day at best as big as they are). That happened over 7 years ago and the machine still doesnt run the same. We almost lost a contract with Boeing for the parts because we were the only ones certified to make them. The guy that crashed it quit soon after thinking he was going to get fired, but found out he wasnt and tried to come back. They declined.

As a new cnc machinist I’m grateful for this advice

I've been a machinest since the early 80's, I founded and owned my own shop for 30+ years. I finally closed and gave up because of braindeads' that spent more time in the parking lot screaming into a cell phone or getting stoned... Quality starts with you making sure your kids understand responsible behavior so when they show up looking for a job they aren't an embarrassment.

always single block and 5% rapid for each tool when first running a new setup.

Dude the ending…. Great companies go down with poor management.

I'm a cnc machinist. Even if I'm in the middle of a run, if I change a tool, I always watch the new tool in for the first time. It's what we were trained to do.

This is why companies invest in Vericut. The programmer/setup/operator should walk through or dry run the program first. But if its a regular production the operator should be held responsible for the error. Where I came from you were terminated after you crashed a machine 3 times. I have seen an operator crash an HMC knocking the tombstone over in the machine so bad the the machine had to be partially disassemble to remove the tombstone because it was unable to shuttle the pallet.

I've plunged tools into the job, nothing too serious apart from the cost of a bit of carbide and a little time. Our programmer is famous for not changing clearance heights when changing over to a metric system. Often, I have had to estop to prevent clamps from being wiped out. Knowing this, I often ask, "Have you set the clearance heights in metric?"

The worst crash I've ever been a witness to, was when the Makino machine next to the Makino PS65 suddenly made the loudest booming sound I've ever heard from one of them. It turned out that the threading tap that was being used to make an M16 thread got stuck in the workpiece, ripped the part out of the fixture (part was 200mm x 200mm with the threaded hole in a corner of it), and then swung it freely in the air at 600RPM for 1 second before snapping the tap and slinging the piece into the door of the machine. In short, the door was bent like hell and someone was spared from being hit in the by a 20kg piece of metal.

So far the largest crash Ive had was Hurco VMC I was being trained to setup and operate. I only had a few months experience from being in school so I was GREEN. I had learned on the FANUC controllers to add height comp or cutter comp to bring a tool in to spec well on a hurco it doesnt work the same way. I added .005 to a height offset in the wrong page and hit cycle start lemme tell you I was standing right there, there was NO time to stop it. Only step back afterwards and reevaluate myself. 5 years later and now Im an instructor at the same school i graduated from and havent made another serious mistake.

I worked in a place where there were only 6 of us in the entire shop. If we were assigned a part, everything from start to finish was on us. If anything ever got sent back, it was on the individual who made it and no one else

Just 2 days ago a classmate of mine dropped a conventional mill's bed on the concrete, bending the Z-axis wheel crooked. He had no remorse and kept blaming the bed being "too slippery". The same guy also didn't fix down his 3-jaw about a year ago, causing it the fly off the machine at 2k rpm and grazing his face. Instead of being shooked or scared he proclaimed loudly that "this wasn't even the worst that had happened to him". Absolute nutcase

Hire more operaters, instead of machinists, and keep having the same problems

Had an old machinist teaching me one day .I walked up to the machine and he said stop are you left or right handed I said right he said take your left hand and put in your pocket , so I did he said now you can only make one mistake at a time .

if they promoted this guy and gave him a raise then it sounds like the people that are making those type of decisions are the same type of people that are running the country right now.

I worked with a guy that missed a tool change in the middle of a boring cycle. The turret indexed and ripped all the bars off the turret, ripped the jaws off the spindle and banged up the doors and the way covers something awful. That’s what you call “totaled” in the machine world lol

I got out of machining cause of bad pay, long work hours, constant anxiety about the machine crashing. I ran a router and a CO2 laser, I was the only guy running these two machines so I was made to the designing, programming, machining and QC. I had to work even whilst at home to stay ahead of schedule.

My production leader was forced to throw away over 300.000,- of parts because he decided us welders could produce parts with a 0% tollerance that NEEDED to be machined before and after welding, eventhough all of us said it was completely impossible to produce these parts this way. Yesterday he decided to paint all of our overhead cranes a "nice" dark blue, eventhough the highvisual yellow is there for safety reasons (ofc). Than again; he used to be a electrician before being promoted to production manager steel...

I was night shift supervisor when I had a guy crash a multi axis lathe by loading a bar end wrong. It hit so hard I thought my machine crashed. $60,000 worth of damage. He supposedly had 25 years experience and immediately tried to blame the machine, then said it could happen to anyone. I had to walk away before I completely lost it. He was fired the next day. I, as a rule, hate firing people. This was a exception. My only regret was not getting rid of him when he scrapped 86% of the parts he ran earlier in the month.

I love this guy, 0 fucks were given! That's the right attitude in this world nowadays, btw!

When I set my tools and datum probe I always used a "0" datum above the job, probe the datum and enter the minus offset and run each tool as a double check to first cut position with a stop program just for safety.

I would have fired him on the spot. Not for the crash but not owning up to it. One thing I learned being a machinist and tool maker for 40 years is nothing creates credibility faster than honesty and admitting to mistakes.

Id be throwing up and probably cry a little if I crashed 200k$ lol How in the absolute fuck do you crash 200k$ and get a promotion? that's insane, I know shit happens sometimes but god damn man

My client has 36 5 axis cancel machines. I see those programmers work for their salary. Every run is tested before the machinist gets to run his component run. Cannot ever leave his machine while it’s running.

I'd love to work as a CNC machinist. My grandpa was an og metal worker before CNC was popular I was 3 when his shop switched to CNC and he retired after. I can't believe someone who has that opportunity would act like that. I'd happily take an apprenticeship and take his place (: but I hope he sees this and builds on his character.

I'm a small one man in his garage type shop, the worst crash I've had was on my ST-10, I was hand programing a shop made bar puller, I proved everything out and it worked great, but then I went and loaded a boring bar and it hit hardened chuck jaws at 6000rpm on tool change. Both the turret and chuck were was knocked out of alignment, it cost me £1800 and two weeks of down time before I could get the Haas tech out to do the job.

Ive seen some bad crashed because of incompetence over the years. Bridge hights not being set correctly, parts smashed under the bridge, one big zayer milling machine 7000x4000x3000 travel in mm crashed so hard it took 6 months to repair. Over a million in damage.. 😅

That's why single block is your best friend when using a new program. You also want to stay on your rapid override and feed rate switches. If your machine has a graph you can actually do a machine lock dry run as well.

Apprentice here. Almost crashed an old CNC once. Forgot to change the tool lenghth, moved with G0. Nothing happened as the center of the pocket I was working on was already cleared out by me and I had my finger on the override at all times.

Thanks for your honest story to share with us, we all do mistakes sometimes and learn from it ✌

Sounds familiar at the shop I am at. Been on cnc machines for 4 years. Learned a lot while making injection molds. Started learning in and outs of mastercam. Coworker of mine gets on a machine for the first time and gets a raise after 3 days. Scraps out thousands of dollars in steel. He never even felt bad about it. Blamed programmers for not teaching him. Made all sorts of excuses. But since he has a good attitude it’s all good. Very toxic place.

Listening to this, now I understand why I run my workday at 20 steps ahead, I like to catch an issue before it becomes an issue, also the reason I like to work alone

I was waiting to hear that he was fired. I was shocked to hear he got promoted. Must be in the same Lodge as the boss.

In high school on a manual lathe, I intended to engage the powered Z+ axis (move the tool to the right) but accidentally pulled the lever in the wrong direction which powered the X- (tool into the work) with the speed set pretty high. Nearly instantly a massive metal "hairball" was produced, and the motor stalled. Luckily there were no injuries, and somehow the only damage was to the HSS tool and the part - Machine was fine miraculously... Learned that lesson.

I have never done CNC machining or any other kind of machining for that matter. But years and years ago I realized I wasn't that smart and that I had a poor memory, so I'd never be able to get away with pulling some complicated hustle or avoid doing the boring, slow work required. So I decided to pay attention at work, try hard, and when I foul up at work, admit it right away, take responsibility, apologize, and try to fix it and not have it happen again. Have I seen people totally lie when they foul up, blame other people, and avoid consequences because of it? I have. And I've even seen those people get promoted. Would I change my philosophy? No. But I sure hope in the afterlife there will be some justice.

One time, I and a new hire were changing out some wire spools on a machine and then heard 3 other of the adjacent winding machines simultaneously crash while the operator had stepped away to move a pallet. The bobbins that the machines were winding wire onto were not secured properly and they were ejected at over 1500 rpm. Fortunately, the guarding on the machines caught the 45lb projectiles before anyone got hurt, but all 3 sets of guarding were catastrophically damaged and had to be rebuilt, by hand, by our maintenance crew because the machine manufacturer no longer supplies replacement parts for these machines.

Early '70's, I was running an Okuma slant bed, 3 axis, 6 station turret machine. It had a Vickers UMAC 7 CNC controller on it where the program was run via punched paper tape in a loop. This is a big machine. 50 HP spindle with an 24 inch swing over the 12 foot long bed. We were running forgings, nose landing gear trunnions for Lockheed L-1011 aircraft. Each forging weighed approximately 60 pounds. We were running the 1st operation on the forgings which was mounted in a (not so...) counter balanced fixture plate.....maximum spindle speed was 31 RPM. The operation was to face, center drill, then drill and bore the hole in the "foot" of the forging. Running each of these forgings took approximately 25 minutes due to the low speed the spindle was forced to run. The set up passed 1st article inspection and we had been running the parts for about 3 days on two shifts. I loaded a new forging into the fixture, torqued the hold down bolts and nuts to specified torque, I then pushed the "CYCLE START" button on the UMAC 7, as I had countless times before. When running any machine you get used to the sounds it makes..... the clunking of gears in the headstock, the whine of the hydraulics, etc. This is what alerted me that something wasn't right. The spindle was limited to 31 RPM per the program....there were NO gear changes, yet after pressing the "CYCLE START" the first thing the machine did was change gears in the headstock. I immediately pressed the "EMERGENCY STOP" button....repeatedly. It was like watching a train wreck. When the machine finally got into the gear it wanted(580 RPM we found out later) the 50 HP spindle motor started, all the while I'm mashing the "EMERGENCY STOP" button in a panic. The spindle motor let out with a groan as it started trying to spin up approximately 350-400 pounds of weight to the new speed it decided upon. I got out of the immediate vicinity of the machine...in a hurry! As I watched, the turret then went to a new "HOME" position....about 6 inches from the accelerating forging. The turret then indexed an 8 inch long tool holder, with a facing tool mounted, directly into the still accelerating fixture/forging. There were several loud "BOOMS!" as the machine self destructed. The forging came loose, flew through the shield and landed almost 80 feet away, just missing the operator of a Warner & Swasey #5 manual turret lathe. The tool holder shattered sending cast iron shrapnel for 50 to 60 feet all over the shop. But still the spindle was trying to spin up to speed! Luckily the operator of a Hardinge ASM behind the Okuma had access to the main power going into the Okuma and was able to shut it off. It took 15 seconds for everything to come to a stop. The imbalance had shifted the 22 ton Okuma lathe 18 inches from where it had been mounted....after shearing the 16 1 inch mounting bolts holding it to the floor. The turret was hanging from it's hydraulic lines. The shield was laying up against a Waddell ASM that was about 15 feet away. All told about $125,000 damage on a $500,000 machine. The reason for all this carnage? Paper fuzz....... The machine ran a paper tape reader that needed to be cleaned daily. The company had only had the Okuma machines(3 of them) for about 4 months when this happened. The company selling and servicing the Okuma machines had neglected informing us that the tape reader needed to be cleaned daily unless plastic tape was being used. Over the 3 days of running the tape reader was fouled with paper fuzz that caused the reader to miss read the tape....altering the program in several different ways. Come to find out, the "EMERGENCY STOP" button doesn't immediately stop the machine.....it puts it in a program hold mode....it'll stop after it finishes it's last instruction from the tape. I never trusted a CNC machine after that and I refused to turn my back on one.......

Talking to a supervisor one day when there was a loud thud and the concrete vibrated under our feet. The supervisor’s eyes got real wide and I swear he levitated and took off like he shot out of a cannon. When we got to where the sound came from the operator was leaning against his work bench shaking because he had just taking a finished part out of the vise and was going to put in a blank in. The counterweights cut loose from the Z axis and the Z axis slammed into the table. The machine was an old Dalih with a several hundred pound weight

Don't get me started on this subject. Too many asshats at my work seem to take more pride in blaming scrapped parts on other people rather than taking pride in preventing them in the first place.

Thank you for making this video. I am still working on the most expensive crash done by a single operator. It is heartbreaking to see careless on any CNC machine tool.

I'll be proving out a new program for a new part and taking my time being safe, and my boss will walk up and give me shit about being slow (he's usually just messing around) but one day someone pissed him off, maybe he didn't get a check for the parts yet or had to buy new tooling and he was in a bad mood and came up to me when I was proving out a new program which was a big ass 316 stainless part for a certain space company, and he was being an actual dickhead telling me to hurry and I wasn't even halfway through the program and he just stood there behind me watching and being an ass, telling me to hurry. So I lowkey lost my shit and looked at him and smiled, and said "100% rapid and full speeds and feeds ahead!" And turned everything up (including the spindle and feed) no single block this time and optional stop off, and sat there right next to him watching. The next few tools went okay, but then it was time for the 6" facemill to start the roughing toolpath, which was a little heavy I'd say. With full speeds and feeds ahead the facemill came in hot with that .250 depth of cut full radial, 7500rpm and 650ipm it made it about 8inches across the part sounding like a helicopter firing a minigin while crashing into a skyscraper and turned a sinister white and red color and the facemill head welded itself and then melted off and flew off fast and bounced off the side of the vise and then slammed off the way cover ruined that and put a huge dent on the side of the machine with a big crack in the middle. The spindle was really fucked after that too.I looked at him and said "oh no I should've been faster" he was speechless and looked like he seen a ghost, then he lit his cigarette and walked over and called the doosan repair guy. I told him I'm going to clock out and go to the bar, and was convinced I'd be fired or end up quitting after that, he said "see ya in the morning" all my coworkers were speechless standing there looking like lost prairie dogs, I didn't say a word to them and went and clocked out then got hammered at the bar.

Even if i scrap a $50 casting, I feel like sh!t. If on a Friday, its ruining my weekend.

We had an operator that did the same thing. New program, hit go and walked away (again, new program... not a new operator. He knew better and had been trained in the correct procedure). He managed to do something I haven't seen in my 25yrs in manufacturing. Whatever was wrong with the program caused a collision that broke the rails in half off a Studor OD grinder to the point where you could see the concrete substrate base. Luckily no one was hurt and the doors contained the part, but I have never seen a machine destroyed like that. It was only a handful of years old and was a total loss. There was no repairing it. Sad part was... he damaged 2 more grinders before he left the company. Some people never learn.

This is why I hate the insurance industry and sue happy culture too ,very rare to see people taking personal responsibility for anything it was always someone else's fault.

Imagine you are working at Titans and you are the machinist that made this mistake and your boss upload it on youtube so that the whole world knows your mistake.I can just imagine the stress level on those machinists.

My former employer bought a brand new Hitachi Highcell with live toolng and a tool changer. Then they put the 2 crashiest oporators in the place on the machine. It didn't last long. The first thing to go was the spindle in a spectacular crash resulting in the spindle having to be re built. Than after non stop smashings the turrit was rendered useless and the machine was scrapped.

Worst crash I've ever seen was a misplaced decimal in the work offsets for a Z. -24.8 inches is a lot different than -248.00 inches. The guy even had rapid down to 40-50%. Unfortunately it wasn't enough time as the fixturing had already tried coming past the spindle. 3 weeks down time. New spindle, B-axis rebuild, Z axis rebuild, and salvaging the fixturing was a fun time. The guy that it happened to now quadruple checks work and tool height offsets when its a fresh setup.

I thought I was the only one who goes through this with operators, I had one where he had two crashes one after the other on the same machine doing the same mistake. Either some people never learn or they just don’t really care. He’s been doing this for 5 years straight and it blows my mind he’s still employed

Dude would have been fired at my shop.

I work in a different industry but it is still the same concept”Those that can’t run a paper machine get promoted to foreman”sad but true.The part about trying to be successful and needing the tools to do it is something that is often overlooked by management .Really enjoyed the video,keep up the good work.

We have this guy that never makes mistakes when sizing up. It’s always “machine must have moved, I did everything right”

Before changing careers into IT in the 90's I worked as a CNC operator in the late 80's for a company that made fuselage tie tools for air craft builder's like Boeing and they had new Mori Seiki CNC's and I've seen quite a few crashes. It takes only one line G code error change to cause a major crash. They are powerful enough to drag a fully mounted eight inch vise across the table with such loud a noise that a horror filmmaker special effects department would envy.

I bent a modular drill once. It was because designer didn't care to properly labed material hardness on the drawing, which was high, shift manager didn't check it either and I was convinced it is the regular one. That teached me that I have to think not only for myself but for two more people too.

Working on very large Horizontal Boring Machines I've seen some big crashes...One happened last year when a worker had a tool in the accessory head of the machine...He drove it down in the Y axis without looking at it and drove it into the bed...Completely snapped the head off the machine and destroyed a lot of the internal components..Head was a write off and a replacement was £250,000

First of all , you don't start 2 machines and then go to break. This should be a lesson for all machine shop owners . When you got a couple of guys who are really sharp and know how to set up, dry run, and optimize programs , OPEN UP YOUR WALLET ,and pay them to keep'em around . Pay your top guys .You can always find losers , there a dime a dozen !!!!!!!!!!!!!!! Also management should have seen this coming with this guy !!! It's there fault too !!!

Perhaps earning trust and competency though manual machining processes does have it's place after all. At one time we earned the title of machinist through merit, intelligent problem solving and trusted accuracy in calculated execution of the trade.

Biggest crash I ever saw was my own. Running a 3 axis router on an unusually hard piece of white oak, had speed only at 60%. REN a compression rougher through a knot, blew the piece off the fixture, bound the bit and sheared the entire spindle off.

I once made a couple of bad mistakes and cost the company I work for about £800. I felt guilty, and still do to this day, but it helps me learn not to make the same mistake again. I once heard a big horizontal milling machine’s inside wall sliding panels jam up and tear apart on a rapid movement. Crazy noise.

Did the same thing , I was working with tall parts and long tools , I set up move to sefe position on "program parameters" and started the cycle , everything was ok , the table was moving to safe position until it didn't , the tool change arm smashes into the part and it bent so bad that we couldn't use it anymore, turns out inside the program were these blocks called "change parameters" that had to have the option to move to safe position on as well or else it stopped when encountered , the next day I told them everything was working fine and that I took a bathroom break and when I came back the arm was bent , for two weeks I was manually changing tools . If you ask me it was everyone's fault: the programmer that didn't set the option and left it to me , the instructor who didn't teach me well enough , I didn't know that I had to do it like that, and lastly my fault for running away from responsible , I watched that ATC arm crashed into the part yet I lied and I told I didn't know what happened and that I was at a bathroom break , in the end the damage was 1000$ and slower made parts due to manually changing tools

I was a machinist for 43 years , just retired a couple years ago . the last shop I worked at had a 18 pallet pool Makino horizontal 4 axis 313 tool machine . Very sweet machine I have to give it credit but the owner who also programmed a lot had a bad habit of hitting start and walking away and twice he destroyed the spindle (in less than 1 year). While we had insurance for that sort of thing that had a $10K deductible but it cost $30K to fix the spindle and another $3K to replace the window on the door . Biggest problem was it took 3 weeks to get the spindle the first time since it got dropped in shipping and a second had to be sent out , and the second time it took just over a week but down time on a 24/7 shop kills the budget especially on a machine that is costing $20K a month on payments .

I'm not a machinist, I'm a cabinetmaker. Rule #1 is never leave the CNC when running a new routine. 20 years ago when I was new to programing, I used a down spiral bit and plunged straight down into the wood at 18,000 rpm. Think of the worlds fastest fire starter using a stick and bow! Within seconds (and due to the vacuum hold down pump) I had a 2" glowing hole. Had I not been there, I could have lost a very expensive CNC not to mention my building. BTW, Love your channel!

I would give anything I've got to be TITAN employee. I fell in love with this trade about 2 and a half years ago. I set out on a mission to be one of the best and I don't see a better option than this company. Love what yall do over

So programmers never watch the program run? There is no trial run? That's insane.

The craziest part of that story is he can’t say: they don’t pay me to do that because he probably makes close to 6 figures and that was his job. Even crazier he still has that job and nobody really cares about stuff like that, sick culture! How do we change that Jessie?

I crashed bt30 mill machine spindle last week. Pull stud broke and the taper is completly distroyed. It's only my foult as a progammer and machinnist. We are waiting for service but I suppose to be fired. I very regret it but especially that this is waste of a lot work and money.

I was a 2nd shift supervisor at a shop and there's a new Mazak 4 axis lathe with a back-chuck where the guy puts the offset in the wrong.column. I don't know whether he didn't get tied in by the first shift properly or not but he'd run it the night before. When that thing crashed you could feel it through the concrete floor. As I approached the machine his face was beet red and I looked through the window at the piece of live tooling laying in the bed. He had crashed the back Chuck and that lathe was never the same. The owner wound up trading it in . . . So watch out when you shop the used machinery market. I've seen more than one supervisor and an owner lose their bet on used machines. The operator of the lathe wasn't there the next night

Learned on fancy machine run 1st parts through at 25% rapid or lower. Had a few machine that had nice load monitors set. So could rapid the tool into the part and It would insta-stop and not break when on slow rapid. Crazy how many times it saved people at my last place lots of money. Then for 2nd part full speed.

Hey your endmill is glowing! "I know, shes just warmin' up" You'd get better tool life if you adjust your feed and speed and put a lil coolant on it.

Worst, load equipment on truck, instruct driver to exit and go south then east to get on expressway. New guy drives north and hits RR bridge with said equipment, "the entrance ramp is closer going north" ya, about $200k flushed and a fight to keep the account.

We had a guy who was milling 12000kg piece(26500lb) and he didn't checked a programm, went on a break and milled fi 2000(78,5inch) hole 15mm(0,6 inch) too deep, they tried to fill it but entire piece bended and created gigantic piece of junk

I couldn't agree more with workers taking pride in the work they produce but after being in several different shops over the years I've found its the owner/management that set the example. If you go the extra mile all the time to make sure the parts that come off the machine are perfect, running efficiently, and your machine is maintained perfectly but that work doesn't get noticed or rewarded it can tank shop moral. As machinist we are all part of a team from the owner to the broom pusher & it's important to promote personal growth and pride within the team

When I was studying CNC machining I could glanced at a program and tell you weather or not it would crash just by looking at the tool. I learned this skill from old manual machines that weren't accurate and would shift. So I got good at eye balling stuff and not trusting the equipment. Never ever trust the equipment check and double check everything

Working in maintenance for the past 4 years at a manufacturing plant with all types of CNC's, I have seen my fair share of operator screw ups and more excuses from them about why it happened than you can shake a stick at. It's never their fault. For example, I had a Mori 3-axis NL. I had to replace the y-axis brake twice and the ballscrew once in two years. Operator kept crashing it and hiding it until the machine stopped running. I just can't with some people SMH. 🙄

I used to work for Lockheed Martin, did for 8 years. One of my jobs was running a robot up and down the front and rear left and right side beams for the wings on C-130J's. This is about around the same time the LM130J was coming out for FAA certifications for putting that aircraft into civilian use; the company bought an AWAC or automated wing assembly cell. Basically a giant tape deck where you put the pinned together beams into a cassette and drive it over to the robot; the robot drilled the holes, shot sealant into the holes, vacuumed the shavings up, ran nuts down and torqued everything. Supposedly. This thing ran fasteners down backwards, double drilled holes every 20-30 holes, ran nuts down on fastener heads and generally acted a fool the whole time it was in operation. Im not sure if Lockheed still uses it, I left not too long afterwards...but Ive seen some of the shit that thing put out and Im glad I never flown on one of these aircraft.

I was just talking about this exact same thing with a coworker. How companies lose so much money because some employees refuse to take responsibility for their actions. If they would take responsibility and improve the way they work then companies wouldn’t produce so much scrap.