Advanced Machining Process Diagnostics

A Three-Day Course on Tolerance Consumption Budgeting and Machining Outcome Prediction

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presented by IQL Independent Quality Labs, Inc.


hosted by Connecticut Center for Advanced Technology, Inc.

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Abstract | Who Should Attend | What You Will Learn | Prerequisites | Instructor | Facility | Outline | Registration | Contact | Lodging


This seminar provides a practical understanding and application of tolerance consumption budgeting for machining process diagnostics and corrective actions. Through lecture and case work, focus is placed on the primary tolerance consumers within machining processes (machine tool positioning capability, thermal effects, process variability and inspection capability), standard terminology for describing these effects, as well as straightforward analysis methods and tools for successful science based diagnostic analysis.

Who Should Attend

This course is designed for design engineers, manufacturing engineers, and technicians concerned with developing, deploying and maintaining successful and stable machining processes. Others who should consider attending this program include:

  • managers, engineers, and technicians engaged in:
    • plant management and supervision
    • manufacturing operations
    • quality assurance, control, and maintenance
    • factory, assembly, and field service
  • machine tool builders and designers
  • machine tool rebuilders and distributors
  • machine tool sales, service, and testing representatives
  • technology educators
  • technicians
  • machinists


What You Will Learn

By attending this information-packed program, you will...

  • create machining process tolerance consumption budgets
  • learn how to identify critical to manufacture (CTMs) part features
  • understand the relationship between toleranced features and machine tool performance capability
  • compare machine tool capabilities using performance grades
  • make informed decisions for machine tool selection / process matching
  • rapidly and confidently identify root cause machining issues
  • learn science based machining process diagnostics methods
  • work with a web based analysis tool


Basic Skills / Prerequisites

To attend this course, you should have a familiarity with manufacturing environments, machine tools (lathes, milling machines, machining centers, measuring machines, etc.) and their functions, terminology, and applications.



Robert (Buz) Callaghan, MSME, is the Senior Engineer at IQL Independent Quality Labs, Inc. He has over 49 years experience in precision tool and machine design and metrology. Buz has published numerous papers on the accuracy of CMMs and CNC machine tools. He is an active member of the ASME standard committees: B5.54 "Methods for Performance Evaluation of Computer Numerically Controlled Machining Centers," and B5.57 "Methods for Performance Evaluation of Computer Numerically Controlled (CNC) Lathes and Turning Centers," as well as a supporter of ISO 230 Test code for machine tools.


Host Facility

The Connecticut Center for Advanced Technology, Inc. (CCAT) is a nonprofit corporation that provides services and resources to entrepreneurs and businesses and, through collaboration with industry, academia, and government, helps companies innovate and compete, thereby strengthening our nation in the global market. Their core programs address military and civilian industrial manufacturing needs, promote energy planning and policy initiatives, stimulate innovation and improve workforce development efforts -- particularly those geared toward technology competitiveness. CCAT is also actively involved in researching and field-testing how advances in lasers, nanotechnology, computational modeling and next-generation manufacturing can aid the competitive needs of U.S. industry. CCAT is located at 409 Silver Lane, East Hartford, CT 06118. Please follow these Directions to the CCAT Advanced Manufacturing Center, rather than using a GPS.


Course Outline

Deterministic Method Applied to Machining Processes - An Introduction

  • Advantages and benefits
  • Focus on process control
  • Machining Tolerance Consumption Budgets
  • Need for a unified language and concise terminology

Critical to Manufacture Features (CTMs)

  • Attribute Feature Pairs (AFPs)
  • Unit Tolerance - Features
  • Critical to Manufacture Filtering
  • “Precision Component” Case Analysis

Machine Tool Performance Behavioral Models

  • Machine Sub-Class definitions and terminology
  • Parametric Error Tables (PENs)
  • Model Configuration
  • Machine Tool Performance Grading
  • Vertical Machining Center Case Analysis

Individual CTM Analysis

  • CTM Machining Process Definition
  • Machining Process Error Analysis
  • Tolerance Consumption Prediction
  • Machine Tool Capability Requirements
  • “Precision Component” Case Analysis

Manufacturing Process Diagnostics

  • Diagnostic Strategies
  • Root Cause Identification based on Tolerance Consumption Budget
  • Application Specific - Key Machine Performance Parameters (PENs)
  • Resolution Strategies
  • “Aerospace Component” Case
  • Analysis Tools

    • AFP Selection and Analysis
    • Generic and Specific Machine Behavioral Models
    • “ANSI Block” Case


    Schedule & Registration

    Registration Fees


    This fee includes all text and note materials, continental breakfast each morning and lunches each day of class. Interested parties may register through IQL.

    Companies sending more than one attendee will receive a 10% discount on each additional registration.


    7:30 AM - 8:00 AM Tuesday

    Course Hours:

    8:00 AM - 5:00 PM Tuesday through Thursday

    Substitution and Cancellations

    A registration may be transferred by submitting the name of the substitute. A full refund will be made for cancellations received 10 working days prior to the start of class. A 10% service fee will be charged for cancellations after that date. Registrants who do not show up for the course will still be billed or may request a credit toward a future course.



    Charlotte Gardiner

    IQL Independent Quality Labs, Inc.

    T: 866-549-2920 X-101




    Lodging and transportation are the responsibility of the attendee. Click here for suggested Lodging and Directions.