Last Post for Oreck

Hello Team.
Since I was laid off on the 16th this week, this will be my last post for Oreck.

I just want everyone to know that I really enjoyed working with everyone. It was a very nice experience to work with such a professional group of maintenance and tooling folks. I have come away with a new perspective on ways to accomplish things in the molding business thanks to all of you.
This is not a goodbye, as we will hopefully remain in contact in the future as associates and friends.
I would say best of luck to you all, but, as we all know, luck has nothing to with it! So best of fortune to you and may God smile upon you all!

Stay in touch,

Sean Kearns

6.27.12 Sean kearns

Mp#25- PM'd robot, replaced sheared screws from the crosswise travel. This appears to be a situation where the machine and robot were set-up incorrectly causing damage.

Mp#10- The nut press was not pressing the square nut on the LH side in all the way. I welded on more metal to the pusher block and replaced the cyclinder that presses in that nut. That seemed to be the problem.

Have a nice day!

Sean

6.26.12 Sean Kearns

Mp#3- removed tramp metal from the nozzle tip...looked like an axle from a baseplate?

Mp#5- had some issue with tonnage not building. Potentiometer was reading correctly but I tried some offset changes with no luck. Then when I put the value back to where it originally was, it started working again.

Mp#6- PM robot and machine. The robot Z axis belt was off track and had started wearing on the belt. I set the tracking back to center.

Mp#25 robot- Bolts are broken on the crosswise travel bracket again.?! When it goes down again they will need to be replaced..

Worked on ANSI stuff on #15. Installed the purge sheild interupt relay for screw rotate. Works fine. Still need to do the Robot/IMM estop interlock. I made the note in the folder.

Have a good day.

Sean

6.7.12 Sean Kearns

Mp#10- Put the jumper on wire no.224. That cleared the problem with the cores not working- after I removed the jumper and turned cores back on.
I do not know why, but evidently 224 needs to be jumpered on that press with 69 -vdc.
The ejctors were still acting eratic and the mold would not close so I put the jumper back in for the ejector back switch and the problem went away. He pulled out the mold and I worked everything just fine with the mold out so evidently there is a problem with the ejector back switch, or he has the knockouts too loose to make the switch.?

Mp#11- started working on the circuit changes for it. I installed the 120 and 210 relays, verified the wiring on the robot/IMM interface plug. The next thing I have to do is change the wiring for the door switches, and E-stop circuit. I did not have time to get into that before they want to run it on days Friday so that is where I am with that.

Mp#25- put the belt back on the small conveyor and tracked it so it was not riding towards the loose side.

I left a PTO form for the floating holiday I have to use this month Josh.

Have a nice day.

Sean

6.5.12 Sean Kearns

Mp#8- Finished tying in the robot e-stop with the machine per circuit changes outlined in the folder. Checked operation, O.K. to run.

Mp#10- Started making changes to circuit. I installed the relays and some wiring, but haven't cut into anything yet. Will continue tomorrow. We are running low of the 16-18 gage insulated terminal spade connectors. I have been using them with these circuit changes. May want to pick up some more, about 200 each. I have some red ones in the project box to go by.

Mp#12- The Eagle Fan Tester fixture was not sealing enough to pass the test. Replaced the O-rings and checked operation, O.K. to run. With the operators testing 8 parts per shift, I am not sure what the life expectancy is on them? We ma need to include a sign on the fixture to advise them to change o-rings if they suspect problems.

Mike and I looked at the leak on MP#3 at the end of my shift and we found the hose leaking under the manifold needs the o-ring replaced as well.

I also broke the porta-power cylinder fitting. Not sure where to get these, may want to check with A&H hydraulics? I will research that more tomorrow and submit something.

Have a nice day.

Sean

6.3.12 Sean Kearns

Mp#8- Wired in the safety gate and purge sheild relays per ANSI drawings. It is not complete as remaining work to robot E-stop needs completed.

Replaced the pump seal in the thermolator that was in the shop. tagged and put it back on the shop floor. I will return the welder to storage tomorrow.

Cleaned up the oil under 3, will keep an eye on it further.

Have a nice day!

Sean

5.29.12 Sean Kearns

Worked on the welder on press #10.
After I cut the slot in the old horn, I had trouble getting everything to line up correctly, when I did manage to get it to line up, it was not welding decent at all.
Mike is going to try to get it going now.

5.23.12 Sean Kearns

The Dryer on MP#8 keeps stopping for no apparent reason and will not restart on its own. Mitch just told me about it at 6 this morning so I passed it on to Ronnie. Mitch asked if there is a way to add an audible alarm to alert when it shuts down.?

Mp#26- I started working on a gate trimming fixture for that wheel # . I would like to have a lawn mower wheel/tire to use on it but I am open to suggestions. I will try to have it further along tomorrow to get some feedback from Josh about it.

The Mold setter asked me about obtaining (10) more mold pallets for the tool storage area to complete his organizing project. I told him I would pass this information up to you Josh.

On press #24- they are running the end cards for the brushrolls #77020-02/77021-02 where they need to use the adhesive sandpaper discs to clean up the gate area on the parts. They have no more #200 grit sandpaper so I mentioned that I would pass this up also. It comes on a roll 6" diameter.

Have a nice day!

5.21.12 Sean Kearns

Mp#15- Completed the ANSI audits, all machine have been inspected at this point. Let me know when you want to start proceeding with circuit changes, etc. I will watch for the presses to be down.

Mp#7- They are running the R2 baseplate subassembly there today and the feedback I am getting relates to a desire to have the light curtains installed and the press set up to run similar to the baseplate press on #6.
The job runs at 76 seconds now, which is kind of long, but the operators have to keep their fingers in the anti-tie down switches for the duration of the cycle (safety issue) which takes approx 7 seconds with each part  x 2 cavs =14 seconds each cycle.
This may be as fast as they can run it under the circumstances? Not sure.
It may be a legitimate claim to ask for this modification, I just don't know if it justifies the expense?
I wanted to pass this on to you Josh and see what you think.

Shift change again. The 5 weeks trial is over after this week. Mike and I texted last night and he is ready to come back after memorial day on  Wednesday.

He is taking off Friday and Tuesday and will return to 3rd's after that. Tonight the dryers were not set on timers and we had wet material on a few hoppers. Evidently he was out last Friday and no one set the timers so this needs to be looked at this week again. I can set them if no one else is going to. Let me know.

I will go back on 2nd's Tuesday evening as scheduled.

Have a nice day!

Sean

5.11.12 -Sean Kearns

Did not get to work on the T-nuts tonight because:

Mp#1- screw problems. Machine was sucking back an inch before running the extruder motor. This was causing splay. I removed the panels and cleaned and regreased the ball screws and extruder. The decompression velocity was set to zero, in my experience if you at least put something on it, it tends to work. We had a problem once before where this was zero and putting a value in there fixed it. Should be ready to go, they did not want to run it the rest of our shift so keep an eye on it.

Mp#10- Nut press was acting sluggish. Cleaned, refilled the FRL oil. Started working good, no further problems this shift, may have a cylinder going bad. Keep an ear out for this.

Cleaned up some oil on #3 and plugged the remainder of holes.

Give a hollar if you have any questions. Have a great day!

Sean

5.10.12 Sean Kearns

MP#10- Completed the ANSI audit.
MP#12- Completed the ANSI audit.
Mp#6- Replaced the regulator for the robot.
MP#3- Removed the hydraulic lines in preparation for pump removal.

Have a nice day!

Call if you have any questions!

Sean

5.7.12 Sean Kearns

Mp#14- I heard the extruder motor is likely shot? That a new press may be in our sights if we can find one for the right $?

Mp#10- The nut press was having some issues getting the left side to fit in correctly to where the sensor would read it. I dug out some nuts from up under the back stop and they fit better. It may still need some final finishing when they are not running it. It works if the operator will "work" with it some.

Mp#3- Completed the ANSI audit. I also had to go back over some of the purge sheild signs and re-fasten them with rivets. I will get to them all if I have enough rivets.

DR12 - A wire had come loose from the process heater contactor causing it not to heat correctly.
Put it back and checked operation, O.K. to run now.

I will continue working on the audits tomorrow and try to get them done this week!
*Only 10, 12, 14?, 15, 20, 21, 25, and 26 remain to be audited.

Have a very nice day!

Sean

5.3.12 Sean Kearns

Mp#14- Extruder problem. Intermittently stopping or turning too slow to recover shot size. They said that if they ran ABS material through the machine, it would not do this, only when the glass filled nylon was in it would it do this. I checked the extruder oil level and it appeared to be low. I added about a quart and a half to it.There was 1500 psi on the gage when it would mess up, when it was running fine it would operate around 700 psi. I separated the screw from the extruder and ran it at high speed for about 5 minutes to allow any crap in the lines or valves to flush out. I also checked to feel if the screw would turn by hand and it turned relatively easy. I reassembled and checked operation, it ran fine for 20 minutes then they shut it back down to run later.

Mp#10- repaired EOAT where some screws had come loose.

Mp#1- Replaced grease in lubricator tube.

Sean

5.2.12 Sean Kearns

MP#17 Core Pump- Over Heating
When I came in it was out of the range of the thermometer so we shut it down to cool.
I placed a fan on it and wrapped it in a coil of water hose and pumped chilled water through it.
It came down to 120*F and we restarted it. I let it idle for about 30 minutes and it did not heat up at all. We then ran it for 5 hours until it reached 150*F. Then we shut it down again. Mike had already adjusted the compansator all the way out on it. After looking at it, I did not see a secondary relief valve for it on the valve stack. Everything I have read about systems overheating indicates that there are usually two relief valves used. The other thing I noticed was that the output stays on core set during most of the cycle loading the pump for 30 seconds each shot. I think that this is where the relief valve either needs to be added to it or the compensator adjusted correctly. When it cools down I will try to adjust it.

MP#15- Moving platen holes stripped out. Drilled and tapped 8 holes from 5/8-11 to 3/4-10.
It needs to be noted that I am beginning to see a trend of holes getting damaged in the smaller presses lately. Maybe we could get Jerome and the team leaders involved to identify some of the reasons this is happening and work out some solutions to prevent damage. Example: MP#13 had very good holes in it until last Friday when one of the clamps fell off during a run because it was set with too short of a bolt in it. It totally destroyed the threads when it ripped out. That hole will now have to be oversized.

Give me a call if there are any questions.

Sean

4.31.12 Sean Kearns

MP#5 Robot- Mike evidently found a loose connection somewhere as the communication problem went away by the time I came in.

Mp#2- Replaced a blown fuse on the 24v4 circuit. They must have smashed a wire when the tool was set on 2nd shift? GMA-5A

Mp#16- Moving -platen has a thread hole damaged on the operator side, needs repaired when down.

Mp#17- Cores were not working on the mold. Both core switches were reading made all the time.
Checked it out and found that the jumpers were still in for core 1. Looked at what was done and already and tied the rest of it together. Wired switches for core 2 inputs, wired control switch in operator panel for core 2, removed necessary jumpers, checked operation. Put a core 2 legend on tghe front of the op station for techs to be advised.

Continued installing safety signs. Need some to put on the R2 fascia label station. I don't know where Mark got the ones for the classic fascia label station?

Have a nice day!

Sean

4.26.12 Sean Kearns

Mp#8- Installed new feed-throat coolant lines. Removed old infrastructure and installed new hoses with isolation valves. Checked for leaks...O.K. to run.

Gil has a tool with a leaking seal in the shop, it has a 20mm shaft, it appears to be Chinese manufacture. I will speak to Henry Yap when I come in about getting a seal replacement to make the repair.

I am moving to 3rd shift beginning Sunday night and Mike Daniels will be moving to 2nd shift on Monday temporarily for 5 weeks for cross training purposes.

Did anyone hear where management decided to have the company picnic this year?

Give me a call if there are any questions, have  a great weekend team!

Sean

4.25.12 Sean Kearns

Mp#4- The error 39 fatal alarm problem has occurred and will not seem to clear after powering down the controls. I shut it down at the disconnect and advised Roger and Marty to leave it down until Josh can contact Milacron in the morning.

Mp#16- Did the ANSI Safety audit on the press.
Need to obtain a sled seal kit for it also, it is leaking.

Give me a call if there are any questions.

Sean

4.23.12 Sean Kearns

Mp#25- F1 Fan -To Set up the press to run the product distinction system: Set "M1" when the press is in automatic and has finished delivering the (*2)forced rejects to the scrap box. Just push "F1" and it will begin flashing "ON". Do not press enter, just let it flash. After a shot it will remain in "ON". When you are ready to read a sample from a "good" cycle, then press "F2", it will also flash until it has "registered" a good cycle. Then it will remain "ON" as well. Adjust the "M1" value to read just below the "INJ END POSITION" of the "good" part cycle and the "M2"value should be just above it.

We tested the process by allowing the cushion to deviate below the "M1" value by lowering the shot size. It gave an indication of the fault and then delivered the faulty parts to the scrap drop. After the (*6) consecutive shots determined to be bad, it will stop the press and alarm. If the nozzle freezes off and the inj end position goes above the "M2" value, it will also fault and deliver them to scrap drop.

Have a nice day!

Sean

4.12.12- Sean Kearns

Mp#12- F1 fan testing station...the inflatable bladder that seals off the fan cavity is worn and likely needs replaced. I could not locate any replacements for it. Order one please.

Mp#7- Replaced one heater band and the contactor for zone #2. It blew the main breaker on the machine. Also found welded contact on the old contactor. Replaced with the SSR type. Checked operation, O.K. to run.

Mp#22- The pendant was not working correctly because it had a piece of broken plastic inside the touch screen area. I took it apart and removed the plastic,  and reassembled pendant, it started working correctly then.
Also repaired broken wires to conveyor/label station, plug had been ripped loose accidentally.

Continuing with ANSI Safety Audits on the presses. I will be off next week but I am leaving the audits in Josh's organizer on his desk.

MP#24- Worked on the "5220" Alarm where the motor stop circuit was activating at the screw rotate part of the sequence,for unknown reasons. Replaced the coils on the screw rotate, and sled forward valve outputs, replaced the relay for the motor start circuit and the emergency stop circuit, and replaced the relay in the power supply inside the cabinet. We think the power supply relay or the sled forward coil may have been the culprit as it was the last things I did to it and the problem has apparently subsided for now?...Unless Mike worked on it last night and did not mention what he found?

Mp#23 Robot- Removed the vertical arm and re-placed and tightened the mounting screws with loctite.

Have a great day.

Sean

4.2.12 Sean Kearns

MP#10- Connector Welder had some problems last night with the deflector radius area not welding very well.
Operator found that they could push up from inside and lift the radius area up and see thru it, while it was still passing the torque test as good.
I made a plate with jack screws to support the part around the cord dump area from underneath. It is working better and the parts cannot be pushed up as before.

Continued working on the F-1 cavity separator.

See you tomorrow- except Mark.

Sean

3.21.12 Sean Kearns

Mp#7- We have an issue where the pressure is not going above 1600 psi on the gauge for injection pressure, clamp pressure, or pump.
The pump is working and changes values below 1600 when changes are made to the controller, but as it is, it is set at 99% for everything related to speeds and pressures and that is all we get.

 I tried to adjust the pump valves but did not get any response at all after making a couple of turns so I put them back to where they were.

I did some voltage checks at the test points for the Kawasaki EPC controller and the VQ appeared to be out of spec according to the calibration sheet I had found. The VQ was supposed to be 3-6 volts and it was at 10 when the pump at standstill.

I discussed this with Mike and left him the calibration sheets I had at 11:00 when I left.

Have a nice day.

Sean

3.15.12 Sean

Mould-Tek Dryer on SB#1- The dyer has stopped in cycle due to the failed gear motor that burned out likely from the mechanical apparatus that ratchets the desiccant beds around. We need to order another gear motor for it. I found them in grainger for about $100. Also, the linkage in the ratchet apparatus needs to be checked out for corrct function, it was sloppy loose so I tightened it up and tried to manipulate it by hand but I was not certain about it. When the motor comes in we can check alignment and operation in further detail.

Mp#15- The mold setter evidently put too long of a screw in the platen holes that I recently tapped to 3/4". I asked Roger to get with him and decide what size screws we needed to accomodate setting molds correctly. Now it has a bolt stuck in it, they did not want to repair it, only set the new tool and run the press. So?

Give me a call if there are any questions.

Sean

3.13.12 Sean

Mp#1- Checked the fans on the cabinet, they are working. replaced cabinet filters and vacuumed inside the cabinet. Cleaned and inspected the machine and core pump.
There were no other alarms on my shift for anything on this press last night.
O.K. to run. I don't know how they continue to get so much liquid color all over the place??

Mp#2- The robot arm looked really bent like it had been crashed. Upon further inspection, found the bearings on the C-axis were mostly destroyed and one of the support arms looked bent really bad. The screws that held the C-axis assembly together were stripped out also. I put 5/16-18 keenserts in the screw holes and had Gil make some inside bushings from Delrin material and I replaced the outside bearings and shoulder bolts. I used permanent strength loctite on all of the screws and checked the operation. Nice and smooth now! There are probably some more C-axis that need repaired but for now we are out of those bearings from MRO (noted on the sign out sheet).

Have a nice day.

Sean

3.12.12 Sean

Mp#10-Replaced the sled cylinder seals. Checked operation, O.K. to run.

Mp#14- Made some new matching ejector bars.

Mp#11- Repaired waterlines on mold at Techncian Roy's request.

Continued with PM program.

Have a great day.

Sean

3.8.11 Sean Kearns

The nut feeder vibratory bowl is not working all the time it comes on from time to time with no LED indicators lit. It is outputting a voltage but no current. The LED's are showing both red and green off. When the nuts are loaded to the sensors, the green comes on indicating the sensors detect presence. I tried adjusting the sensitivity but it still cycles infrequently. I am going to look at testing the triac again. The vibration adjustment knob was maxxed out at 10 again also.

Mp#15- Drilled and tapped out 4 holes on the moving platen at Roger's request. Need to several others when the press is available.

Talk to you tomorrow!

Sean

3.2.12 Sean

MP#21- Is locked out. The key for my lock is on my toolbox. The ejectors were not working. I put a mold in it and clamped it up to set the clamp readout, etc. The ejectors worked once and started leaking from the hose I made. I replaced the fittings and the hose end and it did not leak anymore, but I still couldn't get them to move on their own. Probing the valve, it worked fine.It still needs zeroed out though.

I was looking for the procedure when I got the call to come home, my wife had spotted a tornado. Of course by now, everyone has likely seen the news about our area.

I came back in on Sunday and set the dryers and left them a note for start up.

Call if you have any questions.

Sean

3.1.12 Sean-

Mp#6- The technician Charlie Pack indicated that the press was stopping because the ejectors kept "bouncing" off the rear limit switch. He asked me to replace the switch and it did appear busted so I did. The problems still remained. I then attempted to adjust the EV2 potentiometer to "slow ejectors backs speed". Charlie also indicated that no control over ejector back speed was the problem. The EV2 pot changes did allow control over eject back speed, but the "bounce" problem remained still yet.

 Next, I discussed this with the supervisor Roger who thought the mold needed to have return springs in it. I mentioned that if I could find one, I could install a flow control with one way check valve in line with the hose and that would probably remedy this situation, but, I could not locate one anywhere. He also wanted to change the seals in the ejector cylinder.

The rod seal was not visibly leaking, but to be sure, I went ahead and tore it down and replaced the inside o-rings, rod seal, and both the piston seals. The problem of "ejector plate "bouncing" after retract still remains. The valve was my next choice, as I suspected drifting. It appears to still have the original valve on it. It was 12:00a.m. at this point so I went ahead and left. I will resume on it tomorrow when I come in.

Additionally, I would like to add that we could use some more seal kits for 360 ton Nissei presses as I had to re-use the external wiper rod seal because there was not one in the kit I found in MRO.

MP#8- The fan housing press was over-pressing the push-nut rivet assembly on the service parts they were running. I adjusted the positive stop to meet quality approval. I found out later that the process techs came back and adjusted it several more times. I think there may be some operator error being introduced to this operation. Check it out if anyone gets a chance. There could also be problems that have been overlooked with this process. Thanks.

Give me a call if you have any questions.

Sean Kearns

2.28.12 Sean

Worked on MP#18- seal is ready to remove. Press is locked out, I will get Mike to put his lock on it today when he comes in.
I had Henry put his lock on MP #8 until Ronnie comes in Wednesday morning.

Here are some images of MP#8 for future reference.

Extruder Motor with fittings taped off and tachometer removed to prevent damage.

2.17.12 Sean

Dryers all set that could be set for auto-start. I left a start up sheet for Marty and 3rd shift that indicated which dryers needed to be turned on and which ones were off and not in use.

We had another hydraulic leak on MP#2 core cyclinder hose. I replaced the hose and we cleaned up most of the oil.

Mp#26- Replaced the nozzle heater bands due to a bleedoff. Checked back on it later and there were no further problems with it.

Sean

2.16.12 Sean

Mp#6- Had more trouble with the gate cutter on the baseplate EOAT scratching the parts. The back stop had loosened again. Tightened it up, no further problems.








Mp#20- Has been having bleedoffs around the nozzle tip. It needs to be changed out to a new nozzle, or the old one re-surfaced when it goes down for a mold change. Keep an eye on it.







Repaired the DME in the shop. The clip in the 3rd spot down inside the terminal connector must have a clip in it regardless of whether it is wired to anything (it is not usually). If it does not, cards will not work correctly in it. In this case, it had one missing.







Finished up the conveyor roller covers in the shop and rolled it back out of the shop.







Cleaned up in the shop, took out the trash and cardboard.







Have a nice day.

2.14.12 B-shift Sean

Mp#1- Robot is down until pendant is available.

Nut Press on #10- Replaced a sensor on LH side square nut fixture. Cleaned and inspected it. O.K. to run.

Pm'd Press #5. We are putting loctite on the screws on all the loading receivers on the presses and in the mezzanine to prevent screws from loosening. I am also trying to get around and refill all of the FRL's with oil where needed on robots, etc.

Mp#6- Replaced the rpm tach for the extruder that was busted off. Used the one from MRO.

Have a nice day.

Sean

2.10.12 Sean

Mp#12- Replaced the mercury contactor on zone #3 with a solid state contactor 25 amp. Checked all heater bands. O.K. to run.

Mp#4- Core problems. After determining hydraulics were working, and set to correct pressures and flow rates, had electrical signal dropping out on both core sets. Found they had same card in rack in common and found what appeared to be a bad socket on the terminal connector. I gently bent the top pin enough to where it would make a tight contact. No further problems.

Worked with Roy Smith and Charles Pack on understanding the robot on press #22 better. I strongly emnphasized the need to improve their habits of saving mold set-ups in the robot memory. I showed them how they could change or save set-ups in regards to different conveyors (tall or short).

Worked on the trolley/platform for the new hydraulic power pack unit.

Cleaned up in the shop.

Note about shutdown.
Bill Potter informed the team leader and the process techs that there was no need to set dryer timers since he was coming in early on Monday morning for start up since 3rd shift was not going to start on Sunday.
 I did not get any other information since that so I did NOT set the dryer timers at Rogers' request.

I will call and confirm with him sometime on Sunday.

2.2.12 D-shift Sean

MP#16- Needs a pressure hose on the pump replaced soon. It is bubbled up at the crimp.
I think it is a 16- female compression on both ends approx 48 inches in length, but want to double check. I let Gary know when I came in today.

Mp#9- Replaced the sled seals.

MP#12- fixed the door bar and put together a paddle for the mixer.

Have a good day.

2.1.12 D-shift Sean

Mold#80251-Built another EOAT, they were using the one I had already built for it on another tool.
I did not see anymore of the short stroke cylinders we use for grabbing runners or the jaws for them in the blue drawers. I will look in MRO for some items to restock with.

Mp#4- We need to order a new hose for the core valve pressure line. It is leaking at the crimp. We don't stock those size fittings for it, or the hose, so may have to get one made.

Mp#11Robot- Need to get Elaine to order another belt for the Z-axis. It is a stock item and I used the last one several weeks ago. I signed it out from MRO and indicated that we were out, so it may be order already. The belt on #11 is chewed up pretty bad.

Mp#13- Needs a new lube oiler, or just the reservoir container housing if available. It was damaged a long time ago when we first got it in and I tried to build a support to hold it up. In any case, the oil keeps leaking out or they are bumping into it somehow. Needs replaced or repaired, I can engineer something more permanent if we are strapped for funds?

PM'd on #11 and fixed the air leak on the fan tester behind 12.

Have a great day.

Sean

1.27/28/29.12 Weekend D-shift Sean

Tried to work on PM's as much as possible, we were short the tech they let go and didn't really have anyone come in until Sunday night. So, I helped them with processing some.

Mp#22-built an eoat for mold#80135 haven't logged it on the sheet yet, but it is stamped with the number.

Mp#6- Had some trouble with the EOAT gate cutting on the base plates. It is sporadically missing the cut on the op.side part. When I say sporadic, I mean every 10th-30th shot it may miss the cut. At this point, I suspect the ejector timer may be messing up because I have caught it once and it looked like the ejectors went back too fast, or the compact cylinders delayed too much before moving the nippers.

Mp#17- The door was causing a  "5200: Confirm stopper plate position" alarm and would cause servo control to loose power. I removed the back door and bent the flag slightly so that it would pass a little closer to the prox. It seemed to help. I noticed that press #1 has a magnetic catch on the door to keep bounce to a minimum. I think we should get one for 17 also.

Give me a call if you have any questions.

Have a great day.

Sean

1.24.12 D-shift Sean

MP#6- Still trying to get the kinks worked out of it. Ronnie and I worked with the pressure and flow valves on the pump as well as adjusting the trim pots on the controller. We couldn't ever get it to a point where operation would be acceptable.

 After he left, I changed out the pressure/flow valve on the pump and again went thru adjusting the trim pots. In the process, I was able to get most operations functioning within reason except for the clamp speed CV3. I think the trim pot may actually be bad. When Ronnit and I tried to adjust it on the first valve, there was no response on the mA meter. The same is true with this new valve as well. I pulled another controller from MRO that was aved for parts and will look at the measured value ranges to see what they are averaging so that we may compare it with the one that is in it now, (check the variable resistor).

Note: When I installed this valve, I made no changes at all to it, so it should still be where it was set from the factory.

Ronnie said he would come in today to call Nissei and get some suggestions from their technical support group. Give me a call if there are any questions, I may come in later to see what he found out.

Have a nice day.

Sean

1.23.12 D-shift Sean

Mp#24- Pm'd press. Found some leaks on the core lines and fixed them, also found the pump seal was leaking. It shouldn't be difficult to get to if they are not running it. I will get with Ronnie to see if we have a seal kit.

Mp#21- Emptied the oil vacuum barrel and cleaned up under the clamp again.

Mp#22- Worked with Roy Smith some more making some position adjustments to the robot and helping him get the labels to run good. We made some changes to the posture position on arm #2. After homing, it was not plumb at label insert position, and it was not level at label pick up. We also slowed down the injection velocity because it seemed like the labels were shifting some after insertion.

Tried to mop up around some of the presses where oil has seeped out, etc. Will continue more tomorrow.

Have a great day.

Sean

1.18.12 D-shift Sean

Dr#9- had some fuse blown and bad contactor. Removed the dryer from the mezzanine and put a 200lb dryer in its place. Dryer is in the shop now, work has been done, it just needs to be checked out. I will finish it tonight.

MP#4- 8:00pm -Nozzle heaterband was left with a bleed off on the nozzle tip. I replaced the heater band and thermocouple at Roy Smiths' request. Then at 11:45 Roger asked me to check out the mold heaters which were showing OPi on all of them. I found that the plug at the top of the mold had been smashed down and was not making contact. Replaced it and labelled all the wires inside, then checked operation. At 5:00 they informed me it had filled up the sprue with plastic and had run no parts on it yet. It was the number one priority on the schedule. I did not receive any work orders from any of them. I will write some tonight.

Mp#7- chased out some holes in the bag dock tool, installed new screws with loctite per rogers request. Assisted Roy Smith in getting the Robot going at his request.

See ya tonight. Have a very safe and productive day.

Sean

1.13/14.12 D-shift Sean

Mp#20- Changed nozzle band, aligned sled after removing the shims that were messed up.
the clamp position switches got raked when the mold setter left some clamps near them and closed the mold up. I replaced 2 and fixed the others. Also cleaned and pm's the press.

Mp#24- wired up 2 heater bands on the nozzle at Roy's request.

Mp#1-Conveyor started messing up, it appears to be the gearbox or roller, I'll check it out more tomorrow. I swappped out conveyors for now.

Mp#9- robot relay contacts for conveyor was burned up. Replaced 24vdc relay.

Word on the floor was that one of the operators was throwing scales around.?? They asked me to find another scale for them, Roger and I located one in MRO. The broken one is back in the shop again.

Mp#3- blew a 2" flange hose. Ronnie got it replaced Saturday.

It is really cold this weekend!

Sean