8.29.10 D-shift

Mp#5- Stopped once at 6:30pm, the back door had come ajar. Locked it closed. No further problems with it. Ran all night fine.

Mp#1-
Removed all of the panels from the press and thoroughly cleaned them and inspected all of the lubrication joints. Many were hand loose. Went over all of them with a wrench. All of the lines are in satisfactory working condition. The ones on top of the moving platen have obviously been stepped on a few times but are secure and intact.


Inspected the servo drive belts and mounting brackets on all of the drives including the clamp. They had no cracks or signs of needing replacement yet, other than the extruder belt which I noticed had some damage when I put the barrel back together. It is running very close to the flange on the drive pulley. The problem is that there is not any obvious way to attempt to adjust the "Tracking" or "center" the belt. It only has a tensioning screw. Shimming it might cause it to run back but then there would be the risk of it running back againt the servo motor.
Because of that, I made no adjustment to it without getting more feedback first, it may have came in like that?
.

I went through the list of items this weekend and had some questions as to where the Asset tags needed to go and which presses to put them on so if you can refresh me on that I will try to get those mounted Wednesday when I return.

the Hot stamp press that Ronnie worked on stayed on all night so it should be ready to use again. The heats did not go off.

Also wanted to get more input on the EOAT bench needed for the EOAT area before fabricating. There is a cart there now, did you want to make it portable? Should I check with Wayne? Was that his idea? ...Just Kidding.

Call if you have any questions.

Sean

" C " Shift - Weekend

MP-20  The cycle start timer wasn’t working. We saw input 14 on the plc flickering. Mark traced the wire & found a loose connection in the robot wiring.

 

MP-5 Added hydraulic fluid.

 

MP-2 & 6   PMed.

 

MP-20  Mold # 77015 – The DME heater plug on the mold had a broke pin – zone 6. I replaced the plug. The wires were short in the box so I had to add another splice in       the wiring.  I’ll have tooling let me

               know  when  the mold comes back & I’ll fix it right.

 

MP-5  Pump motor overload tripped. Injection valve – off  fault.  Mark said the pack time was  set too high.  He lowered the time & it hasn’t stopped again.

 

MP-3  Zone 3 barrel temp was running away. The mercury contact was stuck- replaced it.

 

I worked on the bag clip hot stamp. The heat kept dropping out. I found a loose solder connection on the board. I re- soldered it & I have been trying it out

      In the shop. So far I hasn’t cut off.

 

 

 

   R. Upchurch  

8.29.10 D shift

Mp#5- Fhd current input #1 exceeds limits alarm several times.
Pump overloads tripped a few times. We reset the pump and restarted machine and worked with EOAT to get parts.

When Josh came in at 11pm, he said that the throttle valve had been opened up to the extruder and this may have caused some pressure increases frm the pump. Possibly this could be why the pump was tripping out ("over-current").

He printed off the Milacron runoff data for the fhd and made several changes to hidden board values including a reduction in pump pressures output. More specifically he can let you know what he did.

It ran good without stopping since then until 2a.m. when it ran out of material.

Josh wants to make some adjustments to it when it goes down. It just went down for lack of material so we may be able to do something today.

Mp#26- made a support bracket for the thermolator process lines.

Mp#20- ran out of liquid color at 5 a.m. so may transfer the nest over to the other hot stamp press today and possibly look into the control issues with that old hot stamp press that keeps loosing control power or heats dropping out on it..

Cleaned up some oil and swept up shop.

Call if there are any questions.

Sean

8.24.10 D shift

75033 Mold- Seems like each time they change the tool, a new core switch and/or cable have to be replaced on the mold. I am starting to collect a few broken ones now.

I went through presses 6 through 11 and installed a gard so they do not push the trolleys into the robot power plugs.

Installed runner chute from aluminum onto the grinder on #11 because Marty said that Wayne does not like cardboard and tape.

Put the one-shot loader on the Nova-tech hopper/dryer #3 and put it back into operation. Looking at wiring up something to make use of the other top-hat on the table in the shop.(maybe put it on the hopper that is on the trailer?

Worked on PM's tonight, will continue through the weekend.

Call if there are any questions.

Sean

" C " Shift

I  vacuumed out the rest of the oil pans & emptied the waste oil  drum.

 

I installed the QVC fascia pad & set up the hot stamp. The pad isn’t contoured to the part, so it took a lot of shim tape. They changed the location of the artwork

   AGAIN !!!!!    I located the new pad so they can change back to the old one without moving the mounting plate.

 

 

 

 

 

 

 

R. Upchurch

" C " Shift

MP-23 & 25  Replaced broken lube fittings – ( tie bar & skate )

 

MP-14   Replaced broken ¾” water supply line on thermolater.

 

MP-8  Blender regrind valve not opening; may be static causing the controller to lose set points. Will try a ground wire on it.

 

Cleaned out oil pans on MP-6 & 7.

 

MP-25  Lost ejector back position;  Mark & Jason adjusted the encoder.

 

 

R. Upchurch

August 23, 2010

8/23/10

 

Added Flow Controls to MP10 ‘s Dukane Welder Door Ext.  Need to move prox down to clamp close on fixture and eliminate door plumbing to reduce shock and vibration dislodging deflector on part. 

 

Worked with Elaine on out of stock flow controls.

 

Upgraded Robot Displays with on the fly speed control adjustment screens on MP6 and MP2.  Only machines not running.

 

Picked up hose adapters for Dryer / Hoppers 1 ½ to 2”  to eliminate small hoses.

 

Picked up keys for Mike and Josh

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7615

 

August 21, 2010

Me and Gary set up Dukane welder with new fixture and new Branson Horn.  Located, drilled and tapped for new fixture.  Shimmed fixture .080” to get closer to parallel horn to part.  Dropped down stop to just above main part body.  Started with .8 weld time and could not tear weld with pliers.  Weld was very Hot, some weld slag visible on part.  Reduced weld time to .6 sec, still welding all around. Parts look better.  Run 30-40 parts, looks good.  Turned over to production.  Have a Nice Day!

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7615

 

8.19.10 D shift

Dr#2- installed the motor from the dryer on the trailer. Found that OL's were bad also. Replaced them and checked operation, O.K. to run. Also replaced the regen contactor on it as well.

Mp#17- Cleaned up oil and replaced absorbent.

Replaced the pressure gage on the fan housing destructive tester. Evidently someone needed it.

Cleaned up in maintenance shop and hauled out the trash and cardboard.

Submitted a PTO day for September 7th, 2010.

Call if there are any questions.

August 19, 2010

August 19, 2010

 

Upgraded MP 25 with new core sequence program.  Changed P-ROM chips.  Tried out works fine.  Cores “off” , Special Core Seqence “on”.

 

Flipped Slide cyl on gate cutter tooling over for clearance.

 

Worked on Matsui Dryer Hopper DR53.  No display.  Check fuses, power, relays, run/stop switch,  think it needs new board.  Will call Matsui tomorrow.

 

Worked on Cinci Dryer in shop.  Getting overtemp alarm on bed shift.  They were trying to run it at 130 degrees for Acrylic.  Raised the temp to 160 and overtemp to 35, had no problems.

 

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7615

 

Test

Trying to get Mike set up

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

8.18.10 D shift

Mp#15- Replaced nozzle heater band at Roy Smith's request.

Replaced bad contactor on the thermolator that was in the shop. Green tagged it and placed back in the auxilliary equipment area.

Made a fixture for the intake pivot to be drilled out at the mounting tab. The hole was flashed in and several had to be reworked, at Marty's request.

Repaired the web-trak sensor cable on the compact cannister hotstamp press. The cable had rubbed into the heater plate melting through it.
Soldered and tied it back up neatly.

The dryer in the shop needs the process blower changed out. I didn't see one in MRO so I plan to take the one from the dryer on the trailer out back to repair it. Also changed out the bad contactor in it.

Call if there are any questions.

Sean

Branson Welder Setup

Branson Welder Setup with new horn and fixture is Weld Time .700 Hold Time .200 Trigger Press 4 Main Air 35psi.  Also tuned welder with current horn setup.

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7615

 

August 18, 2010

August 18, 2010

 

Replace thermolator on MP1.  Brought the faulty one to shop, not heating.

 

Set up old Branson 910IW Sonic Welder with new fixture and new horn.  Had to go with the BLACK booster, as silver did not have enough power to weld properly.  It is over by the other not used equip, back of molding. 

 

Helped Josh adjust MP21 Screw pressure to correspond with percentage on panel.

 

 

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7615

 

August 17, 2010

8/17/10

 

Ordered switch for power feed on milling machine.

 

Ordered additional 3.6 volt memory back up batteries for mold machines.

 

Replaced mitsu contactor in mold machine in warehouse.

 

IRG trained Mike on hose crimper.  Made new hose for mold #76010.  Replaced hose.

 

Worked on MP10 sonic welder, had slight misalignment.

 

Showed Mike oil storage area to take spent filters to drain.

 

Replaced memory back up battery in MP4.

 

Looked at old hot stamp on MP20, need to schedule it down sometime to tear down and tighten connections from display to main board.

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7615

 

8.15.10 D shift

Mp#5- Prefill alarm came up again. Added about 1350 bits to offset to zero tonnage value back out. Checked the other convecs and they did not need to be adjusted. Alarms cleared and it began working again without incident.

Worked on robot PM's this weekend. I was able to do them all except for the ones on MP#6 and #7 machines.

Call if there are any questions or I can help with anything.

Talked with Wayne McConnel yesterday, his number is 931-646-7853 for anyone who does not have his number.

Sean

8.13.10 D shift

Worked on robot Pm's tonight.
Robot on 2,3,and 5 Pm'd.
Replaced the hopper sensor cable on #6 machine.
Replaced a nozzle heaterband on #2 machine.
Will resume tonight again.
Sean

" C " Shift

MP-2  The bottom core on the top cover mold is leaking. Bill Potter said they had to run it until tomorrow morning. I put some pads down.

 

I worked with Mark on the base plate eoat. It should be ready to start setting up; When ever they give us the press.

 

I set up the fixtures on the band saw in our shop & the saw in the molding shop to rework the cardboard.

 

I  cut & threaded some ½” pipe for molding techs.

 

 

 

R. Upchurch

8.10.10 D shift

Mp#1- Ronnie and I aligned the sled up using a dial indicator atop the purge sheild. Put the last cover on after tightening everything up. Bill said that no one was to touch it until Josh said it was ready.

Put the old screw and barrel from it back in the crate and located it on the storage trailor.

I labelled the #3 novatec hopper/dryer "waiting on repair parts" and put it in the auxilliary equipment area until we decide what we are going to do with it, so it would not be sitting around in the shop. I think we just need some new loader controllers and top hat assemblies to put them back online? We can buy something or rig something up? Let me know what you want to do.

If we can get the go-ahead, I can round up a lot of this stuff we are never going to use and gut the parts out of it and throw the rest in the scrap metal hopper. "5-S" style. See what you think.

Worked on Robot PM's. #20,#21, #22, #23,#24, and #25. I will submit the work order's Friday.

Call if you have any questions or want to make me laugh!

Sean

8.5.10 D shift

Yushin Picker project- Made some progress. The other relay interface box would not work. The controller pendant would operate the picker manually, but when I would try to put it into "Auto" with the Mold Open limit and safety gate signals jumped out, it gave a 5555 alarm, which was not found in the manual information.

Where I am now is, I put the 110vac transformer on the other relay box (the one from 18) and got it working again. Because that model of relay box indicates using the newer style pendants, and because that box supports features that the newer pendant has, I got the other controller cable to use with it when it comes back from being repaired. I do think we should attempt using the old style pendants unless we have a valid interface diagram for them. I contacted Yushin via E-mail for more specific information and am awaiting a response.

The Barrel for MP#1 did not come in last night.

There has been a molding meeting scheduled for Tuesday 5 and 6 pm.

Call if there are any questions.

Sean

" C " SHIFT

I worked on the Classic fascia hot stamp. I got it set up with the small print pad. Randy is supposed to get us the QVC pad with the large print so we

  can locate & drill the mounting holes .

 

I also worked on the Eagle fascia hot stamp. I got the mounting plate cut to fit & transferred holes in the slots to the base. All that’s left is mounting

  the pad to the hot plate & set up.

 

MP-2  The top core on the top cover mold was bleeding off. I put a gauge on the valve & saw it was dropping out. They had it on core 2, so I changed

   It over to core 1 & it worked fine. Will need to check it out when they finish the run.

 

I touched base with security & receiving all day --- Still no sign of the barrel.  WT #*@*!!!!!!!!!!

 

 

 

R. Upchurch

8.04.10 D shift

Mp#18- Ran into problems using the interface box that was on it. It was first bringing up " 0000 " on the pendant display. When I checked for 24volts on the interface board, I was reading 52 volts. Shortly there after it blew a fuse on the 200 volt power circuit.
I took the interface into the shop along with the picker from 14 so I could work on it while they ran press 18.
I hooked up a 200vac supply circuit to it again and it was blowing those fuses as well, but not the ones on the intrface board, so I am looking at a bad transformer possibly on that interface.

Then I looked at the other interface and found a bad fuse on the board. I replaced it and followed through the relays on the diagram. I tested the picker out on it and it worked fine. I jumped out the option we will likely not use (injection verified) so it would not need a relay there. I labelled all the wires after tracing them back on the terminal strip and will put the SPI plug on it tomorrow and double check the wire connections in press #18 if it is down.

I will let you know how it goes.

MP#1-Ronnie is going to call me today when(if) the barrel comes in today and I will help him install it and get it going. provided we have all the parts.

Call if there are any questions.

Sean

" C " Shift Weekend

MP- Robot kept stopping on “ Y “ axis. We found the over stroke block had moved.

 

MP-5  Robot CPU fault.  Mark pulled & replaced the cpu card & cleared the fault.

 

MP-20  Replaced the nozzle heater band & thermocouple.

 

MP-16  Ejector cylinder bolts broke; Found  1/8”  difference in the knock-out length.  Had tooling turn down knock-outs, replaced eject. bolts,

      & made a new eject. switch bracket.

 

Ordered more brass compression fittings from Nissei. ( for tie bar lube )

 

MP-5   Core 2 Leaking at manifold. Removed the fittings and put new Teflon on.

 

MP-6 thru 12  Vacuumed out oil pans.

 

MP-3  hooked up core switches & hydraulics on funnel mold.

 

MP-26  The chiller return line ball valve is cracked -  the valve that comes out of the 4” line up top.

 

MP-3   The barrel end cap is leaking. I kept an eye on it so they could finish the run. At the end of  C  shift, they needed about 100 more parts.

          They’re doing a mold change tonight. The end cap needs to come off to clean & reseat; That is if it’s not cracked.

 

 

 

       R, Upchurch

7.27.10 D shift

Mp#20- Changed out the motor starter...was bad.

Welded the tank for the handle project. It needs to marked for the chiller fitting locations and I will weld the nipples in place and anything else that needs done.

Mp#18- Installed the 120vac Robot receptacle. Fused for 5 amps and checked that E-stop killed power. Labelled everything.

Mp#2- Got an error E00240. We powered it down and when it came back up it automatically went into reloading from the boot card.

When it came back up it evidently did not have the core 2 programming saved on the boot card because it does not have the page on the menu.

It is operational right now as the mold in it is only using core 1, but likely we need to reinstall that.

Call if there are any questions, be back Friday.

Sean

" C " Shift

MP-18  Installed chain on dummy plug.

 

MP-22  The parts were getting black swirls.  We pulled the nozzle & adapter and got Fred to turn down the threads for a better seat.

 

MP-21   Put new heat shrink tubing on the large fan grippers.

 

We started fabricating the water tank for the Hokey handles .

 

MP-6-7-8 & 9  Vacuumed out oil pans.

 

 

 

R. Upchurch

7.21.10-

Mp#25- replaced bands on nozzle and 1st band.

Mp#20- Replaced 3 nozzle bands and reset sled pressure switch. Reinstalled shims under sled as well as i could . looking at a better solution for this repair but for now it is runnable.

Fabricated a detangler for the springs at baseplate sub-assy area. Will put it into use tonight.

" C " Shift

MP-11  Cores not working.  There was a bad spot in the cable. Replaced the cable & six pin plug. Rewired the bad one.

 

Mixer # 1   Replaced the air cylinder on the dump valve; next to the one that was replaced last week. It was getting weak.

 

I made the Eagle fascia hot stamp pads a stock item. It wasn’t done when Randy ordered them & there was only one spare. When the

  new pads come in for the hokey, I’ll get those put in stock too. Randy only ordered two.

 

 

 

   R. Upchurch   

7/17/10 weekend D shift

We have the Hot Stamp for the fascia cover working. Ronnie mentioned that someone needs to get another flat shaped "Oreck" hot stamp pad made because we used the ones for the HOKY which are curved.

Likely it will cause it to eventually wear out and then there will be none to replace it with.

It is in the shop.

Robot on #9- Rack and gear stripped out on the X- axis. I replaced them both and cleaned and greased the bearings. O.K. to run.

Mp#19- at 7pm on Sunday, we found the grinder completely full of santoprene from the handle overmold. It had not melted down yet but was on its way. The operator on our shift had put no runners in it yet because he was told that it was not working from the previous operator.

Mp#13- had a water leak and water got into the ejector valve cover causing it to short and malfunction. They had reported to Ronnie that it was running and the ejectors just quit working. We cleaned it out and they started working again. It stopped a few more times and I blew everything out with an air hose under there and set-up a fan for the rest of the night.

Robot on #4-Put new Keenserts in the Robot wrist to accept end of arm tooling. Holes were stripped out.

Mp#20- Butterfly bolts broke on ejector platen and eject forward switch was damaged. Replaced screws and switch, checked operation. O.k. to run.

Call if there are any questions.

Sean

" C " Shift

MP-17  PVC rusted the hopper;  It wasn’t sprayed with acid neutralizer.  I took it off & bead blasted it.

 

MP-21   Worked with Mark on the robot vacuum switch.

 

 We rounded up some more of the large metric wrenches & hung them up with the rest of the wrenches.

 

 The aluminum came in. We put the sheets in the rack & the plates for the fixtures are on our work table.

 

 I moved the hot stamp to our shop & will get started on it when Randy gets the nest to me.

 

 

 

 

 R. Upchurch

MP21 Robot

Robot on MP21, vacuum would not work.  Voltage was toggling on board but not out on the connector (V3V) for vacuum solenoid, solid red wire was broken in tray somewhere.  Spliced into another connector.  OK.

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

Week of July 12, 2010

MP4,  Zone 1 was running away, contactor stuck, replaced with new one.

 

MP15,  Replace small shock absorber on crosswise for sprue picker.  More are on order.

 

We received a spare pressure transducer for the Cincinati’s.  It is on shelves to the left in MRO.

 

Helped Gary change linear scale for the clamp on MP21.  The new scale is different and requires an inline transformer plugged in to the clamp board.

 

Ordered program change to include additional core sequence for MP25 from NIssei to EJECT before CORE pull.

 

Worked on MP21 inject side.  Back Screw position was stopping short of desired location.  Made adjustments to internal codes 32 and 33 to remedy.

I sent out procedure on previous log.

 

Talked with R Russell about Hoky wheel and hub press.  Ordered 2 hand tie down and pilot operated valve for new station.  Also ordered alum tabletop.

 

Working on setting up Vendor for Robot EOAT quick change plates.  I tested the orings on the dovetail slide and they held at 80psi.

 

Filled out PR for Rapid Grinder components destroyed by grinding hot runners.  It was rejected at this time due to lack of funds.

 

Ordered, received, installed new hooks and shackles for robot chain slings.  They are located in the bottom of the gray cabinet in the shop labled Large Hand Tools.

 

Ordered fittings and bolt kit for core valve install on MP23. 

 

Ordered and received Asco valves for Thermolators.  They are located in MRO on the RH shelves above the alum load system fittings.

 

Started replacing the adjustable stop screws with winged handles on MP23 Robot.  Some bolt hole patterns were to close for 2 handles.  I will check with HIro for some different stops.  More handles with longer bolts and metal handle are on order.

 

Any questions just give me a call,

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

MP21 Toshiba ISE250N Procedure to Make Screw Return to Full Back Position

MP21 (TOSHIBA ISE250N) Screw Back Position Correction

 

1)   With the power on, open the Main Control Cabinet Doors,

 

2)       On the inside of the LH door, locate a blue tuning pot, with the numbers 0-9,

it is extreme upper LH side of injection control board under a terminal strip, dial the

pot to the #1 position.

 

3)       Under the blue tuning pot, locate and depress, a push button labeled “3SW”.

 

4)       Now, over on the Data Cell Display, punch in code 32 and change the value to 1.0 or .5

Record the original value.

 

5)      Now punch in code 33 and change the value to 40.  Record the original value.

Make sure the value you enter are retained.

 

6)      Turn the tuning pot back to the “0” position.

 

7)  Depress the “3SW” push button.  You are finished.

 

Original Values on July 14, 2010 were Code 32 = 4.0 and Code 33 = 16.

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

7.12.10 D shift

Worked on liquid color pumps that were left on the cart in the shop. Repaired one of them.
One needs a new wheel for the color tube pump.
The other two are probably not worth repairing as they likely have been dropped really hard.
One of them had the tranformer knocked completely from the board.
The other has a short somewhere in the board and also has a bad shaft on the gear housing.
I red tagged them accordingly.

Also worked on water strainers and drained water from some of the water traps that you could see water standing in.

We had some trouble with EOAT on presses #22 and #4 but just parts coming loose.

Left at 4 a.m.

Call if there are any questions or anything I can do to help.

Sean

6.28.10 D shift

Put up the aluminum brackets on all of the presses that Bill Potter requested for the purge checklist sheet he wants to display.

Installed the new core standard on presses #9 and #10.

Replaced the ejector limit switch flag on press#7, it had broken. Made one from stronger materials.

Replaced the handle on the pilot fan tester, it was broken.

I will continue to watch the presses that are down and work from the "tracker"list.

Call if you need to.

Sean

6.24.10 D shift

Finished putting up the EOAT Boards.
Suggest that we put up some guidelines for the techs to see when hanging new tool arms etc., so it will remain organized.

Changed out the bottom core switch on #4 last night.

I think it had come out of adjustment, but the LED was not working.

When I installed the new switch, LED would not work on it either.

The input was reading on menu 41 though.

I checked the switch with my meter and it appears to be good so I will returtn it to MRO.

Installed new core standard plug on MP #3, also installed ejector back limit switch receptacle on junction box (in parallel) so it can be used either way.


Talked to everyone on the D shift and there are 3 guys who want to volunteer for any or all of the 3 work-days of shutdown. They are all mechanically inclined.

1 process tech- Johnny Stamps
1 moldsetter- Cameron Wilson
1 operator- Mike Sells

They understand that it is likely 8 hrs /dayshift ,if they can work. ?

I told them I would let them know by Monday or Tuesday so please get back to me by then.

Thanks

Sean

6.23.10 D shift

GR6- grinder, tore it completely apart and started reassembling it. I still have more plastic to clean out from the screen area (slow going), but it looks like I will only need to do some welding on the pan to complete the repair.

It was welded once before and had new bearings/seals installed last time. They appear to be holding up o.k. for now, so we won't need any new parts for it, unless just want to buy a new pan, etc?

Repalced the nozzle tip and T/C on #13.

Placed a note on the loader for 25. Someone had switch 1 on and 2 off, this was causing the loader to load constantly even though the sensor appeared to be working. I placed a label on it so they would know to use 2 with that sensor cable.

Left at 4:30a.m. puts me at around 40 hrs right now. Plan on working till 6a.m. on Thursday night.

Call if there are any questions.

Sean

6.22.10 B shift

Put up EOAT boards outside of molding office. Will continue the rest of it after I find some wood. I used what Facilities had in their locker area. I made a note on the "Tracker" spreadsheet about what wood I need but I may be able to scratch it up from around the pallet room or something.

Tightened up the filter clamps for the vacuum loader pumps. Looks like they had come out of adjustment.

I plan to tear down the peanut butter grinder Wednesday evening and should have an idea of what parts we will need to get it going again by Thursday morning.

Left at 12:30 a.m.- trying to keep hours down this week. I'll be in the next 2 nights and try to take off Fri-Sat-Sunday.

Call if there are any questions.

Shutdown Attachment

Sorry, I didn’t send attachment.  Here it is..

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

Shutdown 2010

Attached is a calendar for shutdown this year.  Also, for anyone who does not already know, we are tracking issues, projects, and parts ordering here-  O:\Molding\MOLDINGSUPPORT\Oreck\Departments\Maintenance\Tracker.xls

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

6.21.10 B shift

Installed new Core wiring standard on presses 6 and 7.

Replaced any switch covers/knobs on all the nissei presses that had stuff missing.

Replaced Nozzle heater band on MP#17 at Darryl's request.

Checked all the machine hoppers for air line leaks, made repairs, replaced some hoses.

Left at 3:30a.m. Be back Tuesday and Wednesday evening to work full shift.

Looks like the board must have worked on #1?

Sean

6.20.10 D shift

Mp#18- sight glass was broken and all of the extruder oil had leaked out. I press fit a peice of plexiglas into it and it is holding for now but need to replace it.

Mp#21- refilled extruder on that one also.

Put together a list of the machines we have completed the core standardization on, robot interface, liquid color plugs, etc. Going to try to combine it with everyone else's machine spreadsheets so we can all be on the same page.

The SB#3- pocket valve has a busted glass in it as well. I sent mark an email to order parts. It was already taped up, but may cause a leak if left unrepaired.

We had some trouble with #22 slider mold. They ran that conductive material on it and had difficulties removing it from the mold consistently.

If there is anything I can do to help prepare for shutdown,...or if any new info about shutdown surfaces, please keep me in the loop, Thanks.

Sean

" C " Shift

• Wiped down & lubed all tie bars before start up. Made sure the chiller & pumps were operating.

 

MP-19  Replaced broken oiler fitting ;bottom  non – operator side.

 

MP-11  Robot not going to home position ; turned off main robot power & rebooted- OK

 

D-32 ( mezzanine )   Alarm 11 -  Adjusted index switch.

 

MP-9  Robot  Z  axis brake not releasing – checked all connections, & cleaned the contacts. Working fine now

 

MP-22  Tech burned his arm while purging out barrel. I checked to make sure we didn’t have a heater problem. The last shift that ran did a mold change &

           didn’t purge the barrel. They went from Santopren to nylon. When the new set up was loaded, it was 200 degrees higher

           than the new material being  loaded.

 

 

 

 R. Upchurch  

6.16.10 Nights

MP#6- Charlie thinks the screw tip may be worn out on it. They ran the big blue Hoky and had short shots off and on all night. We may need to do a static test on that one as well.

Worked on robot PM's all night. Replaced the vacuum generator unit on #20 robot, it was still functional but leaking air really bad. The gasket on the pilot valve was blown. It can be repaired if we can get a new gasket. I think Mark is going to check with Motion Ind.

Sean

" C " Shift

MP-9  Robot wasn’t homing;  the reference block had been moved & one of the home blocks was loose. I got that straightened out & then there was

          no vacuum on the cups. There was water in the system; bled it off & set the vac verify switch—ok to run.

 

MP-17  The nozzle heat controller was in hi - temp alarm & wouldn’t heat.  There was a loose T.C. connection at the controller—Repaired.

 

MP-12  The grinder was making a noise ;  I cleaned it out – the material was hot & just about to start melting. I let it cool down, & had to adjust the rear

           stationary blade. I reassembled the grinder & got them to turn up the regrind load time. OK to run.

 

 

 

 

  R.Upchurch  

6.10.10 D-shift

D shift had 2 process techs out wed/thurs so today I did spend some time assisting with set-ups etc.

MP#9- built and end of arm tool for mold # 78165 and roughed in the parameters.

Made a tool for them to insert the magnet in the fans they were welding at #12.

As it stands, I told Darryl that I will not be working Saturday and Sunday, but if he needed me to come in and fix anything that was down, all he had to do was give me a call. My number is posted in the molding office.

Sean

" C " Shift

MP-3   Left side gate cutters not cutting good; I swapped out cutting tables. I changed out the left side cutters. It’s always harder to cut the polycarb parts.

          We need to order spare cutters.

 

MP-13   I installed the new screw tip . They hung a mold in it.

 

 

 

 

 

 

 

 

R.Upchurch

6.8.10-D shift

Mp#4- changed the thernocouple, reused the heaterband. Darryl requested that I remove the purge that was stuck to the wires.

Mp#15- helped Jeff set-up the Sprue picker. It needed some maintenance and also needs some work on a screw that is stripped out where they adjust the in/out from the mold<>.

MP#21- hot stamp had a blown fuse. Replaced it and it began working fine. Replaced a gage on one of the air regulators, cleaned, lubed and tightened things up on it.

Worked on liquid color pumps that were in the shop. Cleaned, repaired and generally just fixed what needed fixing on them. Still have a few more that may need parts.

Call if there are any questions.

Sean

MP19 Nozzle Touch Alarm

If anyone gets an alarm on MP19 that says “Nozzle Touch PS2 Unconfirmed”, here is the fix-

Go to clamp factory screen by hitting “Shift” and then the “Clamp” screen button.  Go to the page titled “Mold Adjust 1”.  At the top there is a setting named “HPCV”.  Not really sure what it is or what it does, but it controls what the pump loads to for nozzle contact force.  I found it set at 60% the other day when we were getting the alarm and set it to 99% and this fixed the problem.  Evidently they had the problem again over the weekend and I’m assuming the value got set back to 60% when someone reloaded a new process set up.  We changed again from 60% to 99% and this fixed the problem.

Call with any further questions.

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

6.6.10 D shift

Finished repairing the connector nest for vibratory welder. Replaced broken/missing screws loctited them. Cleaned and inspected the tool. It looks like the adjustment method they have been using requires a hammer sometimes.

Lubed all of the tiebars and refilled reservoirs and greased the machines.

We need to get a repair kit for the Milacron machines complete with 3/16" nylon tubing and the ferule type fitting they use.

MP#15- has a broken lube line that needs repaired when it is down.

MP#17- has an extruder hose that is leaking. I tagged and measured it. Made a new hose up and left a note so we can change it when it is between molds.

I left a note on the Fastenal board to restock the "assorted springs" drawer. I used a spring last night to repair one of the gasket locating tools (used on the intake pivots) but didn't really have what was needed.

I left the old clamp tonnage transducer with Mark so we can possibly stock a spare.

Replaced the cabinet fan on robot #3 panel.

Basically fixed little things most of the night and helped the techs because this shift has no tooling person. We repaired the tool on press#22 that broke out all 4 keen-serts. There were only 2 left in the box so we patched it up to get it running.

Let me know how you want to do that blocked nozzle test. I am supposing you want to do a dynamic check ring reliability test for bad screw tips?


I plan to take off this evening but will work on till Friday night. Call tomorrow if there are any questions.

Sean

" C " Shift Weekend

MP-22  Tech said cores not working --  found eject. back switch wasn’t made – they forgot to tie in the knock-outs.

 

MP-2   Mid zone heat kept dropping out;  contactor was bad – replaced

 

MP-22   Checked torque on the screw gun for the valve body. Max torque on the SOP is 14 ;  It is running 12.5 – 12.75.  They had a few

            parts  crack . I think the parts may have just been too hot.

 

MP-5  One of the wheel mounting brackets on the ( small parts ) shelf unit broke off.  I took it to the shop & brazed it back on.

 

MP-5  Getting  the prefill alarm again. Changed settings & offset.  It ran until right before shift change & alarmed out FHD exceeded limit.

          I left it with Sean.

 

Cleaned up oil & changed pads on MP-17 & 21.

 

MP-11  The core pin broke & when they pulled the core cylinder off, they pulled the wires loose. Repaired.

 

 PM’s  on press 2 , 3 , & 4.   MP-3  needs new fan in robot cabinet.

 

 

 

 

R. Upchurch

6.5.10 D shift

Mp #5- the tonnage readout was stuck at 500, even after powering it down, etc.
I changed the tonnage transducer and when I powered it back up, it was a teading negative value (-28). I calibrated the offset and changed the convecs 921, 812, and 813 so they were 150 apart, etc. It worked.
Started it up and ran production at 7:10pm. Has ran good all night so far.

Changed out the screw gun on #22 because it would not stop running. I advised the process techs to monitor the screw bosses so they would notice if they were breaking out. They are doing fine so far.

Assisted Lynn Smith in changing out the welder nest and setting it up. I took the connector tool back into the shop, I have to make some repairs to it where it has been broken.

Sean

Cleaned up out on the floor and in the shop.