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.

6.4.10 D-shift

Mp#5- stopped for the prefill alarm again. I couldn't find any information about what was done to it the other day to get it going. I tried calibrating the tonnage transducer again, but it did not work. Milacron thought there was problem with the FHD board for it to be continuing to have this problem. It is down now.

Jerome never replied to my request to schedule it down to do the screw-tip, so for now I will leave it.

I was able to extract the broken peices out of the screw for MP#13. I think it will be alright to use. Still need a new tip though.

Right now I plan on leaving at 2am Saturday night.

Will work all night Sunday.
Off on Monday.
Will work Tuesday through Friday nights.

Call if there are any questions.

P.S. Leave me some info this time on #5 so I can gain a better understanding of how to patch this thing for production. Thanks.

Sean.

" C " Shift

MP-13   Pulled the screw & screw tip. The rear seat wasn’t there. They continued to run it after it broke, so the threads in the screw were gone.

          Nissei didn’t have a 32mm screw in stock, so I called Chaseland  to make us one. They will fax the quote for the screw & tip Monday.

 

MP-14   Jason said some metal was showing up when he purged it out. Thought I was going to have to tear into that one when I finished 13.

           He got it running, so hopefully this one won’t jam up the check ring.

 

 

 

 

 

  R. Upchurch

6.3.10 B shift

Mp#13-Redid the heater bands on the nozzle. Checked and found that screw tip was indeed broken. Mitch was running it but they were scrapping too many so they eventually shut it down.

Repaired the cannister gate cutter fixture. Tested it out and it works great.

The drill press in the rework area broke the quill return spring. I was able to heat and rebend it and it is working again for now but we need to order another one. I gave Mark a lead with the drill press info.

Cleaned up oil around #17 and #21. Put some new oil absorbent down.

I am sending Jerome an email to see if he will leave #5 down on Saturday nite to do the screw tip change and barrel measurements.

Call if there are any questions.


Sean

Out of plant

I will be out tomorrow, Friday the 4th.
Josh
Sent From My Verizon Blackberry

Thursday A Shift

Suspect screw tip in 13 is broke. I've ordered a new one that will be there tomorrow. 
Josh
Sent From My Verizon Blackberry

6.1.10 D-shift

Mp#5- stopped for "Prefill did not open in time" alarm.
I was able to open the clamp by changing the offset for clamp tonnage on menu 93 from 1799 to 2250,and menu 92/convec 921, from 2000 to 2350 to get the clamp tonnage to zero, but it will not run yet. It now will alarm again but will open if you clear the alarm.
I spoke with Clarence at Milacron service who thought it sounded like the prefill valve was bad. I looked in MRO for another directional valve like it but couldn't locate one. They are using press #3 or I would have tried some parts from it maybe. I wasn't so convinced it was the valve bad yet, and I want to talk with Josh about it first.

Mp#11- Potter asked me to check the cores when I came in, I checked that the machine was working fine, used our test rig to verify switches and hoses. They had the collar tool out working on it and when it was set back in they never worked, it appears to be jammed up internally.

Worked on DME boxes, replaced cooling fan, and installed #3 jumper in all of them so they will work with the new style cards.

Changed the cord plug on liquid colr pump for 13 also.

May want to look over the gate cutting fixture that is for the cannisters. it is in the tool room because it needs another braket made. It looks like it is time for an overhaul of that fixture, I am welcome to any ideas with it.

Be back in at 6pm.

Sean