10.10.10 D shift weekend Sean

Mp#1- was making a squeaking sound when the screw was almost complete with building a shot. I greased the extruder bearing assembly but that did not appear to be the source of the sound. Then I actually put a little grease on the screw itself at the back of where it entered the barrel and it seamed to help. It did not run long enough to know for sure though and likely needs to be inspected further when it starts back up.





Mp#3- Had an E00240 error. Had to reboot from the boot card. Then we had to reload a set-up in it. Ran good the rest of the day.



Mp#5-had leaks from where someone just left a hose dragging beside the clamp.



Mp#2- Has a leak on the core/ejector hose valve block we installed for the steamer molds. When it goes down we can re-do it. Put it on a shared tasks outlook item.



DR#6- Finished what Ronnie was working on and replaced the desiccant in all of the canisters. Checked it out with the Dew point meter @-40. Tagged it and located it in the mezz room.



We have been seeing quite a few dryer issues lately. I followed the email suggestions for testing the touch pad on that Cincinnati dryer/hopper and it appeared that the display board is likely defective as jumpering the touch pad pins gave no response.



Checked out several DME cards, replaced fuses and tested them on a mold. They all worked fine. Tagged them and put them back out on the shelf.



Worked on PM's all weekend. Finding many issues with loose components on the loading system. Also finding robot Y-axis are getting loosened. Tightening them up, and other wrist components are getting loose.



One issue that we need to start getting into is the sled shims on these Nissei machines. Many are working out from under the sleds. I think we can get some brass the full length of the guides and secure it with screws? The problem is that we will have to schedule them down and figure out how to get them elevated enough to install them. Shouldn't be too much of a problem. I will measure all of them that need repaired now and come up with a parts list on Thursday morning.



Since Ronnie is going to be out on the

Ronnie Upchurch

I emptied all the overflow jugs on the presses, cleaned up the oil on MP-17, & vacuumed the pan on MP-6.

 

MP-4   I made an eoat for the rear steemer handle mold & installed it.

           Somebody left the air poppet fittings out of the mold. We found them in tooling & installed them.

       

 

D-6  ran in the maint. shop for nearly 24 hrs. & the beds never did dry. I started pulling the desiccant cans to change them out.

Ronnie Upchurch

 10/8/10

 

MP-16  The touch pad on the Milacron dryer wasn’t working. I called & requested a quote from Uni-Dyn.

 

MP-11  The core pull hydraulic hose came loose at the threads behind the quick-connect. It was never tightened. I cleaned up an oil pond around the press.It ran all night

     & nobody saw it leaking.

 

Dryer- D-7 on the mezzanine had a bad regin. contactor. Replaced

 

 

10/9/10

 

Mezzanine -  I played musical dryers all day to get one that worked.  I pulled D-6 off station 2  & took it to the shop. I replaced it with D-32 from floor. I looped out

      D-7 on station 4, to try & dry the beds. I also loop out D-6 in the shop to see if it would dry out. After several hours, D-7 came down to – 40, so I put it on station 2.

      D-32 wasn’t drying, so I looped it out.  D-32 & D-6 , after  6 to 8 hours, the dewpoint is finally starting to drop somewhat.

 

MP-3 Installed core plug on the steemer handle mold.

 

MP-1 Die height alarm- The position had to be moved manually before the auto die height function would work.It was too close to the end of the threads to lock in.

         After that, it was getting an eject alarm----- I found the knock-outs weren’t tied in. OK  now.

 

MP-3  Robot was alarming out – not seeing eject. forward.  Found the multi-eject. on the special option page was not turned on. OK now.

 

Ronnie Upchurch

MP-23  I worked with Mark M. setting up the new eoat for the 2 cav. fan  mold 74022.

 

MP- 6  The mold wouldn’t close. I checked all the limit switches & found the operator side gate switch wasn’t making. I adjusted the jam-

      bar  flag.

 

MP- 1  It was getting a lube alarm. Josh reset the manual lube count to the maximum setting.

 

Two molds fell off the pallet while being transported.  We got them stood up & checked them out for damage. Mold 76003 cav.1 had a broke strap bolt.

       76003 cav. 2 had a pinched wire & cracked mounting brackets on the heater junction box. All is repaired except the box. We can fix it when they

       Finish the run on MP-6.

 

MP-17 Cleaned up oil .

 

MP- 6  Vacuumed out oil pan. Oil vac. is still behind the press.

10.5.10 Sean D-shift

Mp#5- Put the EOAT w/gate cutter back on and set values into the controller from the set-up sheet. Should be ready to start up.

Re-did some hydraulic core 2 fittings that were leaking and had been red tagged for repair. No further leaking.

Mp#3- Put the new EOAT w/gate cutter on and set it in as close as possible w/out running parts. I dry cycled it several times to check operation and get it timed close. May need to adjust the clamp position and ejectors, or the Y-axis up or down.

CAUTION!- The cutters are very SHARP. I bumped into them and punctured by hand!

Set the dryer temp correctly on the stainless cincinatti dryer on the mezzanine. It went down for wet material mid-shift, and after looking at it, it had been set to 32 F..?
Set it at 180 and it has been running fine.

Call if you have any questions. Be back Friday.

Josh-I submitted the rest of my PTO for the year, on your desk.

Thanks,

Sean

9.30.10 Sean

Mp#2- Smashed core wires twice. They have been tied up as neatly as possible to prevent further problems.

Got called into the assembly area to assist with helping the girl get the programming software working for the stepper drivers in the lab. ?

Mp#1- baseplate press stopped operating. Found sensor loose on the shuttle forward position.

Mp#21- while doing the PM I found the press had no control power. Looking further, it seems that the power from the disconnect on the bus was 100 volts short on the brown leg?
Mark and Gary are investigating that further now.

Have a portable hopper loader receptacle that is broken, may need to either order a replacement receptacle or rewire with something else on both ends.

Worked on PM's the rest of the time in between activities.

Call if there are any questions. have a great weekend.

Sean

9.29.10 Sean

Mp#5- They had a problem with the cores not working at all.
I went through replacing hoses and checking with the test cylinder and still was not working. Put gages on and had pressure at valve, but not at cylinders.
They would work when i probed valve m,anually.
Then I checked voltages at coils and had none on the set side.
At this point neither core 1 or core 2 were working but I was focusing on #1 for now.
Then I noticed that the output menu 41 slot 6 would energize 2 outputs when trying core 1, but the card was only lighting up the led for pressure and not the set output.
I tried swapping the card and then both sets of cores started working.
I suspected that there was a problem with the output card that I had moved to slot 8 so I left it down until we could find another one.
Ronnie mentioned that they had worked on it today but was not real sure what was done to get it going again.
I would like to know what you found?

Also had the problem with the Chilled water supply being dirty, in which I discovered, after speaking with Ronnie colson, that there is no filtration on the Chilled water system.? I temporarily bypassed the pressure switches on the Thermolators pumping chilled water until the problem is resolved and we have taken the corrective actions.

Call if there are any questions. Enjoy your evening!

Sean.

Ronnie Upchurch

MP-15  Oil leak.  I am ordering a new pump seal for this one.

 

We were having problems with thermolators cutting off on MP-2 & 3. ( chiller supply )  The flow & temp looked OK.  In tooling the EDM was over heating.

     they bled the line & got quite a bit of air & rusty water out. After that, the thermolators straightened out. There must have been an air lock.

     Ronnie Coleson was notified.

 

I installed the new overload on MP-5. They will hang the base plate back in.

 

If the hydraulic oil doesn’t come in today, I’ll call them in the morning.   

Mike Daniels-B Shift

Good morning Gents,

 

Typical night in molding no major problems. Mp2 has a issue with the core switches, the i/o page shows they are set when they are and pulled when they are but when put in cycle clamp moves about 6in. then stops and reads core 1 not pulled when it is. We ran it on timers  with no problems.

Repaired 3 more trollies

Replaced prox switch on fixture on mp10

Replaced blown nozzle heat fuse on mp2

 

Have a great day

Gone Fishin

 Mike

Sept 28, 2010

MP5 keeps tripping overload on pump.  A complete contactor and overload should be here Wed. UPS Red.

They moved the baseplate mold to #1.

 

Lexan sheets came in today.  Been trying to replace broken panels in trolleys as I can, if you pick up where I left off, measure each one individually as there are slight differences between them.

 

 

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

 

9.26.10 D-shift Weekend

Stripped equipment Friday. Reassembled the grinder on Saturday.
Worked on PM's Sunday. Turned in some work orders for some of the issues we had.
There was a problem with #4 that had to do with frayed core wire and a blown fuse.
We cleaned out all the water strainers on all the presses this morning.
I have noticed that the moisture in the air system seems to have been resolved.

I will be coming in on Wednesday at 10a.m. for Forklift refresher training. Afterwards I will see whats going on with our PM program. call if there are any questions.

Have a great day!

Sean

Ronnie Upchurch

One of the bucket tumblers quit working. I just had to tighten the belt. I asked Elaine to order two more motors for the two spare tumblers. I put them

       in the trailer for now.

 

MP-7  The bolts vibrated loose & the deflector fell in the grinder. I cleaned it out & restarted it. It still needs a new deflector.

 

MP-2  I hooked up the cores to the eject circuit for them. Also replaced a broken core switch on the stationary side. One of the mold heater plug pins was pushed in

        & not making contact; repaired.

 

MP-6  The clamp wouldn’t close. I tried probing the valve, no luck. When I opened the cabinet to check the input & restarted the pump, it started working.

 

I worked on stripping & scrapping equipment in shop. I cleaned out the cabinet in the bone yard.

 

I finished up on the grinder that Sean put back together. We put it back in service Sunday.

 

Cleaned up oil on 17 & 21.

 

I put the gaylord of spare parts in the trailer.

 

Ronnie Upchurch

MP-2  Nozzle heaters quit working. Found blown fuse & shorted wire on front band. The blown fuse was 20amp -  should be 15amp -  Replaced

          with correct fuse.

 

MP-15  The chuck was closing before it reached the sprue. Changing the timer or mode didn’t work. I found that when I removed the air exhaust

       muffler, It worked fine. I tried to clean it & reinstall it, but didn’t work, so I left it off.

 

MP-4  We still have a leak at the top of the eject. pump. It looks to be coming from the bottom of the block where the boss fitting ties in. If they  don’t

       shut it down in the next two days, I’ll get it when I get back Friday.

 

I’ve been bleeding a lot of water out of the air lines today; loaders, robots, & support equip.

 

I started vacuuming oil pans – MP-4 -6 & 7.

 

The chiller temp. started climbing again. 70 degrees in the shop. The temp. was set at 48, but actual was 57. I called Ronnie C. & he said he would

      come out & start the other chiller.

Ronnie Upchurch

I worked with Mark some in MRO, sorting parts that were stored in gaylords.

 

Mezzanine – DR-1 had two bad regin. heaters. Replaced.

 

Mezzanine -  DR-32  The turntable got in a bind because the limit switch was adjusted too tight against it. One of the motor gears stripped out &

              two teeth on the bed gear broke off. I replaced the motor. We had to order another bed gear. I swapped the dryer out on the mezzanine.

 

Mark replaced the nozzle heater on MP-13.

 

MP-17  Oil on the floor & the jug was full “ Again .“  Cleaned up.

 

New  hydraulic fluid has been ordered.

9.20.10 D-Shift

Matsui dryer not heating up to process temp.

The control does not appear to be outputting any contactor signal.

I am going to look at it again this evening to try and be sure that everything other than the controller is working alright. I suspect that there could be an input such as a switch or sensor causing the control not to output.?

I organized the machine and equipment manuals and labelled everything as well as possible. Maybe we can keep it this way?

Next problem is Brelands' encroaching desk area!

I could have made some mistakes in identifying presses with particular manuals so if anyone finds something wrong let me know or pencil it in and we can have some form to our function! I followed the asset list by serial number and old press number before labelling them. They are separated by machine brand, (i.e. Nissei, Milacron, and Toshiba, etc.)

Call if you have any questions, have a great day!

Sean

Mike Daniels-B Shift

Good morning,

Just a few issues last night

Replaced 4 nozzle bands on mp20 due to bleed off. Apparently it ripped wires from bands when sled was backed off.

Replace lexan in 2 buggys from junk yard and placed them in molding

Replaced a e-stop switch on grinder at mp6.ginder wouldn’t run

A core wire on mp2 got cut and shorted out blowing a fuse.

Swept the shop.

 

Have a Great Day

Mike

Mike Daniels-B Shift

Good morning all,

 

Quiet night no major problems on molding floor. I put the new control in matsui drier, its still in shop I let it run for around an hr or so with no problems so I green tagged it.

 

Have a great day

Mike

 

9.16.10 D shift continued.

Also, thought you might like to know that Marty informed me that he and Darryl might be trading shifts per Wayne's decision.??

9.16.10 D shift

Mp#8 - Mixer was leaking material from cylinder not shutting off flow from hopper.
Lubricated the cylinder and had no other problems with it.
May have to replace the cylinder (one on the back side) if there are any other problems.

Repaired one of the small conveyors.

Stripped major components from that dryer and put the rest of it in the scrap metal hopper.

Put one of the slow speed grinders back into circulation.

Added a task to the task list for the DME boxes, per Mark.

Cleaned up in the shop, took out trash and cardboard, swept, and picked up behind the metal shear in the shop.

Call if there are any questions.

Sean

Ronnie Upchurch

 MP-16   Dryer  D-9 Temp. probe alarm.  They were running it at 250 & the High limit was at 200. Reset- OK.

 

Loader #6 on mezzanine not loading. The loader flap was stuck & not making the switch.

 

MP- Lube cycle alarm. Reset the counter & installed a new tube of grease.

 

MP-The boss fitting on the top inj. pump line was leaking. I took the line & fitting off ; the o-ring was cut. Mark had to go to IR-G to get

       the right o-ring. He reinstalled it – looks good.

 

MP-9  The  C- axis on the robot wasn’t working. I found a cracked air fitting at the solenoid. Also the coil piston was gummed up.Cleaned &

          reinstalled – Working good.

9.15.10 D shift

Mp#10-Robot- Stopping infrequently over the belt after part delivery.
Restarts fine, then runs for a few hours until it does it again. Has not stopped in awhile, they want to keep running it.

Moved everything out of the trailer out back and staged it to the left of the dock per Josh. Should be easy to sort and move now.

Put all of the items tagged for "shop" or to "strip" in the shop. Also Ronnie and I put the grinder from the bunker back in the shop and put the little one that was in the shop to the bunker.

Removed all of the Yushin pickers from the machines and located them in the staging area as well.

Mp#6- replaced nozzle heater band and repaired wiring from blow back.

Cleaned up the oil from #17 again.

Cleared the lubrication alarm on MP#1 also.

Swept up in the shop.

Call if there are any questions!

Sean

Mike Daniels-B Shift

Good morning,

 

Fairly peaceful night, minor adjustment on nippers on the fixture on press 3.

Tried to calibrate gravity loader on the dryer that is behind press 8 it still not acting right

Removed another small nozzle leak from press 15 no damage only down couple minutes.

 

Have good day

Mike

9.13.10 D shift weekend

Worked on Pm's for machines.
Started putting the core 2 stuff on 23.
Helped with processing some this weekend, we were short 1 tech.
Worked on the nut press cleaning the phosphate build up out of the tracks.

We need to order some repair parts to get some of our DME boxes back up and going again. a few have collected in the shop as well as some cards.
It would be nice if the techs could tag them with a brief description of what has been wrong with each card?

The weekend went relatively well.

Call if there are any questions. Have a great day.

Sean

Josh A Shift 09/09/2010

Hello All,

They finally released some funds to order parts to repair one of the two grinders we still have tore down.  I chose the bigger one and ordered the parts for it today.  I’ll order the parts to repair the little Solo grinder next month.

Also, I’m got approval to do a CER tomorrow for two New Grinders specified for Pelethane (Santoprene).  I chose to go with AEC because they have recently purchased Cumberland and Nelmor which are both good brands.  I sent them a box of our runners to heat up and do grinding trials on.  Rapid makes a good grinder, but I just guess the cheap ones Hank bought have left a bad taste in my mouth.

Attached are the specs and quote so that everyone can check it out.

 

Thanks

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

Mike Daniels-B Shift

Good morning, 

                       

 I helped Gary replace dump cylinder on pump#1 on mezz. It was sticking at start of shift. Went ahead and replaced the cylinders on pumps #2,3,4 and 5(per josh) found that the flange on pump 3 was cracked bad. I called Josh to see if we had a replacement,(we didn’t) so I tig welded it back together and Josh and I put it back together. Probably down 2hrs. Other than that fairly peaceful night in molding.

 

Have a great day.

Ronnie Upchurch

MP-20  Nozzle adapter heater band was bad---- replaced.

 

MP-25  The cores were backwards.  Normally the core cylinder is fixed & the shaft moves ;  on the hokey handle mold the cylinder moves , so the

            set & pull lines hook up backwards.

 

MP-25  Replaced the motor overload on the grinder.

 

MP-2  The rear zone heater - mercury contactor blew up. Mark & I  contacted Walter Marcum. We cleaned out the cabinet & disposed of the mercury

          In the drum in the recycle room. Installed a new contactor.

  

9.2.10 D shift

Mp#2 Grinder- It was overfilled with material and clogged up almost to the point of meltdown. We unclogged it and cleaned it out reset the breaker and tightened up the E-stop switch. Put back in use.

This occurred at 6:05 pm and had to have been clogged for at least a half an hour earlier on C shift, before our shift began.

This would make a good action item for September!

Vibratory Welder- Did a full P.M. on it. Tightened up door limit switches, brackets, and checked out hydraulic unit. greased the linear rails and inspected for anything loose. Relabelled tubing and Mark and I reset the adjustments on the laser range sensors.

Repaired leaking core fittings on the single cavity top cover tool in #11.

Continued with PM program, lubed tie bars and refilled reservoirs, checked for damged lines etc.

Have a good weekend.

Sean

9.01.10 D shift

Mp#4- Built EOAT for Edge Baseplate. Got it running, had to adjust Core pressures and flow controls. Was operating below 5oopsi. Now around 1600psi.

Mp#15- did PM on sprue picker. Repaired stripped out screw on advance stroke adjustment plate. Greased and inspected.

Repaired broken lube line on non-op side platen skate. replaced the nylon tubing with a piece of aluminum tubing. Hopefully it will last longer this time.

Chaged out EOAT on #11 for the Edge Top-cover core.

Set-up robot on press #23 for top cover single cavity tool.

Mostly helped process techs tonight, as we had one leave early in the shift for personal issues so we were short handed.

Will continue P.M. program tonight. Need to look into a way of tracking which ones are getting done so that we do not miss any.

Call if there are any questions.

Sean

August 30, 2010

Upgraded robot displays with speed control adjust on MP3, 8, 9, 10, and 11 today.

 

Ran chiller water to the dryer behind MP8 off the machine manifold and hung a sign on the ball valves, not to shut off unless machine pump and dryer are shutdown first.

 

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 for Mike Daniels

Test

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