Friday, February 3, 2012

2.2.12 D-shift Sean

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

Mp#9- Replaced the sled seals.

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

Have a good day.

Thursday, February 2, 2012

2.1.12 D-shift Sean

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

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

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

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

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

Have a great day.

Sean

Monday, January 30, 2012

1.27/28/29.12 Weekend D-shift Sean

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

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

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

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

Give me a call if you have any questions.

Have a great day.

Sean

Wednesday, January 25, 2012

1.24.12 D-shift Sean

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

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

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

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

Have a nice day.

Sean

Tuesday, January 24, 2012

1.23.12 D-shift Sean

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

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

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

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

Have a great day.

Sean

Thursday, January 19, 2012

1.18.12 D-shift Sean

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

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

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

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

Sean



Sunday, January 15, 2012

1.13/14.12 D-shift Sean

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

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

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

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

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

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

It is really cold this weekend!

Sean

Saturday, December 31, 2011

12.30.11- D-shift Sean

Mp#15- Motor coupling had a catastrphic failure and will need replaced. I removed the coupling and inspected the motor shaft and the pump shaft. Both are in good shape, pump is not locked up and moves freely. It simply appears that the coupling has worn out over time. It is laying in the shop on next to the vise. We need to order one when you read this Josh, Mark or Ronnie. They are running part number 09-79048-03 (Fascia w/ pad print) and the mold is closed up. I advised Roger that the clamp could be opened with a portapower if he needed to pull out the tool to run else where, but he said it was not necessary. I looked it MRO and did not locate another Coupling.

Have a happy new year. Keep it between the lines!

Sean

Wednesday, December 28, 2011

12.27.11 D-shift Sean

Dryer DR-10 on the mezzanine had low regen temp alarm. Found bad heaters and replaced them.

Mp#-24 had a leaking hydraulic hose on the core line fitting. Tightened it up, stopped the leak.

The Fan housing press with fan seal verification is ready to be cheked out and make the final adjustments to it. It should be ready to use on Friday.

Give me a call if there are any questions, Thanks.

Sean

Saturday, December 17, 2011

12.16.11 D-shift Sean

Mp#7- The ejector bar studs broke and he could not get the plate to retract completely, checked it out and found the nut with the broken stud peice was lodged under the plate. Freed it and got it working again. Also noticed the ejector back switch was broken. I replaced it and checked operation.

Pump#5 Loading system- The surge bins #1 and #2 ran out of material. The pneumatic loading valve malfunctioned, solenoid valve bad. I replaced the whole thing so they could restore operations as quickly as possible. Need to re-order the solenoid valve and a spare.

Mp#26- The ejector were not working correctly. Found that the ejector plate of the mold was jammed up. Put some chain lube spray grease on it and adjusted them correctly. Restarted for production.

Continued with Pm's on press #24.

Also began changing the fan housing press to sensors and finishing it up. The Turck sensor vending machine screwed up when delivering the cables. It will still work on other items though. Maybe Elaine or vendor can get it straightened out soon.

Have a nice day.

Sean

Tuesday, December 13, 2011

12.12.11 D-shift Sean

Mp#21- Pm'd press and robot. Replaced the sled forward position limit switch. Mark had mentioned it was screwed up awhile back. There was a direct replacement for it in MRO in the aisle with assembly's prox switches etc.






Order?**The star robot pendant "control" pushbutton switch on the side has a rubber cover that is now worn out or worn off. May try to see if Star sells the rubber grommet type cover by itself and get a few of them?

Tuesday, November 29, 2011

11.28.11- D-shift Sean

Mp#5- Finished re-installing the core on Mold#77041-top cover tool. When I checked it out, the core switch on the "pull" side was not working. Had to cut it out to remove the bad switch and installed a new one from mro. Checked operation for leaks and performance, turned it over to techs at 8pm, who started it a little after 12:30.

Mp#12- The core box on the press had not been standardized yet and they were in a hurry to start it up, rigged it up with an adapter to accomodate the ejector back limit switch, etc.
Need to complete the install correctly when the press is available.

Mp#7- Collar mold cores jammed up again, tested the hydraulics with the test cylinder and it worked fine. Advised that they pull the tool at 2am.

Continued working out the mechanics and design ideas for the fan press poke yoke project. Building parts and gathering up components still. Looked again for the plc that was there the other day, could not locate it, found another in the cabinet that I can make work.
Quick thought:
Mark had mentioned once that OSHA did not recognize the use of plc logic for anti-tie down safety switches, however, they were using them this way on those test fixtures that we tore down the other day. Need to know if I can do that or not with this project, if not: will need a safety relay.

Saturday, November 19, 2011

11.18.11 - D-shift

MP#17- They set that mold that needed to run with cores tonight, then pulled it out after I told them it could not run in there yet.

Do we need to wire in air eject or cores for this machine?

I was not certain as to what was decided as far as that goes, but I thought that Josh was going to have them install air cylinders on the tool.

Please let me know what we need to do so as not to attempt any rigging unauthorized!

What are we going to tie into? Air? Core 1? etc. Need a control switch installed? Is there outputs assigned? Software ready for it?

Roger put me on the spot with it and I wasn't really sure what to tell him so give me a call later or talk to Ronnie today so I can pick up where he leaves off today. Thanks.

Also got the cav 2 gate cutter disassembled, the intake test fixture disassembled, the air ten gate cutter stell table stripped down, and the welder table disassembled and palletized.

Saved the opto switches for the fan hsg assy project and plc from intake tester.

Sean

Wednesday, November 16, 2011

11.15.11- Sean

Mp#20- Put on a nozzle heater band.

Mp#1- They set a mold in the press that was too short for the daylight again. Roger requested that I make up some spacer bars to bolt onto the moving platen so it could be installed.
I drilled and marked them with "Caution" and put threaded 1/2" holes on top so they could be moved with lifting rings or eye bolts.

It was late before he got it set so I was only able to clean the outside of the press and around it .
I noticed the lube oil line is broken on the non-operator side skate and I could not locate any fittings with ferules for that tubing.

I did replace the grease tube and noticed that we are running very low on that grease, especially now that we have 2 presses, we should order some more for them.

Mp#10- replaced missing screws from the nut feeder tracks and unstuck a screw that had found its way into it.

Have a nice day.

Sean

Monday, November 7, 2011

11.6.11-Weekend...Sean

Mp#7- The water manifolds to the feedthroat are rusted out and dripping water. They are running the press but when it goes down it will need re-done. Probably need to cut the manifold out and throw it away.
The sled cylinder is leaking pretty good on it also. Need to get a replacement seal kit.

Mp#17- Ronnie and I continued working on it this weekend. As Josh and I discussed setting the dip switch to enable the "shifted key boards" , I looked at presses #1 and #23. The boards are different from each other and a different dip switch has been left on each one.
Press#1 has dip 1 switch #3 on
Press#23 has dip 1 switch #2 on
With this information, I decided to wait and lets just ask Nissei.

Another issue came up when we decided to run it. Not so sure if it is a safety issue but needs to be pointed out.
In semi-override mode- after making parts cycle, with door open after a few seconds, due to mold spring tension against ejectors, the plate drifts backward and an alarm for "Ejector Axis Overload" occurs.
I was asked If there is a way to set ejectors to stop in the "back" position after 1 or more strokes so the pins stay back before the operator opens the door?
I couldn't see a way to do that within the process parameters so this is a question that nissei may have an answer to? Let me know if you find anything out please.

Mp#23- operator side skate on the moving platen is broken. When it is down again, I will try to remove it and measure it out and make another one...or we can just order one?

Mp#1- replaced the cover from the back of the injection unit... don't know how or why it came off?

Have a great day...give me a call if there is anything on your mind.

Sean

Wednesday, November 2, 2011

11.1.11

MP#6-
Baseplate presses messed up tonight. I had to borrow the booster from one and put it on the other so they could run the poly carb. The one in the shop needs the regulator replaced on the booster, I could not find one. It also needs an air cylinder for the fixture shuttle. I could not locate one of those either. Need to order the parts to repair the booster and replacement cylinder.

Mp#9- The conveyor belt came off track enough to stop working. Re-tracked it but have not tightened it up yet as it needs to be checked again over the next few days...keep an eye on it please Mike or Gary.

New Hopper in the shop has the bottom feed tube done. Needs the loader installed and a threaded pipe cap put back on the drain.

Ronnie found a bed motor for that 200lb dryer that is tagged out. If no one gets to it over the next couple of days I will on Friday.

Give me a call if you need me to come in or just want to bs.

Sean

Monday, October 24, 2011

10.23.11 D-shift Weekend...Sean

Mp#1- replaced heaterband and thermocouple on the nozzle. Also constructed an end of arm tool for the canister filter cover. Labelled it on the tool but have not updated the location sheet in EOAT storage area.
Also built one for the D-grip overmold tool.

Mp#3- Nozzle solid state relay went bad. Replaced it and a fuse. Checked operation, O.K. to run.

Mp# 22- assisted the process technician Roy Smith with setting up and programming the slider mold. Although he programmed it well, he did not save the program to the memory in the controller so he will have to reprogram again the next time it goes in.

Small grinder in the shop-
Started working on the small grinder, broke the end plate on the rotor. I built another one on sunday and got it put on the rotor but haven't finished putting it back together yet.

Large grinder in the shop, looked at attempting to dis-assemble the rotor. We can probably turn the shaft down after breaking the sections apart?

DR16- Has a bad index motor, looks like the gear oil has leaked out all over the carousel. It is shot.
We do not have any in MRO. There are (4) 100 lb per hour dryer motors in there but none for the 200lb per/hr dryers.
It is a dayton brand, should be an old PR for them somewhere.

Have a nice day, give me a call if you need anything.

Sean

Wednesday, October 19, 2011

10.18.11 D-shift Sean

Continued with PM's.

Mp#4- They set the Top cover mold in and Ronnie had just put the core switch in. It was not adjusted yet and there were several other core wire related problems. I repaired wires and adjusted the switch until all was working correctly. O.K. to run.

Mp#22- Worked with the process tech Roy Smith to set up the edge valve body to run on the robot.
I fabricated a tool arm for mold #74008 and walked him through programing each step, then copying the "takeout only fascia" and renaming it 74008 valve body, then saving it again after the changes to the program were made. It is saved under the "takeout only" folder in slot #9.

Give me a call if there are any questions or you need to share anything with me.

I will return on Friday! Have a great day!

Sean