Dryers all set that could be set for auto-start. I left a start up sheet for Marty and 3rd shift that indicated which dryers needed to be turned on and which ones were off and not in use.
We had another hydraulic leak on MP#2 core cyclinder hose. I replaced the hose and we cleaned up most of the oil.
Mp#26- Replaced the nozzle heater bands due to a bleedoff. Checked back on it later and there were no further problems with it.
Sean
Friday, February 17, 2012
Thursday, February 16, 2012
2.16.12 Sean
Mp#6- Had more trouble with the gate cutter on the baseplate EOAT scratching the parts. The back stop had loosened again. Tightened it up, no further problems.
Mp#20- Has been having bleedoffs around the nozzle tip. It needs to be changed out to a new nozzle, or the old one re-surfaced when it goes down for a mold change. Keep an eye on it.
Repaired the DME in the shop. The clip in the 3rd spot down inside the terminal connector must have a clip in it regardless of whether it is wired to anything (it is not usually). If it does not, cards will not work correctly in it. In this case, it had one missing.
Finished up the conveyor roller covers in the shop and rolled it back out of the shop.
Cleaned up in the shop, took out the trash and cardboard.
Have a nice day.
Mp#20- Has been having bleedoffs around the nozzle tip. It needs to be changed out to a new nozzle, or the old one re-surfaced when it goes down for a mold change. Keep an eye on it.
Repaired the DME in the shop. The clip in the 3rd spot down inside the terminal connector must have a clip in it regardless of whether it is wired to anything (it is not usually). If it does not, cards will not work correctly in it. In this case, it had one missing.
Finished up the conveyor roller covers in the shop and rolled it back out of the shop.
Cleaned up in the shop, took out the trash and cardboard.
Have a nice day.
Tuesday, February 14, 2012
2.14.12 B-shift Sean
Mp#1- Robot is down until pendant is available.
Nut Press on #10- Replaced a sensor on LH side square nut fixture. Cleaned and inspected it. O.K. to run.
Pm'd Press #5. We are putting loctite on the screws on all the loading receivers on the presses and in the mezzanine to prevent screws from loosening. I am also trying to get around and refill all of the FRL's with oil where needed on robots, etc.
Mp#6- Replaced the rpm tach for the extruder that was busted off. Used the one from MRO.
Have a nice day.
Sean
Nut Press on #10- Replaced a sensor on LH side square nut fixture. Cleaned and inspected it. O.K. to run.
Pm'd Press #5. We are putting loctite on the screws on all the loading receivers on the presses and in the mezzanine to prevent screws from loosening. I am also trying to get around and refill all of the FRL's with oil where needed on robots, etc.
Mp#6- Replaced the rpm tach for the extruder that was busted off. Used the one from MRO.
Have a nice day.
Sean
Friday, February 10, 2012
2.10.12 Sean
Mp#12- Replaced the mercury contactor on zone #3 with a solid state contactor 25 amp. Checked all heater bands. O.K. to run.
Mp#4- Core problems. After determining hydraulics were working, and set to correct pressures and flow rates, had electrical signal dropping out on both core sets. Found they had same card in rack in common and found what appeared to be a bad socket on the terminal connector. I gently bent the top pin enough to where it would make a tight contact. No further problems.
Worked with Roy Smith and Charles Pack on understanding the robot on press #22 better. I strongly emnphasized the need to improve their habits of saving mold set-ups in the robot memory. I showed them how they could change or save set-ups in regards to different conveyors (tall or short).
Worked on the trolley/platform for the new hydraulic power pack unit.
Cleaned up in the shop.
Note about shutdown.
Bill Potter informed the team leader and the process techs that there was no need to set dryer timers since he was coming in early on Monday morning for start up since 3rd shift was not going to start on Sunday.
I did not get any other information since that so I did NOT set the dryer timers at Rogers' request.
I will call and confirm with him sometime on Sunday.
Mp#4- Core problems. After determining hydraulics were working, and set to correct pressures and flow rates, had electrical signal dropping out on both core sets. Found they had same card in rack in common and found what appeared to be a bad socket on the terminal connector. I gently bent the top pin enough to where it would make a tight contact. No further problems.
Worked with Roy Smith and Charles Pack on understanding the robot on press #22 better. I strongly emnphasized the need to improve their habits of saving mold set-ups in the robot memory. I showed them how they could change or save set-ups in regards to different conveyors (tall or short).
Worked on the trolley/platform for the new hydraulic power pack unit.
Cleaned up in the shop.
Note about shutdown.
Bill Potter informed the team leader and the process techs that there was no need to set dryer timers since he was coming in early on Monday morning for start up since 3rd shift was not going to start on Sunday.
I did not get any other information since that so I did NOT set the dryer timers at Rogers' request.
I will call and confirm with him sometime on Sunday.
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.
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
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
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
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
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
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
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
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
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?
Wednesday, November 30, 2011
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.
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
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
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
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