This Weekend

Hey Guys,

They are running 6 presses today and plan on running tonight.  Do not put yourself in danger to come in here.  If you can make it, plan on working.

For anyone working this weekend, here are some projects that need to be addressed-

 

1)     MP13 still needs to be leveled.  I still need to order two more feet to put under it, put it can be leveled with the four that it has.  The level is on MP19 with a magnetic V-Block to help stabilize it when placing on top of a tie bar.

2)     MP19 needs to be leveled also.  There are some minor things that still need to be done to 19 as well, including hanging material pipes, etc.

3)     MP19 cores do not work.  Pull works, but Set does not.  We’re still not sure if the pressure and tank lines are plumbed correctly.  Also, the solenoid could be wired wrong.  Input switches are wired correctly.

4)     MP01 pump still needs to be addressed.  New pump is $8K and 45 day lead time.  I want someone to take measurements of Mainframe mold to see what would have to be done to robot riser on MP02-MP05 to accommodate hanging this mold (Spreading the riser legs out).  That way we can run the mainframe somewhere else until we figure out what we are going to do with MP01.

5)     Someone can get the hydrostatic oil filer out of the storage trailer and put casters on it and see what it will take to get it functional.  We need to get that trailer cleaned out sometime to store extra stuff.

6)     Someone can also bring in those little conveyors and see what we can use them for.

 

Thanks

 

  Joshua Ledbetter

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

1/27/10

MP1 pump number two was making a loud noise. I took the coupling loose and the motor and coupling seem fine. It sounds like the pump bearing is out.

Robot number 10 alarmed only one time tonight with in the mold. It gave a "Mold not open. Robot in unsafe position." alarm

MP23 over stroked the ejector limit switch and had to be dialed back into zero.

Robot on #3 hit the conveyor belt and tripped the 220V breaker inside the press.

Worked on new MP19 tonight

" C " Shift

   MP – 16    Installed a plug for the eject. back safety switch.

 

  MP – 19   Pulling everything off the press that we may need later; scrapping the rest.

 

  MP – 25   Nozzle was blowing back,  Checked level of sled.  Breland said it’s been doing it on the last three molds. They’re suppose to be

                 trying a new tip on it & letting us know how it’s doing.

 

 

 

   R. Upchurch

   Molding Maint.

1.20.10 night shift

#23- finished putting screw back together. Set a mold in and made sure nozzle was aligned correctly. The machine had not used cores before so I put quick connects on. Also wired the core switches up on the mold and put QD fittings on it as well. When I tried it out, cores would not work. I remembered Collin saying that he had found a problem on the circuit board inside the valve on 22, so I swapped out boards to eliminate that. Still did not work. I swapped out hydraulic hoses. Still not working.

I was at the point of replacing the quick connect fittings I put on the machine but there are none left in MRO. You can manually probe the valves while someone energizes switch and the cores will move, they just do not seem like they are getting an output signal. I tried to bypass the switches and run it on timers but it still will not work.

I went through it all with Mark and Ronnie, we got to a point where we had isolated a problem with the valve.

Sean

1.18.10 nights shift D

Mp#15-had a bleedoff back about 3 bands. We cleaned it off and patched it up without replacing anything but the nozzle clamp. O.K. to run.



Mp#7- put a material loading sensor on the hopper sight glass at the request of Process Techs. Had to get one from the Turck vending machine. Used the number 00344.



Mp#23- put another 120vac receptacle at the rear of the machine per Mitch's work order request.



Robot on press # 2 - Did a pm on it. Mounted some brackets to hold the HMI touch panel securely to pendant. I still need to do one on #11 when it is down.

Robot on press#25- Also did pm. Cleaned, greased, inspected, tightened screws etc.



The single cavity topcover mold is leaking on press#11. It was pulled out with a workorder last time it ran, instead of moving it to a repair location, someone just put it back in the racks. Bill mentioned to me that it was back there with the work order, but by then it was already scheduled to go back in on our shift and run again. I asked Marty if he wanted to shut it down to fix the leak, he said no.



I did notice that many of the ISO work instructions on the Online Document website have not been revised since 2002, etc. Including the molding maintenance work order request instruction. We were looking for the procedure for mixing up the ink for the pad printer. It was not there or at the support site.

Need to order some cabinet fans like we use in the robot control panels and DME boxes. Need both 240 and 12oVAC. 3 are out in the robot panels, and I think one of the Cincinatti's has one out also. Then the DME's run on 240vac and we do not have any of those either.

Call if you need me to come in or have any questions.

Sean

" C " Shift

    Tightened up the pump drain plug on the vib. welder; It had a slow leak. I’ll check it again after they run it awhile.

 

 MP-21   Vacuumed oil under sled & on rear deck.

 

Installed eject. back switch on new mold # 74017.

 

Installed conveyor tray behind MP-25.  They can try it out---- see if they need to modify it.

 

Loader # 7 on mezzanine wasn’t pulling from Gaylord. I found  two other loaders leaking at the vacuum ports. I changed out the seals

 

 

 

          R.Upchurch

          “ C “ Shift  Maint..

1.17.10 night shift D

MP#10 - robot was stopping above conveyor after part delivery. Ronnie and I looked at it briefly,didn't see anything obvious. We adjusted tracking on Z-belt. I did a PM on it after they shut it down an hour later and dry cycled it for about 20 minutes, it did not stop anymore. Will keep an eye on it.

MP#2- Robot had no apparent alarms but would not give permission to close to machine, turned out that someone had left the robot in "DRY CYCLE" mode.

MP#7- looked at the baseplate tool, had open thermocouples, we checked boxes, cables, etc, turned out to be open TC's in the mold. They are running it in Manual.

I vacuumed out all the robot control cabinets and found 3 cooling fans bad.
I could not locate any in MRO so we need to order those. Also need a few other items to complete some workorders so I will leave Mark a list Monday morning.

I mounted a tray on the crane column behind the Welder on #12 to store nest screws so they will be 5-S compliant.

Worked on PM's and misc. oddball requests from the Moldsetter, process techs and team leader throughout the night. Call if there are any questions.

Sean.

" C" Shift

   MP-4  Robot not holding position & conveyor not working.  They had the “ Z” at home position set the same as “ Z “ at part drop. I changed

             The part drop setting & it homed .  The conveyor  relay  had no  incoming power---- someone had it unplugged..

 

   Hopper # 13 @ mezzanine wasn’t unloading material to MP – 5 .  The supply air to the valve wasn’t plugged in all the way  & the material line got

                  stopped up. I fixed the air line & opened the material line to clean it out.

 

  MP-16  New mold had two eject. back switches – I wired them in series & put a plug on it .

 

  MP-10  Robot stopping occasionally. Haven’t found the problem yet.

 

  MP-24  Mark worked on the cores on a new mold; both core set & pull lights were on at the same time. He found the  polarity  wrong at the plug wiring.

 

 

 

              R. Upchurch

              “ C” Shift Maint.

" C " shift

  MP- 19 Grinder  “on” push button  came apart;  installed new one.

 

 MP- 21 robot wouldn’t home ;  Limit switch on air cylinder not making. Adjusted.

 

 MP- 2  Drill not drilling everytime .  The vacuum port was clogged & drill shavings were preventing swivel fixture cylinder sensor  from making.

 

 Started working on incline conveyor catch pan.

 

 Unboxed new equipment & sorting out hyd. fittings & manifolds for new molds.

 

 

 

  R. Upchurch

  “ C “ Shift Molding Maint.

January 14, 2010

Worked some on the Eagle sole plate press controls, the main panel is wired and installed.  Gary mounted the cabinet and is working on some sensor mounts.  Ordered the solenoid valve block for this station.

 

MP20, process tech had problem with new DME cables not fitting or clamping up right.  They were six pin instead of five pin.  We have both on the floor, but we only stock the six pin.

 

MP13 shut down, ends up the front door switch was not made.  Use code 100 to find out.

 

Helped Elaine establish a healthy list of Robot EOA components and Josh ordered today from EMI.

 

Talked to EMI guys today about a quote for (3) Decline Conveyors for new machines.

 

Ordered two new hydraulic cylinders for one of the new molds.  Ortman brand.  Should be here in 4 days.  They are prepped for Go switches.

 

Ordered more Omron micro switches for new molds.

 

Ordered (2) station junction boxes from Motion.  Daman brand.  Hydraulic, 3/8” Ports, 3000psi working pressure.  Should be here 1/15/10.

 

Worked on MP14 sub station.  Replaced LH pneumatic PB on cord hook snap.

 

Loaded the truck headed for Zag with the Wittman Robot and Air Skates.

 

Mark

1/14/10

 

 

 

 

 

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

1/13/10

Took apart and tapped three hydraulic cylinders on the new molds for 3/8" pipe thread. Only had time to put fittings on one cylinder.

Made a bracket for MP22 conveyer to keep hoses off it.

Worked on dual ratio valve on MP23. It wasn't loading regrind.

Wired a new heater and thermocouple on a mold that came in the shop.

Thermolater T31 tripped the motor overloads. The motor is bad and will not start. I got a new one from MRO and a pump seal kit but didn't have time to replace them. I'll try to get to it tonight.

Collin
"C" Shift

1.12.10 night shift

Very uneventful tonight. Worked on PM's throughout the night.

Replaced ejector hose and fittings on MP#17, that were leaking. Went over fittings checking for tightness and redid o-rings as needed. Made a hose for it. ..
Question:
Do we need to put some kind of form at the hose crimper to keep track of what gets used? Who keeps things topped off there?

I did get to look at the support site and viewed some of the new equipment coming in. Looks like it is in great shape.

Let me know how I can help with the upcoming install/replacement of
machines and robots.

I will be working this weekend, be back Friday evening. Call if there are any questions.

Sean

1.11.10 night shift

#23- worked on the regrind / virgin loader blender controller. It was not functioning. Found a bad valve, when I looked at the other controller, it had a different valve, so I changed out the whole controller, and it worked fine.

#5- The robot conveyor belt tripped out, after looking at it, the NO contact was bad. I put a jumper across it since the tether had already been removed anyway. Working fine now.

Mark and I looked at the robot on #8, for future reference and to eliminate process tech changes, the Timers set-up is as follows:


Delay Before Sprue Grip: 2.50 sec (Grabbers)
Delay Before Part Grip : 2.00 sec (Kickers)
Delay After Sprue/Part Grip : 0.50

Continued working on PM's, I mentioned to Bill that he might see if Jerome would schedule the fans to run in 22 or 23 so we can have a repair window for the leaks on #21. Haven't heard anything back yet.

Also: I looked at the new mold with cores,, unless we change the cylinders we are going to need to install some mechanical switches to read set/pull with it. Maybe attach locking collars or position flags with microswitches??
They are not done tearing it down for cleaning but likely they will want to sample it soon and we will need to decide how to proceed.

Call if there are any questions...Sean

1/10/10

#15-Nozzle was leaking around threads. Tried to tighten it but it still leaked so I changed  it with one I'd faced off.

#8-Robot missing parts. I started the machine back up and fixed the robot and ran it for an hour to verify it was ok.

#9-Robot missing parts. Two of the suction cup level compensators were worn out and allowing the cups to moved around freely. Replaced them with new ones.

#15-Water leak on feedthroat fitting. The  cooling hose had been cut down to short and was catching on the sled so I added some to it and replaced the fitting.

Collin
"C" Shift

" C " Shift

  MP-16   Mold wouldn’t close.   Eject back limit switch had loose connection @ teminal strip.

 

 MP-8   EOAT  was dropping parts.  Mark & I  made some adjustments on grippers & “ Z “ axis.

 

 MP- 4. 11, 12, 14, 18, 19, & 24 are low on oil .  I’ll get them between today & the weekend while doing PM’s.

 

 MP-20  Sight glass may be plugged ;  not showing any oil.  I’ll  check it through the top tank hatch & fill , if needed.

 

       We need to get with tooling to see if any of the new molds need fittings, switches, etc.

 

 

 

 

     R. Upchurch

     “ C “ Shift Maint.

Jan 7, 2010

 

Thursday, Jan 7, 2010

 

Started the day with problems at MP10, the connector nut insertion station.  The left side was jamming every 10 parts or so, with somehow feeding (2) black nuts and trying to press them.  It ends up that it was an inertia problem with the black nut slide, it traveled so fast outward and was bumping the track so that the first nut moved forward and allowed a second nut to feed down in place to be pressed.  We disassembled the left side, installed a directional flow control on the black nut slide cylinder and adjusted it about half way and reassembled.  The problem went away. 

 

There was an eight bank D-M-E heater controller and some cards that were burned up, probably from inserting or removing cards with the power on.  Ronnie and I gathered enough new components from MRO to put a new system together.  The problem was that who ever ordered the new D-M-E controllers a few years ago, ordered them wired 240V three phase.  So we had to rewire the controller for single phase 240VAC.  After checking everything out plugged in to a mold, I attached a label indicating not to move cards with power on. 

 

Helped set up robot on press 25 for brush roll end caps.

 

Snowing today, I heard the plant was closing at 4pm because of weather.

 

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

1/7/10

1/7/10  FYI

 

Stiffener and nut press station at MP10 would not seat the stiffeners consistently in the plastic connector.  Ronnie and myself checked the machine, it was OK.  Ronnie increased the supply air pressure to max line pressure.  Still problems.  We checked the parts and it looked like the opening in the parts for the stiffener was smaller than the print allowed.  On further examination of the inside of the pocket where the metal stiffener seats, we found additional plastic down in the hole about three-quarters of the way down that provided interference.  We checked the chiller temp, set at 53 degrees.

Checked the water and water flow.  Cores for the stiffener pocket were blazing hot.  We got the process tech to slow the machine down from 54 seconds to 59 and immediately the parts looked much better and we were pressing with no problems.  I believe the correct cycle time on paper is 60 seconds.

 

Mark McKee

Technical Specialist

Oreck Manufacturing Company

1400 Salem Rd

Cookeville,  TN  38506

mmckee@oreck.com

PH      931.646.7856

CELL  931.644.5289

FAX    931.646.7851

 

1.07.10 night shift

Mp#7-had to replace fuses in the 120/240 transformer. The DME box arced when they were changing out cards.
Marty asked me to put an EOAT together for the wheel cover they were running, its running good.

MP#11- replaced 2 hydraulic hoses to the ejectors, they were worn and looked like they were leaking in several places. Checked operation, good to go.

Worked on PM's on machines and robots most of the night with other odds and ends such as making mold lock straps etc.

If there actually is bad snow, I may not be able to come in, I will try anyway if the roads are clear though.

Sean

1.03.10 night shift

Cleaned up in preparation for the "QVC film crew" which is supposedly coming in this week.

I tried to get as much tagged equipment repaired as possible. The only thing left was that dryer DR20 which for some reason iss not providing a control output for the regen beds to kick in? We may have some spare parts somewhere or I can try to swap out parts with another dryer when possible.

Had a few minor issues this weekend, I turned in workorders for most of them. Have a good day call if there are any questions.

Sean

" C " Shift

   MP-11   I shut the press down & cleaned up oil on the clamp end. Found two leaks on eject. Manifold ,  tightened , & restarted press.

 

  MP-16   Mold not closing – error 122 – not making eject. back switch .   The eject. back jumper had a broken wire.

 

  MP-17   Hose on eject. manifold sprung a leak. Made up a hose & replaced. I made a hose for the other side too, but I couldn”t  find

              any ½”  boss fittings.

 

  MP 6,7,8,10,11,& 12    Vacuumed oil pans Then emptied oil vac.  I started on # 1 ;  The vac .  will probably need to be emptied again.