D shift had 2 process techs out wed/thurs so today I did spend some time assisting with set-ups etc.
MP#9- built and end of arm tool for mold # 78165 and roughed in the parameters.
Made a tool for them to insert the magnet in the fans they were welding at #12.
As it stands, I told Darryl that I will not be working Saturday and Sunday, but if he needed me to come in and fix anything that was down, all he had to do was give me a call. My number is posted in the molding office.
Sean
Friday, June 11, 2010
Wednesday, June 9, 2010
" C " Shift
MP-3 Left side gate cutters not cutting good; I swapped out cutting tables. I changed out the left side cutters. It’s always harder to cut the polycarb parts.
We need to order spare cutters.
MP-13 I installed the new screw tip . They hung a mold in it.
R.Upchurch
6.8.10-D shift
Mp#4- changed the thernocouple, reused the heaterband. Darryl requested that I remove the purge that was stuck to the wires.
Mp#15- helped Jeff set-up the Sprue picker. It needed some maintenance and also needs some work on a screw that is stripped out where they adjust the in/out from the mold<>.
MP#21- hot stamp had a blown fuse. Replaced it and it began working fine. Replaced a gage on one of the air regulators, cleaned, lubed and tightened things up on it.
Worked on liquid color pumps that were in the shop. Cleaned, repaired and generally just fixed what needed fixing on them. Still have a few more that may need parts.
Call if there are any questions.
Sean
Mp#15- helped Jeff set-up the Sprue picker. It needed some maintenance and also needs some work on a screw that is stripped out where they adjust the in/out from the mold<>.
MP#21- hot stamp had a blown fuse. Replaced it and it began working fine. Replaced a gage on one of the air regulators, cleaned, lubed and tightened things up on it.
Worked on liquid color pumps that were in the shop. Cleaned, repaired and generally just fixed what needed fixing on them. Still have a few more that may need parts.
Call if there are any questions.
Sean
Tuesday, June 8, 2010
MP19 Nozzle Touch Alarm
If anyone gets an alarm on MP19 that says “Nozzle Touch PS2 Unconfirmed”, here is the fix-
Go to clamp factory screen by hitting “Shift” and then the “Clamp” screen button. Go to the page titled “Mold Adjust 1”. At the top there is a setting named “HPCV”. Not really sure what it is or what it does, but it controls what the pump loads to for nozzle contact force. I found it set at 60% the other day when we were getting the alarm and set it to 99% and this fixed the problem. Evidently they had the problem again over the weekend and I’m assuming the value got set back to 60% when someone reloaded a new process set up. We changed again from 60% to 99% and this fixed the problem.
Call with any further questions.
Joshua Ledbetter
Molding Maintenance Manager
Manufacturing Engineer
Oreck Manufacturing Company
931-239-3235
Monday, June 7, 2010
6.6.10 D shift
Finished repairing the connector nest for vibratory welder. Replaced broken/missing screws loctited them. Cleaned and inspected the tool. It looks like the adjustment method they have been using requires a hammer sometimes.
Lubed all of the tiebars and refilled reservoirs and greased the machines.
We need to get a repair kit for the Milacron machines complete with 3/16" nylon tubing and the ferule type fitting they use.
MP#15- has a broken lube line that needs repaired when it is down.
MP#17- has an extruder hose that is leaking. I tagged and measured it. Made a new hose up and left a note so we can change it when it is between molds.
I left a note on the Fastenal board to restock the "assorted springs" drawer. I used a spring last night to repair one of the gasket locating tools (used on the intake pivots) but didn't really have what was needed.
I left the old clamp tonnage transducer with Mark so we can possibly stock a spare.
Replaced the cabinet fan on robot #3 panel.
Basically fixed little things most of the night and helped the techs because this shift has no tooling person. We repaired the tool on press#22 that broke out all 4 keen-serts. There were only 2 left in the box so we patched it up to get it running.
Let me know how you want to do that blocked nozzle test. I am supposing you want to do a dynamic check ring reliability test for bad screw tips?
I plan to take off this evening but will work on till Friday night. Call tomorrow if there are any questions.
Sean
Lubed all of the tiebars and refilled reservoirs and greased the machines.
We need to get a repair kit for the Milacron machines complete with 3/16" nylon tubing and the ferule type fitting they use.
MP#15- has a broken lube line that needs repaired when it is down.
MP#17- has an extruder hose that is leaking. I tagged and measured it. Made a new hose up and left a note so we can change it when it is between molds.
I left a note on the Fastenal board to restock the "assorted springs" drawer. I used a spring last night to repair one of the gasket locating tools (used on the intake pivots) but didn't really have what was needed.
I left the old clamp tonnage transducer with Mark so we can possibly stock a spare.
Replaced the cabinet fan on robot #3 panel.
Basically fixed little things most of the night and helped the techs because this shift has no tooling person. We repaired the tool on press#22 that broke out all 4 keen-serts. There were only 2 left in the box so we patched it up to get it running.
Let me know how you want to do that blocked nozzle test. I am supposing you want to do a dynamic check ring reliability test for bad screw tips?
I plan to take off this evening but will work on till Friday night. Call tomorrow if there are any questions.
Sean
Sunday, June 6, 2010
" C " Shift Weekend
MP-22 Tech said cores not working -- found eject. back switch wasn’t made – they forgot to tie in the knock-outs.
MP-2 Mid zone heat kept dropping out; contactor was bad – replaced
MP-22 Checked torque on the screw gun for the valve body. Max torque on the SOP is 14 ; It is running 12.5 – 12.75. They had a few
parts crack . I think the parts may have just been too hot.
MP-5 One of the wheel mounting brackets on the ( small parts ) shelf unit broke off. I took it to the shop & brazed it back on.
MP-5 Getting the prefill alarm again. Changed settings & offset. It ran until right before shift change & alarmed out FHD exceeded limit.
I left it with Sean.
Cleaned up oil & changed pads on MP-17 & 21.
MP-11 The core pin broke & when they pulled the core cylinder off, they pulled the wires loose. Repaired.
PM’s on press 2 , 3 , & 4. MP-3 needs new fan in robot cabinet.
R. Upchurch
6.5.10 D shift
Mp #5- the tonnage readout was stuck at 500, even after powering it down, etc.
I changed the tonnage transducer and when I powered it back up, it was a teading negative value (-28). I calibrated the offset and changed the convecs 921, 812, and 813 so they were 150 apart, etc. It worked.
Started it up and ran production at 7:10pm. Has ran good all night so far.
Changed out the screw gun on #22 because it would not stop running. I advised the process techs to monitor the screw bosses so they would notice if they were breaking out. They are doing fine so far.
Assisted Lynn Smith in changing out the welder nest and setting it up. I took the connector tool back into the shop, I have to make some repairs to it where it has been broken.
Sean
Cleaned up out on the floor and in the shop.
I changed the tonnage transducer and when I powered it back up, it was a teading negative value (-28). I calibrated the offset and changed the convecs 921, 812, and 813 so they were 150 apart, etc. It worked.
Started it up and ran production at 7:10pm. Has ran good all night so far.
Changed out the screw gun on #22 because it would not stop running. I advised the process techs to monitor the screw bosses so they would notice if they were breaking out. They are doing fine so far.
Assisted Lynn Smith in changing out the welder nest and setting it up. I took the connector tool back into the shop, I have to make some repairs to it where it has been broken.
Sean
Cleaned up out on the floor and in the shop.
Saturday, June 5, 2010
6.4.10 D-shift
Mp#5- stopped for the prefill alarm again. I couldn't find any information about what was done to it the other day to get it going. I tried calibrating the tonnage transducer again, but it did not work. Milacron thought there was problem with the FHD board for it to be continuing to have this problem. It is down now.
Jerome never replied to my request to schedule it down to do the screw-tip, so for now I will leave it.
I was able to extract the broken peices out of the screw for MP#13. I think it will be alright to use. Still need a new tip though.
Right now I plan on leaving at 2am Saturday night.
Will work all night Sunday.
Off on Monday.
Will work Tuesday through Friday nights.
Call if there are any questions.
P.S. Leave me some info this time on #5 so I can gain a better understanding of how to patch this thing for production. Thanks.
Sean.
Jerome never replied to my request to schedule it down to do the screw-tip, so for now I will leave it.
I was able to extract the broken peices out of the screw for MP#13. I think it will be alright to use. Still need a new tip though.
Right now I plan on leaving at 2am Saturday night.
Will work all night Sunday.
Off on Monday.
Will work Tuesday through Friday nights.
Call if there are any questions.
P.S. Leave me some info this time on #5 so I can gain a better understanding of how to patch this thing for production. Thanks.
Sean.
Friday, June 4, 2010
" C " Shift
MP-13 Pulled the screw & screw tip. The rear seat wasn’t there. They continued to run it after it broke, so the threads in the screw were gone.
Nissei didn’t have a 32mm screw in stock, so I called Chaseland to make us one. They will fax the quote for the screw & tip Monday.
MP-14 Jason said some metal was showing up when he purged it out. Thought I was going to have to tear into that one when I finished 13.
He got it running, so hopefully this one won’t jam up the check ring.
R. Upchurch
6.3.10 B shift
Mp#13-Redid the heater bands on the nozzle. Checked and found that screw tip was indeed broken. Mitch was running it but they were scrapping too many so they eventually shut it down.
Repaired the cannister gate cutter fixture. Tested it out and it works great.
The drill press in the rework area broke the quill return spring. I was able to heat and rebend it and it is working again for now but we need to order another one. I gave Mark a lead with the drill press info.
Cleaned up oil around #17 and #21. Put some new oil absorbent down.
I am sending Jerome an email to see if he will leave #5 down on Saturday nite to do the screw tip change and barrel measurements.
Call if there are any questions.
Sean
Repaired the cannister gate cutter fixture. Tested it out and it works great.
The drill press in the rework area broke the quill return spring. I was able to heat and rebend it and it is working again for now but we need to order another one. I gave Mark a lead with the drill press info.
Cleaned up oil around #17 and #21. Put some new oil absorbent down.
I am sending Jerome an email to see if he will leave #5 down on Saturday nite to do the screw tip change and barrel measurements.
Call if there are any questions.
Sean
Thursday, June 3, 2010
Thursday A Shift
Suspect screw tip in 13 is broke. I've ordered a new one that will be there tomorrow.
Josh
Sent From My Verizon Blackberry
Wednesday, June 2, 2010
6.1.10 D-shift
Mp#5- stopped for "Prefill did not open in time" alarm.
I was able to open the clamp by changing the offset for clamp tonnage on menu 93 from 1799 to 2250,and menu 92/convec 921, from 2000 to 2350 to get the clamp tonnage to zero, but it will not run yet. It now will alarm again but will open if you clear the alarm.
I spoke with Clarence at Milacron service who thought it sounded like the prefill valve was bad. I looked in MRO for another directional valve like it but couldn't locate one. They are using press #3 or I would have tried some parts from it maybe. I wasn't so convinced it was the valve bad yet, and I want to talk with Josh about it first.
Mp#11- Potter asked me to check the cores when I came in, I checked that the machine was working fine, used our test rig to verify switches and hoses. They had the collar tool out working on it and when it was set back in they never worked, it appears to be jammed up internally.
Worked on DME boxes, replaced cooling fan, and installed #3 jumper in all of them so they will work with the new style cards.
Changed the cord plug on liquid colr pump for 13 also.
May want to look over the gate cutting fixture that is for the cannisters. it is in the tool room because it needs another braket made. It looks like it is time for an overhaul of that fixture, I am welcome to any ideas with it.
Be back in at 6pm.
Sean
I was able to open the clamp by changing the offset for clamp tonnage on menu 93 from 1799 to 2250,and menu 92/convec 921, from 2000 to 2350 to get the clamp tonnage to zero, but it will not run yet. It now will alarm again but will open if you clear the alarm.
I spoke with Clarence at Milacron service who thought it sounded like the prefill valve was bad. I looked in MRO for another directional valve like it but couldn't locate one. They are using press #3 or I would have tried some parts from it maybe. I wasn't so convinced it was the valve bad yet, and I want to talk with Josh about it first.
Mp#11- Potter asked me to check the cores when I came in, I checked that the machine was working fine, used our test rig to verify switches and hoses. They had the collar tool out working on it and when it was set back in they never worked, it appears to be jammed up internally.
Worked on DME boxes, replaced cooling fan, and installed #3 jumper in all of them so they will work with the new style cards.
Changed the cord plug on liquid colr pump for 13 also.
May want to look over the gate cutting fixture that is for the cannisters. it is in the tool room because it needs another braket made. It looks like it is time for an overhaul of that fixture, I am welcome to any ideas with it.
Be back in at 6pm.
Sean
Friday, May 28, 2010
This week 5/24/10
Ordered new Saskawa servo amp from Nissei for MP1. Should be here 6/1/10. Called Saskawa and requested they send us our unrepaired unit and regenerative pack.
Should be here 6/1/10. Nissei is now set up to accept P.O.’s, net 30.
Set up welder ejectors on MP12 for new Edge fan housing ejector cylinders, used outputs 12 and 13, top two single valves. Firing sequence is top ejectors step 5, bottom ejectors step 6. When door open part is laying loose for operator to remove.
Changed out safety latches in hoist ring hooks in molding production area. (both hoists)
Installed additional 480 outlet on MP18. Two outlets share a 30A breaker for Thermalators.
Fabbed and installed extrusion frame to hang heater wire junction box on MP2. Mount junction box to new frame. Replace and label all heater wiring.
Install and adjust spare Robot EOAT for fan housing on MP8
Replaced (4) 2” load system hose sections up in mezzanine area with what hose we had on hand. More hose is coming. Replaced 2.5” material hose on top of surge bins. Installed elbows and partially hard piped some drops. We are trying to eliminate all vacuum leaks.
Install sand paper to the bottom of rework fixture for orbiter disks and realign.
Worked on color pump signal for MP1. Parts are here to steal a signal from the output of the servo drive to the motor.
Mark McKee
Technical Specialist
Oreck Manufacturing Company
mmckee@oreck.com
PH 931.646.7856
CELL 931.644.5289
FAX 931.646.7851
This week 5/24/10
Ordered new Saskawa servo amp from Nissei for MP1. Should be here 6/1/10. Called Saskawa and requested they send us our unrepaired unit and regenerative pack.
Should be here 6/1/10. Nissei is now set up to accept P.O.’s, net 30.
Set up welder ejectors on MP12 for new Edge fan housing ejector cylinders, used outputs 12 and 13, top two single valves. Firing sequence is top ejectors step 5, bottom ejectors step 6. When door open part is laying loose for operator to remove.
Changed out safety latches in hoist ring hooks in molding production area. (both hoists)
Installed additional 480 outlet on MP18. Two outlets share a 30A breaker for Thermalators.
Fabbed and installed extrusion frame to hang heater wire junction box on MP2. Mount junction box to new frame. Replace and label all heater wiring.
Install and adjust spare Robot EOAT for fan housing on MP8
Replaced (4) 2” load system hose sections up in mezzanine area with what hose we had on hand. More hose is coming. Replaced 2.5” material hose on top of surge bins. Installed elbows and partially hard piped some drops. We are trying to eliminate all vacuum leaks.
Install sand paper to the bottom of rework fixture for orbiter disks and realign.
Mark McKee
Technical Specialist
Oreck Manufacturing Company
mmckee@oreck.com
PH 931.646.7856
CELL 931.644.5289
FAX 931.646.7851
5.27.10 D shift
Replaced wiring to purge sheilds on presses #6 and #12, tied them up neatly and repaired sheilds with new screws and fasteners, etc.
Checked all of the presses that were down for loose safety circuit switches and door latches, fixed whatever I found. Replaced screws as needed.
Checked the lube lines for broken fittings.
MP#8 -Finshed where Ronnie left off on oil pan clean-up.
I left a paper for Mark to see about ordering those vacuum drainage reservoirs for the 500 Cincinatti's clamp drain line. They might give us one as a sample since you order them 48 to a case.?
Mark and I went over the procedure for HMI programming for the AEC robot displays.
Call if there are any questions...have a great weekend. I will be working Tuesday-Friday or Saturday nights next week or until? I sent Darryl an email.
Sean
Checked all of the presses that were down for loose safety circuit switches and door latches, fixed whatever I found. Replaced screws as needed.
Checked the lube lines for broken fittings.
MP#8 -Finshed where Ronnie left off on oil pan clean-up.
I left a paper for Mark to see about ordering those vacuum drainage reservoirs for the 500 Cincinatti's clamp drain line. They might give us one as a sample since you order them 48 to a case.?
Mark and I went over the procedure for HMI programming for the AEC robot displays.
Call if there are any questions...have a great weekend. I will be working Tuesday-Friday or Saturday nights next week or until? I sent Darryl an email.
Sean
Thursday, May 27, 2010
" C " SHIFT
MP-19-22-23-25 Filled lube reservoirs.
MP-19 & 22 Replaced broken tie bar & skate lube fittings
MP-21 Robot crashed into mold. All of the gripper mounts were either bent or broken off. Replaced all mounts, tightened the gripper posts, chased
threads & replaced bolts on eoat mount.
MP-6 Vacuumed out oil pan.
R. Upchurch
Molding Maint.
5.26.10 D shift
Mp#260 Changed out the temperature contoller. It quit reading actual temp. Auto-tuned the new one. Checked operation, O.K. to run.
#11-Robot
Would not reference the Z-axis. Went thru the whole z-circuit, found loose connection on break relay module.
Call if there are any questions.
Thanks.
Sean
#11-Robot
Would not reference the Z-axis. Went thru the whole z-circuit, found loose connection on break relay module.
Call if there are any questions.
Thanks.
Sean
Wednesday, May 26, 2010
Molding Support Tracking Spreadsheet
Hey Guys,
I put together a To-Do spreadsheet today and put it on the server. Attached is a shortcut.
The spreadsheet has multiple page tabs at the bottom for Issues, Parts, Projects, and ShutDown Projects.
Some of the cells have drop down boxes for your convenience.
Collin- Don’t let your feelings get hurt because I left your name out of the “Assigned To” drop down box.
Thanks
Joshua Ledbetter
Molding Maintenance Manager
Manufacturing Engineer
Oreck Manufacturing Company
931-239-3235
Monday, May 24, 2010
5.23.10 Weekend D-shift
Worked on conveyors repairing broken parts and generally looking them over to see if they need anything. There is still one that is going to need the Baldor drive repaired or replaced, but it is working for now.
#3 has a busted reservoir basin for the drain line that draws from the clamp seal. It is mounted under the automatic lube greaser. The words respiratory health care are printed on it so maybe it is something we can get cheaply at a hospital supply place?
#10- Had issues with the ultrasonic welder. The thermolator had been off and the positive stop was adjusted too far down. It was giving an error some of the time that would require you to press the reset button. It is working fine now.
Cal if there are any questions.
#3 has a busted reservoir basin for the drain line that draws from the clamp seal. It is mounted under the automatic lube greaser. The words respiratory health care are printed on it so maybe it is something we can get cheaply at a hospital supply place?
#10- Had issues with the ultrasonic welder. The thermolator had been off and the positive stop was adjusted too far down. It was giving an error some of the time that would require you to press the reset button. It is working fine now.
Cal if there are any questions.
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