6.28.10 D shift

Put up the aluminum brackets on all of the presses that Bill Potter requested for the purge checklist sheet he wants to display.

Installed the new core standard on presses #9 and #10.

Replaced the ejector limit switch flag on press#7, it had broken. Made one from stronger materials.

Replaced the handle on the pilot fan tester, it was broken.

I will continue to watch the presses that are down and work from the "tracker"list.

Call if you need to.

Sean

6.24.10 D shift

Finished putting up the EOAT Boards.
Suggest that we put up some guidelines for the techs to see when hanging new tool arms etc., so it will remain organized.

Changed out the bottom core switch on #4 last night.

I think it had come out of adjustment, but the LED was not working.

When I installed the new switch, LED would not work on it either.

The input was reading on menu 41 though.

I checked the switch with my meter and it appears to be good so I will returtn it to MRO.

Installed new core standard plug on MP #3, also installed ejector back limit switch receptacle on junction box (in parallel) so it can be used either way.


Talked to everyone on the D shift and there are 3 guys who want to volunteer for any or all of the 3 work-days of shutdown. They are all mechanically inclined.

1 process tech- Johnny Stamps
1 moldsetter- Cameron Wilson
1 operator- Mike Sells

They understand that it is likely 8 hrs /dayshift ,if they can work. ?

I told them I would let them know by Monday or Tuesday so please get back to me by then.

Thanks

Sean

6.23.10 D shift

GR6- grinder, tore it completely apart and started reassembling it. I still have more plastic to clean out from the screen area (slow going), but it looks like I will only need to do some welding on the pan to complete the repair.

It was welded once before and had new bearings/seals installed last time. They appear to be holding up o.k. for now, so we won't need any new parts for it, unless just want to buy a new pan, etc?

Repalced the nozzle tip and T/C on #13.

Placed a note on the loader for 25. Someone had switch 1 on and 2 off, this was causing the loader to load constantly even though the sensor appeared to be working. I placed a label on it so they would know to use 2 with that sensor cable.

Left at 4:30a.m. puts me at around 40 hrs right now. Plan on working till 6a.m. on Thursday night.

Call if there are any questions.

Sean

6.22.10 B shift

Put up EOAT boards outside of molding office. Will continue the rest of it after I find some wood. I used what Facilities had in their locker area. I made a note on the "Tracker" spreadsheet about what wood I need but I may be able to scratch it up from around the pallet room or something.

Tightened up the filter clamps for the vacuum loader pumps. Looks like they had come out of adjustment.

I plan to tear down the peanut butter grinder Wednesday evening and should have an idea of what parts we will need to get it going again by Thursday morning.

Left at 12:30 a.m.- trying to keep hours down this week. I'll be in the next 2 nights and try to take off Fri-Sat-Sunday.

Call if there are any questions.

Shutdown Attachment

Sorry, I didn’t send attachment.  Here it is..

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

Shutdown 2010

Attached is a calendar for shutdown this year.  Also, for anyone who does not already know, we are tracking issues, projects, and parts ordering here-  O:\Molding\MOLDINGSUPPORT\Oreck\Departments\Maintenance\Tracker.xls

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

6.21.10 B shift

Installed new Core wiring standard on presses 6 and 7.

Replaced any switch covers/knobs on all the nissei presses that had stuff missing.

Replaced Nozzle heater band on MP#17 at Darryl's request.

Checked all the machine hoppers for air line leaks, made repairs, replaced some hoses.

Left at 3:30a.m. Be back Tuesday and Wednesday evening to work full shift.

Looks like the board must have worked on #1?

Sean

6.20.10 D shift

Mp#18- sight glass was broken and all of the extruder oil had leaked out. I press fit a peice of plexiglas into it and it is holding for now but need to replace it.

Mp#21- refilled extruder on that one also.

Put together a list of the machines we have completed the core standardization on, robot interface, liquid color plugs, etc. Going to try to combine it with everyone else's machine spreadsheets so we can all be on the same page.

The SB#3- pocket valve has a busted glass in it as well. I sent mark an email to order parts. It was already taped up, but may cause a leak if left unrepaired.

We had some trouble with #22 slider mold. They ran that conductive material on it and had difficulties removing it from the mold consistently.

If there is anything I can do to help prepare for shutdown,...or if any new info about shutdown surfaces, please keep me in the loop, Thanks.

Sean

" C " Shift

• Wiped down & lubed all tie bars before start up. Made sure the chiller & pumps were operating.

 

MP-19  Replaced broken oiler fitting ;bottom  non – operator side.

 

MP-11  Robot not going to home position ; turned off main robot power & rebooted- OK

 

D-32 ( mezzanine )   Alarm 11 -  Adjusted index switch.

 

MP-9  Robot  Z  axis brake not releasing – checked all connections, & cleaned the contacts. Working fine now

 

MP-22  Tech burned his arm while purging out barrel. I checked to make sure we didn’t have a heater problem. The last shift that ran did a mold change &

           didn’t purge the barrel. They went from Santopren to nylon. When the new set up was loaded, it was 200 degrees higher

           than the new material being  loaded.

 

 

 

 R. Upchurch  

6.16.10 Nights

MP#6- Charlie thinks the screw tip may be worn out on it. They ran the big blue Hoky and had short shots off and on all night. We may need to do a static test on that one as well.

Worked on robot PM's all night. Replaced the vacuum generator unit on #20 robot, it was still functional but leaking air really bad. The gasket on the pilot valve was blown. It can be repaired if we can get a new gasket. I think Mark is going to check with Motion Ind.

Sean

" C " Shift

MP-9  Robot wasn’t homing;  the reference block had been moved & one of the home blocks was loose. I got that straightened out & then there was

          no vacuum on the cups. There was water in the system; bled it off & set the vac verify switch—ok to run.

 

MP-17  The nozzle heat controller was in hi - temp alarm & wouldn’t heat.  There was a loose T.C. connection at the controller—Repaired.

 

MP-12  The grinder was making a noise ;  I cleaned it out – the material was hot & just about to start melting. I let it cool down, & had to adjust the rear

           stationary blade. I reassembled the grinder & got them to turn up the regrind load time. OK to run.

 

 

 

 

  R.Upchurch  

6.10.10 D-shift

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

" 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

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

 

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

" 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.

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.

" 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