" C " Shift

MP-17  PVC rusted the hopper;  It wasn’t sprayed with acid neutralizer.  I took it off & bead blasted it.

 

MP-21   Worked with Mark on the robot vacuum switch.

 

 We rounded up some more of the large metric wrenches & hung them up with the rest of the wrenches.

 

 The aluminum came in. We put the sheets in the rack & the plates for the fixtures are on our work table.

 

 I moved the hot stamp to our shop & will get started on it when Randy gets the nest to me.

 

 

 

 

 R. Upchurch

MP21 Robot

Robot on MP21, vacuum would not work.  Voltage was toggling on board but not out on the connector (V3V) for vacuum solenoid, solid red wire was broken in tray somewhere.  Spliced into another connector.  OK.

 

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

 

Week of July 12, 2010

MP4,  Zone 1 was running away, contactor stuck, replaced with new one.

 

MP15,  Replace small shock absorber on crosswise for sprue picker.  More are on order.

 

We received a spare pressure transducer for the Cincinati’s.  It is on shelves to the left in MRO.

 

Helped Gary change linear scale for the clamp on MP21.  The new scale is different and requires an inline transformer plugged in to the clamp board.

 

Ordered program change to include additional core sequence for MP25 from NIssei to EJECT before CORE pull.

 

Worked on MP21 inject side.  Back Screw position was stopping short of desired location.  Made adjustments to internal codes 32 and 33 to remedy.

I sent out procedure on previous log.

 

Talked with R Russell about Hoky wheel and hub press.  Ordered 2 hand tie down and pilot operated valve for new station.  Also ordered alum tabletop.

 

Working on setting up Vendor for Robot EOAT quick change plates.  I tested the orings on the dovetail slide and they held at 80psi.

 

Filled out PR for Rapid Grinder components destroyed by grinding hot runners.  It was rejected at this time due to lack of funds.

 

Ordered, received, installed new hooks and shackles for robot chain slings.  They are located in the bottom of the gray cabinet in the shop labled Large Hand Tools.

 

Ordered fittings and bolt kit for core valve install on MP23. 

 

Ordered and received Asco valves for Thermolators.  They are located in MRO on the RH shelves above the alum load system fittings.

 

Started replacing the adjustable stop screws with winged handles on MP23 Robot.  Some bolt hole patterns were to close for 2 handles.  I will check with HIro for some different stops.  More handles with longer bolts and metal handle are on order.

 

Any questions just give me a call,

 

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

 

MP21 Toshiba ISE250N Procedure to Make Screw Return to Full Back Position

MP21 (TOSHIBA ISE250N) Screw Back Position Correction

 

1)   With the power on, open the Main Control Cabinet Doors,

 

2)       On the inside of the LH door, locate a blue tuning pot, with the numbers 0-9,

it is extreme upper LH side of injection control board under a terminal strip, dial the

pot to the #1 position.

 

3)       Under the blue tuning pot, locate and depress, a push button labeled “3SW”.

 

4)       Now, over on the Data Cell Display, punch in code 32 and change the value to 1.0 or .5

Record the original value.

 

5)      Now punch in code 33 and change the value to 40.  Record the original value.

Make sure the value you enter are retained.

 

6)      Turn the tuning pot back to the “0” position.

 

7)  Depress the “3SW” push button.  You are finished.

 

Original Values on July 14, 2010 were Code 32 = 4.0 and Code 33 = 16.

 

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

 

7.12.10 D shift

Worked on liquid color pumps that were left on the cart in the shop. Repaired one of them.
One needs a new wheel for the color tube pump.
The other two are probably not worth repairing as they likely have been dropped really hard.
One of them had the tranformer knocked completely from the board.
The other has a short somewhere in the board and also has a bad shaft on the gear housing.
I red tagged them accordingly.

Also worked on water strainers and drained water from some of the water traps that you could see water standing in.

We had some trouble with EOAT on presses #22 and #4 but just parts coming loose.

Left at 4 a.m.

Call if there are any questions or anything I can do to help.

Sean

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