Ronnie Upchurch

MP-2  Nozzle heaters quit working. Found blown fuse & shorted wire on front band. The blown fuse was 20amp -  should be 15amp -  Replaced

          with correct fuse.

 

MP-15  The chuck was closing before it reached the sprue. Changing the timer or mode didn’t work. I found that when I removed the air exhaust

       muffler, It worked fine. I tried to clean it & reinstall it, but didn’t work, so I left it off.

 

MP-4  We still have a leak at the top of the eject. pump. It looks to be coming from the bottom of the block where the boss fitting ties in. If they  don’t

       shut it down in the next two days, I’ll get it when I get back Friday.

 

I’ve been bleeding a lot of water out of the air lines today; loaders, robots, & support equip.

 

I started vacuuming oil pans – MP-4 -6 & 7.

 

The chiller temp. started climbing again. 70 degrees in the shop. The temp. was set at 48, but actual was 57. I called Ronnie C. & he said he would

      come out & start the other chiller.

Ronnie Upchurch

I worked with Mark some in MRO, sorting parts that were stored in gaylords.

 

Mezzanine – DR-1 had two bad regin. heaters. Replaced.

 

Mezzanine -  DR-32  The turntable got in a bind because the limit switch was adjusted too tight against it. One of the motor gears stripped out &

              two teeth on the bed gear broke off. I replaced the motor. We had to order another bed gear. I swapped the dryer out on the mezzanine.

 

Mark replaced the nozzle heater on MP-13.

 

MP-17  Oil on the floor & the jug was full “ Again .“  Cleaned up.

 

New  hydraulic fluid has been ordered.

9.20.10 D-Shift

Matsui dryer not heating up to process temp.

The control does not appear to be outputting any contactor signal.

I am going to look at it again this evening to try and be sure that everything other than the controller is working alright. I suspect that there could be an input such as a switch or sensor causing the control not to output.?

I organized the machine and equipment manuals and labelled everything as well as possible. Maybe we can keep it this way?

Next problem is Brelands' encroaching desk area!

I could have made some mistakes in identifying presses with particular manuals so if anyone finds something wrong let me know or pencil it in and we can have some form to our function! I followed the asset list by serial number and old press number before labelling them. They are separated by machine brand, (i.e. Nissei, Milacron, and Toshiba, etc.)

Call if you have any questions, have a great day!

Sean

Mike Daniels-B Shift

Good morning,

Just a few issues last night

Replaced 4 nozzle bands on mp20 due to bleed off. Apparently it ripped wires from bands when sled was backed off.

Replace lexan in 2 buggys from junk yard and placed them in molding

Replaced a e-stop switch on grinder at mp6.ginder wouldn’t run

A core wire on mp2 got cut and shorted out blowing a fuse.

Swept the shop.

 

Have a Great Day

Mike

Mike Daniels-B Shift

Good morning all,

 

Quiet night no major problems on molding floor. I put the new control in matsui drier, its still in shop I let it run for around an hr or so with no problems so I green tagged it.

 

Have a great day

Mike

 

9.16.10 D shift continued.

Also, thought you might like to know that Marty informed me that he and Darryl might be trading shifts per Wayne's decision.??

9.16.10 D shift

Mp#8 - Mixer was leaking material from cylinder not shutting off flow from hopper.
Lubricated the cylinder and had no other problems with it.
May have to replace the cylinder (one on the back side) if there are any other problems.

Repaired one of the small conveyors.

Stripped major components from that dryer and put the rest of it in the scrap metal hopper.

Put one of the slow speed grinders back into circulation.

Added a task to the task list for the DME boxes, per Mark.

Cleaned up in the shop, took out trash and cardboard, swept, and picked up behind the metal shear in the shop.

Call if there are any questions.

Sean

Ronnie Upchurch

 MP-16   Dryer  D-9 Temp. probe alarm.  They were running it at 250 & the High limit was at 200. Reset- OK.

 

Loader #6 on mezzanine not loading. The loader flap was stuck & not making the switch.

 

MP- Lube cycle alarm. Reset the counter & installed a new tube of grease.

 

MP-The boss fitting on the top inj. pump line was leaking. I took the line & fitting off ; the o-ring was cut. Mark had to go to IR-G to get

       the right o-ring. He reinstalled it – looks good.

 

MP-9  The  C- axis on the robot wasn’t working. I found a cracked air fitting at the solenoid. Also the coil piston was gummed up.Cleaned &

          reinstalled – Working good.

9.15.10 D shift

Mp#10-Robot- Stopping infrequently over the belt after part delivery.
Restarts fine, then runs for a few hours until it does it again. Has not stopped in awhile, they want to keep running it.

Moved everything out of the trailer out back and staged it to the left of the dock per Josh. Should be easy to sort and move now.

Put all of the items tagged for "shop" or to "strip" in the shop. Also Ronnie and I put the grinder from the bunker back in the shop and put the little one that was in the shop to the bunker.

Removed all of the Yushin pickers from the machines and located them in the staging area as well.

Mp#6- replaced nozzle heater band and repaired wiring from blow back.

Cleaned up the oil from #17 again.

Cleared the lubrication alarm on MP#1 also.

Swept up in the shop.

Call if there are any questions!

Sean

Mike Daniels-B Shift

Good morning,

 

Fairly peaceful night, minor adjustment on nippers on the fixture on press 3.

Tried to calibrate gravity loader on the dryer that is behind press 8 it still not acting right

Removed another small nozzle leak from press 15 no damage only down couple minutes.

 

Have good day

Mike

9.13.10 D shift weekend

Worked on Pm's for machines.
Started putting the core 2 stuff on 23.
Helped with processing some this weekend, we were short 1 tech.
Worked on the nut press cleaning the phosphate build up out of the tracks.

We need to order some repair parts to get some of our DME boxes back up and going again. a few have collected in the shop as well as some cards.
It would be nice if the techs could tag them with a brief description of what has been wrong with each card?

The weekend went relatively well.

Call if there are any questions. Have a great day.

Sean

Josh A Shift 09/09/2010

Hello All,

They finally released some funds to order parts to repair one of the two grinders we still have tore down.  I chose the bigger one and ordered the parts for it today.  I’ll order the parts to repair the little Solo grinder next month.

Also, I’m got approval to do a CER tomorrow for two New Grinders specified for Pelethane (Santoprene).  I chose to go with AEC because they have recently purchased Cumberland and Nelmor which are both good brands.  I sent them a box of our runners to heat up and do grinding trials on.  Rapid makes a good grinder, but I just guess the cheap ones Hank bought have left a bad taste in my mouth.

Attached are the specs and quote so that everyone can check it out.

 

Thanks

 

  Joshua Ledbetter

  Molding Maintenance Manager

  Manufacturing Engineer

  Oreck Manufacturing Company

  931-239-3235

 

Mike Daniels-B Shift

Good morning, 

                       

 I helped Gary replace dump cylinder on pump#1 on mezz. It was sticking at start of shift. Went ahead and replaced the cylinders on pumps #2,3,4 and 5(per josh) found that the flange on pump 3 was cracked bad. I called Josh to see if we had a replacement,(we didn’t) so I tig welded it back together and Josh and I put it back together. Probably down 2hrs. Other than that fairly peaceful night in molding.

 

Have a great day.

Ronnie Upchurch

MP-20  Nozzle adapter heater band was bad---- replaced.

 

MP-25  The cores were backwards.  Normally the core cylinder is fixed & the shaft moves ;  on the hokey handle mold the cylinder moves , so the

            set & pull lines hook up backwards.

 

MP-25  Replaced the motor overload on the grinder.

 

MP-2  The rear zone heater - mercury contactor blew up. Mark & I  contacted Walter Marcum. We cleaned out the cabinet & disposed of the mercury

          In the drum in the recycle room. Installed a new contactor.

  

9.2.10 D shift

Mp#2 Grinder- It was overfilled with material and clogged up almost to the point of meltdown. We unclogged it and cleaned it out reset the breaker and tightened up the E-stop switch. Put back in use.

This occurred at 6:05 pm and had to have been clogged for at least a half an hour earlier on C shift, before our shift began.

This would make a good action item for September!

Vibratory Welder- Did a full P.M. on it. Tightened up door limit switches, brackets, and checked out hydraulic unit. greased the linear rails and inspected for anything loose. Relabelled tubing and Mark and I reset the adjustments on the laser range sensors.

Repaired leaking core fittings on the single cavity top cover tool in #11.

Continued with PM program, lubed tie bars and refilled reservoirs, checked for damged lines etc.

Have a good weekend.

Sean

9.01.10 D shift

Mp#4- Built EOAT for Edge Baseplate. Got it running, had to adjust Core pressures and flow controls. Was operating below 5oopsi. Now around 1600psi.

Mp#15- did PM on sprue picker. Repaired stripped out screw on advance stroke adjustment plate. Greased and inspected.

Repaired broken lube line on non-op side platen skate. replaced the nylon tubing with a piece of aluminum tubing. Hopefully it will last longer this time.

Chaged out EOAT on #11 for the Edge Top-cover core.

Set-up robot on press #23 for top cover single cavity tool.

Mostly helped process techs tonight, as we had one leave early in the shift for personal issues so we were short handed.

Will continue P.M. program tonight. Need to look into a way of tracking which ones are getting done so that we do not miss any.

Call if there are any questions.

Sean

August 30, 2010

Upgraded robot displays with speed control adjust on MP3, 8, 9, 10, and 11 today.

 

Ran chiller water to the dryer behind MP8 off the machine manifold and hung a sign on the ball valves, not to shut off unless machine pump and dryer are shutdown first.

 

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    931.646.7615

 

Test for Mike Daniels

Test

8.29.10 D-shift

Mp#5- Stopped once at 6:30pm, the back door had come ajar. Locked it closed. No further problems with it. Ran all night fine.

Mp#1-
Removed all of the panels from the press and thoroughly cleaned them and inspected all of the lubrication joints. Many were hand loose. Went over all of them with a wrench. All of the lines are in satisfactory working condition. The ones on top of the moving platen have obviously been stepped on a few times but are secure and intact.


Inspected the servo drive belts and mounting brackets on all of the drives including the clamp. They had no cracks or signs of needing replacement yet, other than the extruder belt which I noticed had some damage when I put the barrel back together. It is running very close to the flange on the drive pulley. The problem is that there is not any obvious way to attempt to adjust the "Tracking" or "center" the belt. It only has a tensioning screw. Shimming it might cause it to run back but then there would be the risk of it running back againt the servo motor.
Because of that, I made no adjustment to it without getting more feedback first, it may have came in like that?
.

I went through the list of items this weekend and had some questions as to where the Asset tags needed to go and which presses to put them on so if you can refresh me on that I will try to get those mounted Wednesday when I return.

the Hot stamp press that Ronnie worked on stayed on all night so it should be ready to use again. The heats did not go off.

Also wanted to get more input on the EOAT bench needed for the EOAT area before fabricating. There is a cart there now, did you want to make it portable? Should I check with Wayne? Was that his idea? ...Just Kidding.

Call if you have any questions.

Sean

" C " Shift - Weekend

MP-20  The cycle start timer wasn’t working. We saw input 14 on the plc flickering. Mark traced the wire & found a loose connection in the robot wiring.

 

MP-5 Added hydraulic fluid.

 

MP-2 & 6   PMed.

 

MP-20  Mold # 77015 – The DME heater plug on the mold had a broke pin – zone 6. I replaced the plug. The wires were short in the box so I had to add another splice in       the wiring.  I’ll have tooling let me

               know  when  the mold comes back & I’ll fix it right.

 

MP-5  Pump motor overload tripped. Injection valve – off  fault.  Mark said the pack time was  set too high.  He lowered the time & it hasn’t stopped again.

 

MP-3  Zone 3 barrel temp was running away. The mercury contact was stuck- replaced it.

 

I worked on the bag clip hot stamp. The heat kept dropping out. I found a loose solder connection on the board. I re- soldered it & I have been trying it out

      In the shop. So far I hasn’t cut off.

 

 

 

   R. Upchurch