9.30.10 Sean

Mp#2- Smashed core wires twice. They have been tied up as neatly as possible to prevent further problems.

Got called into the assembly area to assist with helping the girl get the programming software working for the stepper drivers in the lab. ?

Mp#1- baseplate press stopped operating. Found sensor loose on the shuttle forward position.

Mp#21- while doing the PM I found the press had no control power. Looking further, it seems that the power from the disconnect on the bus was 100 volts short on the brown leg?
Mark and Gary are investigating that further now.

Have a portable hopper loader receptacle that is broken, may need to either order a replacement receptacle or rewire with something else on both ends.

Worked on PM's the rest of the time in between activities.

Call if there are any questions. have a great weekend.

Sean

9.29.10 Sean

Mp#5- They had a problem with the cores not working at all.
I went through replacing hoses and checking with the test cylinder and still was not working. Put gages on and had pressure at valve, but not at cylinders.
They would work when i probed valve m,anually.
Then I checked voltages at coils and had none on the set side.
At this point neither core 1 or core 2 were working but I was focusing on #1 for now.
Then I noticed that the output menu 41 slot 6 would energize 2 outputs when trying core 1, but the card was only lighting up the led for pressure and not the set output.
I tried swapping the card and then both sets of cores started working.
I suspected that there was a problem with the output card that I had moved to slot 8 so I left it down until we could find another one.
Ronnie mentioned that they had worked on it today but was not real sure what was done to get it going again.
I would like to know what you found?

Also had the problem with the Chilled water supply being dirty, in which I discovered, after speaking with Ronnie colson, that there is no filtration on the Chilled water system.? I temporarily bypassed the pressure switches on the Thermolators pumping chilled water until the problem is resolved and we have taken the corrective actions.

Call if there are any questions. Enjoy your evening!

Sean.

Ronnie Upchurch

MP-15  Oil leak.  I am ordering a new pump seal for this one.

 

We were having problems with thermolators cutting off on MP-2 & 3. ( chiller supply )  The flow & temp looked OK.  In tooling the EDM was over heating.

     they bled the line & got quite a bit of air & rusty water out. After that, the thermolators straightened out. There must have been an air lock.

     Ronnie Coleson was notified.

 

I installed the new overload on MP-5. They will hang the base plate back in.

 

If the hydraulic oil doesn’t come in today, I’ll call them in the morning.   

Mike Daniels-B Shift

Good morning Gents,

 

Typical night in molding no major problems. Mp2 has a issue with the core switches, the i/o page shows they are set when they are and pulled when they are but when put in cycle clamp moves about 6in. then stops and reads core 1 not pulled when it is. We ran it on timers  with no problems.

Repaired 3 more trollies

Replaced prox switch on fixture on mp10

Replaced blown nozzle heat fuse on mp2

 

Have a great day

Gone Fishin

 Mike

Sept 28, 2010

MP5 keeps tripping overload on pump.  A complete contactor and overload should be here Wed. UPS Red.

They moved the baseplate mold to #1.

 

Lexan sheets came in today.  Been trying to replace broken panels in trolleys as I can, if you pick up where I left off, measure each one individually as there are slight differences between them.

 

 

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

 

9.26.10 D-shift Weekend

Stripped equipment Friday. Reassembled the grinder on Saturday.
Worked on PM's Sunday. Turned in some work orders for some of the issues we had.
There was a problem with #4 that had to do with frayed core wire and a blown fuse.
We cleaned out all the water strainers on all the presses this morning.
I have noticed that the moisture in the air system seems to have been resolved.

I will be coming in on Wednesday at 10a.m. for Forklift refresher training. Afterwards I will see whats going on with our PM program. call if there are any questions.

Have a great day!

Sean

Ronnie Upchurch

One of the bucket tumblers quit working. I just had to tighten the belt. I asked Elaine to order two more motors for the two spare tumblers. I put them

       in the trailer for now.

 

MP-7  The bolts vibrated loose & the deflector fell in the grinder. I cleaned it out & restarted it. It still needs a new deflector.

 

MP-2  I hooked up the cores to the eject circuit for them. Also replaced a broken core switch on the stationary side. One of the mold heater plug pins was pushed in

        & not making contact; repaired.

 

MP-6  The clamp wouldn’t close. I tried probing the valve, no luck. When I opened the cabinet to check the input & restarted the pump, it started working.

 

I worked on stripping & scrapping equipment in shop. I cleaned out the cabinet in the bone yard.

 

I finished up on the grinder that Sean put back together. We put it back in service Sunday.

 

Cleaned up oil on 17 & 21.

 

I put the gaylord of spare parts in the trailer.

 

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.