Last Post for Oreck

Hello Team.
Since I was laid off on the 16th this week, this will be my last post for Oreck.

I just want everyone to know that I really enjoyed working with everyone. It was a very nice experience to work with such a professional group of maintenance and tooling folks. I have come away with a new perspective on ways to accomplish things in the molding business thanks to all of you.
This is not a goodbye, as we will hopefully remain in contact in the future as associates and friends.
I would say best of luck to you all, but, as we all know, luck has nothing to with it! So best of fortune to you and may God smile upon you all!

Stay in touch,

Sean Kearns

6.27.12 Sean kearns

Mp#25- PM'd robot, replaced sheared screws from the crosswise travel. This appears to be a situation where the machine and robot were set-up incorrectly causing damage.

Mp#10- The nut press was not pressing the square nut on the LH side in all the way. I welded on more metal to the pusher block and replaced the cyclinder that presses in that nut. That seemed to be the problem.

Have a nice day!

Sean

6.26.12 Sean Kearns

Mp#3- removed tramp metal from the nozzle tip...looked like an axle from a baseplate?

Mp#5- had some issue with tonnage not building. Potentiometer was reading correctly but I tried some offset changes with no luck. Then when I put the value back to where it originally was, it started working again.

Mp#6- PM robot and machine. The robot Z axis belt was off track and had started wearing on the belt. I set the tracking back to center.

Mp#25 robot- Bolts are broken on the crosswise travel bracket again.?! When it goes down again they will need to be replaced..

Worked on ANSI stuff on #15. Installed the purge sheild interupt relay for screw rotate. Works fine. Still need to do the Robot/IMM estop interlock. I made the note in the folder.

Have a good day.

Sean

6.7.12 Sean Kearns

Mp#10- Put the jumper on wire no.224. That cleared the problem with the cores not working- after I removed the jumper and turned cores back on.
I do not know why, but evidently 224 needs to be jumpered on that press with 69 -vdc.
The ejctors were still acting eratic and the mold would not close so I put the jumper back in for the ejector back switch and the problem went away. He pulled out the mold and I worked everything just fine with the mold out so evidently there is a problem with the ejector back switch, or he has the knockouts too loose to make the switch.?

Mp#11- started working on the circuit changes for it. I installed the 120 and 210 relays, verified the wiring on the robot/IMM interface plug. The next thing I have to do is change the wiring for the door switches, and E-stop circuit. I did not have time to get into that before they want to run it on days Friday so that is where I am with that.

Mp#25- put the belt back on the small conveyor and tracked it so it was not riding towards the loose side.

I left a PTO form for the floating holiday I have to use this month Josh.

Have a nice day.

Sean

6.5.12 Sean Kearns

Mp#8- Finished tying in the robot e-stop with the machine per circuit changes outlined in the folder. Checked operation, O.K. to run.

Mp#10- Started making changes to circuit. I installed the relays and some wiring, but haven't cut into anything yet. Will continue tomorrow. We are running low of the 16-18 gage insulated terminal spade connectors. I have been using them with these circuit changes. May want to pick up some more, about 200 each. I have some red ones in the project box to go by.

Mp#12- The Eagle Fan Tester fixture was not sealing enough to pass the test. Replaced the O-rings and checked operation, O.K. to run. With the operators testing 8 parts per shift, I am not sure what the life expectancy is on them? We ma need to include a sign on the fixture to advise them to change o-rings if they suspect problems.

Mike and I looked at the leak on MP#3 at the end of my shift and we found the hose leaking under the manifold needs the o-ring replaced as well.

I also broke the porta-power cylinder fitting. Not sure where to get these, may want to check with A&H hydraulics? I will research that more tomorrow and submit something.

Have a nice day.

Sean

6.3.12 Sean Kearns

Mp#8- Wired in the safety gate and purge sheild relays per ANSI drawings. It is not complete as remaining work to robot E-stop needs completed.

Replaced the pump seal in the thermolator that was in the shop. tagged and put it back on the shop floor. I will return the welder to storage tomorrow.

Cleaned up the oil under 3, will keep an eye on it further.

Have a nice day!

Sean

5.29.12 Sean Kearns

Worked on the welder on press #10.
After I cut the slot in the old horn, I had trouble getting everything to line up correctly, when I did manage to get it to line up, it was not welding decent at all.
Mike is going to try to get it going now.

5.23.12 Sean Kearns

The Dryer on MP#8 keeps stopping for no apparent reason and will not restart on its own. Mitch just told me about it at 6 this morning so I passed it on to Ronnie. Mitch asked if there is a way to add an audible alarm to alert when it shuts down.?

Mp#26- I started working on a gate trimming fixture for that wheel # . I would like to have a lawn mower wheel/tire to use on it but I am open to suggestions. I will try to have it further along tomorrow to get some feedback from Josh about it.

The Mold setter asked me about obtaining (10) more mold pallets for the tool storage area to complete his organizing project. I told him I would pass this information up to you Josh.

On press #24- they are running the end cards for the brushrolls #77020-02/77021-02 where they need to use the adhesive sandpaper discs to clean up the gate area on the parts. They have no more #200 grit sandpaper so I mentioned that I would pass this up also. It comes on a roll 6" diameter.

Have a nice day!

5.21.12 Sean Kearns

Mp#15- Completed the ANSI audits, all machine have been inspected at this point. Let me know when you want to start proceeding with circuit changes, etc. I will watch for the presses to be down.

Mp#7- They are running the R2 baseplate subassembly there today and the feedback I am getting relates to a desire to have the light curtains installed and the press set up to run similar to the baseplate press on #6.
The job runs at 76 seconds now, which is kind of long, but the operators have to keep their fingers in the anti-tie down switches for the duration of the cycle (safety issue) which takes approx 7 seconds with each part  x 2 cavs =14 seconds each cycle.
This may be as fast as they can run it under the circumstances? Not sure.
It may be a legitimate claim to ask for this modification, I just don't know if it justifies the expense?
I wanted to pass this on to you Josh and see what you think.

Shift change again. The 5 weeks trial is over after this week. Mike and I texted last night and he is ready to come back after memorial day on  Wednesday.

He is taking off Friday and Tuesday and will return to 3rd's after that. Tonight the dryers were not set on timers and we had wet material on a few hoppers. Evidently he was out last Friday and no one set the timers so this needs to be looked at this week again. I can set them if no one else is going to. Let me know.

I will go back on 2nd's Tuesday evening as scheduled.

Have a nice day!

Sean

5.11.12 -Sean Kearns

Did not get to work on the T-nuts tonight because:

Mp#1- screw problems. Machine was sucking back an inch before running the extruder motor. This was causing splay. I removed the panels and cleaned and regreased the ball screws and extruder. The decompression velocity was set to zero, in my experience if you at least put something on it, it tends to work. We had a problem once before where this was zero and putting a value in there fixed it. Should be ready to go, they did not want to run it the rest of our shift so keep an eye on it.

Mp#10- Nut press was acting sluggish. Cleaned, refilled the FRL oil. Started working good, no further problems this shift, may have a cylinder going bad. Keep an ear out for this.

Cleaned up some oil on #3 and plugged the remainder of holes.

Give a hollar if you have any questions. Have a great day!

Sean

5.10.12 Sean Kearns

MP#10- Completed the ANSI audit.
MP#12- Completed the ANSI audit.
Mp#6- Replaced the regulator for the robot.
MP#3- Removed the hydraulic lines in preparation for pump removal.

Have a nice day!

Call if you have any questions!

Sean

5.7.12 Sean Kearns

Mp#14- I heard the extruder motor is likely shot? That a new press may be in our sights if we can find one for the right $?

Mp#10- The nut press was having some issues getting the left side to fit in correctly to where the sensor would read it. I dug out some nuts from up under the back stop and they fit better. It may still need some final finishing when they are not running it. It works if the operator will "work" with it some.

Mp#3- Completed the ANSI audit. I also had to go back over some of the purge sheild signs and re-fasten them with rivets. I will get to them all if I have enough rivets.

DR12 - A wire had come loose from the process heater contactor causing it not to heat correctly.
Put it back and checked operation, O.K. to run now.

I will continue working on the audits tomorrow and try to get them done this week!
*Only 10, 12, 14?, 15, 20, 21, 25, and 26 remain to be audited.

Have a very nice day!

Sean

5.3.12 Sean Kearns

Mp#14- Extruder problem. Intermittently stopping or turning too slow to recover shot size. They said that if they ran ABS material through the machine, it would not do this, only when the glass filled nylon was in it would it do this. I checked the extruder oil level and it appeared to be low. I added about a quart and a half to it.There was 1500 psi on the gage when it would mess up, when it was running fine it would operate around 700 psi. I separated the screw from the extruder and ran it at high speed for about 5 minutes to allow any crap in the lines or valves to flush out. I also checked to feel if the screw would turn by hand and it turned relatively easy. I reassembled and checked operation, it ran fine for 20 minutes then they shut it back down to run later.

Mp#10- repaired EOAT where some screws had come loose.

Mp#1- Replaced grease in lubricator tube.

Sean

5.2.12 Sean Kearns

MP#17 Core Pump- Over Heating
When I came in it was out of the range of the thermometer so we shut it down to cool.
I placed a fan on it and wrapped it in a coil of water hose and pumped chilled water through it.
It came down to 120*F and we restarted it. I let it idle for about 30 minutes and it did not heat up at all. We then ran it for 5 hours until it reached 150*F. Then we shut it down again. Mike had already adjusted the compansator all the way out on it. After looking at it, I did not see a secondary relief valve for it on the valve stack. Everything I have read about systems overheating indicates that there are usually two relief valves used. The other thing I noticed was that the output stays on core set during most of the cycle loading the pump for 30 seconds each shot. I think that this is where the relief valve either needs to be added to it or the compensator adjusted correctly. When it cools down I will try to adjust it.

MP#15- Moving platen holes stripped out. Drilled and tapped 8 holes from 5/8-11 to 3/4-10.
It needs to be noted that I am beginning to see a trend of holes getting damaged in the smaller presses lately. Maybe we could get Jerome and the team leaders involved to identify some of the reasons this is happening and work out some solutions to prevent damage. Example: MP#13 had very good holes in it until last Friday when one of the clamps fell off during a run because it was set with too short of a bolt in it. It totally destroyed the threads when it ripped out. That hole will now have to be oversized.

Give me a call if there are any questions.

Sean

4.31.12 Sean Kearns

MP#5 Robot- Mike evidently found a loose connection somewhere as the communication problem went away by the time I came in.

Mp#2- Replaced a blown fuse on the 24v4 circuit. They must have smashed a wire when the tool was set on 2nd shift? GMA-5A

Mp#16- Moving -platen has a thread hole damaged on the operator side, needs repaired when down.

Mp#17- Cores were not working on the mold. Both core switches were reading made all the time.
Checked it out and found that the jumpers were still in for core 1. Looked at what was done and already and tied the rest of it together. Wired switches for core 2 inputs, wired control switch in operator panel for core 2, removed necessary jumpers, checked operation. Put a core 2 legend on tghe front of the op station for techs to be advised.

Continued installing safety signs. Need some to put on the R2 fascia label station. I don't know where Mark got the ones for the classic fascia label station?

Have a nice day!

Sean

4.26.12 Sean Kearns

Mp#8- Installed new feed-throat coolant lines. Removed old infrastructure and installed new hoses with isolation valves. Checked for leaks...O.K. to run.

Gil has a tool with a leaking seal in the shop, it has a 20mm shaft, it appears to be Chinese manufacture. I will speak to Henry Yap when I come in about getting a seal replacement to make the repair.

I am moving to 3rd shift beginning Sunday night and Mike Daniels will be moving to 2nd shift on Monday temporarily for 5 weeks for cross training purposes.

Did anyone hear where management decided to have the company picnic this year?

Give me a call if there are any questions, have  a great weekend team!

Sean

4.25.12 Sean Kearns

Mp#4- The error 39 fatal alarm problem has occurred and will not seem to clear after powering down the controls. I shut it down at the disconnect and advised Roger and Marty to leave it down until Josh can contact Milacron in the morning.

Mp#16- Did the ANSI Safety audit on the press.
Need to obtain a sled seal kit for it also, it is leaking.

Give me a call if there are any questions.

Sean

4.23.12 Sean Kearns

Mp#25- F1 Fan -To Set up the press to run the product distinction system: Set "M1" when the press is in automatic and has finished delivering the (*2)forced rejects to the scrap box. Just push "F1" and it will begin flashing "ON". Do not press enter, just let it flash. After a shot it will remain in "ON". When you are ready to read a sample from a "good" cycle, then press "F2", it will also flash until it has "registered" a good cycle. Then it will remain "ON" as well. Adjust the "M1" value to read just below the "INJ END POSITION" of the "good" part cycle and the "M2"value should be just above it.

We tested the process by allowing the cushion to deviate below the "M1" value by lowering the shot size. It gave an indication of the fault and then delivered the faulty parts to the scrap drop. After the (*6) consecutive shots determined to be bad, it will stop the press and alarm. If the nozzle freezes off and the inj end position goes above the "M2" value, it will also fault and deliver them to scrap drop.

Have a nice day!

Sean

4.12.12- Sean Kearns

Mp#12- F1 fan testing station...the inflatable bladder that seals off the fan cavity is worn and likely needs replaced. I could not locate any replacements for it. Order one please.

Mp#7- Replaced one heater band and the contactor for zone #2. It blew the main breaker on the machine. Also found welded contact on the old contactor. Replaced with the SSR type. Checked operation, O.K. to run.

Mp#22- The pendant was not working correctly because it had a piece of broken plastic inside the touch screen area. I took it apart and removed the plastic,  and reassembled pendant, it started working correctly then.
Also repaired broken wires to conveyor/label station, plug had been ripped loose accidentally.

Continuing with ANSI Safety Audits on the presses. I will be off next week but I am leaving the audits in Josh's organizer on his desk.

MP#24- Worked on the "5220" Alarm where the motor stop circuit was activating at the screw rotate part of the sequence,for unknown reasons. Replaced the coils on the screw rotate, and sled forward valve outputs, replaced the relay for the motor start circuit and the emergency stop circuit, and replaced the relay in the power supply inside the cabinet. We think the power supply relay or the sled forward coil may have been the culprit as it was the last things I did to it and the problem has apparently subsided for now?...Unless Mike worked on it last night and did not mention what he found?

Mp#23 Robot- Removed the vertical arm and re-placed and tightened the mounting screws with loctite.

Have a great day.

Sean

4.2.12 Sean Kearns

MP#10- Connector Welder had some problems last night with the deflector radius area not welding very well.
Operator found that they could push up from inside and lift the radius area up and see thru it, while it was still passing the torque test as good.
I made a plate with jack screws to support the part around the cord dump area from underneath. It is working better and the parts cannot be pushed up as before.

Continued working on the F-1 cavity separator.

See you tomorrow- except Mark.

Sean