Line All Casting Die Cast
Equipment Name All DC Robot 1 DC Robot 2 DC Robot 3 DC Robot 4 DC Robot 5 DC Robot 6 DC Robot 7 DC Robot 8 DC Robot 9 DIE 5A2 Breather Cover F-1 DIE Water Passage F-1 DIE Water Passage F-2 DIE Water Passage F-4 Die Cast 1 Die Cast 10 Die Cast 2 Die Cast 3 Die Cast 4 Die Cast 5 Die Cast 6 Die Cast 7 Die Cast 8 Die Cast 9 Diemaint 5A2 Diemaint AP4 Diemaint RNA Diemaint RPY / 59B
Failure Location All Brake DC Robot 1 DC Robot 2 DC Robot 3 DC Robot 4 DC Robot 5 DC Robot 6 DC Robot 7 DC Robot 8 DC Robot 9 DIE 5A2 Breather Cover F-1 DIE Water Passage F-1 DIE Water Passage F-2 DIE Water Passage F-4 Die Cast 1 Die Cast 10 Die Cast 2 Die Cast 3 Die Cast 4 Die Cast 5 Die Cast 6 Die Cast 7 Die Cast 8 Die Cast 9 Diemaint 5A2 Diemaint AP4 Diemaint RNA Diemaint RPY / 59B PLC
Failure Phenomenon All "ALARM" FILTER CLOGGED, REPLACED "Holding" ONLY Crucible filter Broke "NON INVENTORY " PLUNGER TIP "NON INVENTORY VACUUM BLOCK" "NON INVNETORY EXHAUST FILTER BAUSH" "Shot position sensor/wiring broken" alarm. "non inventory filt-0073" "shot sensor broken wire alarm." # 4 Die Cast is out for furnace rebuild so Chuck Winters and I are installing a non inventory ladle arm unit. #1 scrap conveyor motor overload #2 having some ladle issues from previous shift when ladle comes out of machine it bounces causing ladle bar malfuntions. #3 flipper Assembly worn allowing parts to drop to NG when good. #30C Hepa filter reading high in the red. Replace Hepa filter. Now OK #4 TAPPET PIN LEAKING, REPLACE HYDRAULIC HOSE #4 machine blew a hydraulic flex hose that was a modification #4 squeeze pin bent. Replace #4 squeeze pin and bushing. #5 CHUCK (1) crushed parts in trim press from chill block trees sticking on 1st and 2nd shift and still happening on 3rd shift. (2) this machine has been getting high shot speed alarms on all three shifts and (1) hydraulic leak under plunger unit behind crucible. (2) Started leaking again just a small drip now from a different spot. (1) robot fault at helper door. SVO-046 OVC alarm (group 1 axis 5)....(2) fault later occurred again at water tank. (Forgot to clock in after starting work order. actual time 3 hours) robot positions off at die, trim press, and scrap press. Also R/B chuck fingers would not grab biscuit.
3rd shift machine start up. (No downtime m/c scheduled down for PM)
What: Leak detect not working for lower crucible
R/C: Connecting rods for leak detect failed
C/M: replaced connecting rods for leak detect with new and tested (WHAT)- Ladel arm wouldn't move.
(WHY)- broken wires.
(COUNTER MEASURE)- put new copper terminals on ladel arm wires.
(RE-OCURRENCE)- no (WHAT)- NOT GETTING DIE RELEASE.
(WHY)- PUMP WENT BAD.
(COUNTER MEASURE)- CHANGED SPRAY UNIT PUMP.
(RE-OCURRENCE)- NO (WHAT)- PLUNGER ROD WOULDNT MOVE.
(WHY)- SCRAP IN SLEEVE.
(COUNTER MEASURE)- CLEANED SLEEVE, TOOK ROD OUT RAN CYLINDER IN AND OUT, (OK).
(RE-OCURRENCE)- YES (WHAT)- SHOT DETECT SENSOR BROKEN WIRE.
(WHY)- UNKNOWN, SCRAP BUILD UP?
(COUNTER MEASURE)- CHECKED WIRES, CLEANED BLOW-BACK AWAY.
(RE-OCCURRENCE)- YES (WHAT)- SQUEEZE MASTER TRIPPING HYDRAULIC PUMP.
(WHY)- ? START-UP
(COUNTER MEASURE)- RESET MOTOR STARTER.
(RE-OCURRENCE)- (WHAT)- robot crashing at trim press.
(WHY)- shots sticking to die.
(COUNTER MEASURE)- made biscuit size larger, confirmed spray cartridge, adjusted robot going into trim press.
(RE-OCURRENCE)- NO (WHAT)-SCRAP PARTS GOING INTO OK CONVEYOR FROM TRIM PRESS.
(WHY)- FLIPPER 1 WASNT WORKING. BARRELL NUT CONNECTING CYLINDER TO ROD CAME OFF.
(COUNTER MEASURE)- CONNECTED BARRELL NUT TO CYLINDER AND ROD (what)- air leak
(why)- bad air bowl
(counter measure)-changed air bowl (what)- cracked slide core, s1
(why)- unknown, spec issues
(counter measure)- changed slide core s1
(re-occurrence)- yes (what)- flipper on scrap conveyor not shifting
(why)- air lines on valve was backwards, sensors on cylinder lose (swapped around) weight on scale not set
(counter measure)- set weight on scale, switch (what)- ok conveyor not working
(why)- chain jumped on one side making it uneven
(counter measure)- evened chain out and tightened (what)- part detect errors.
(why)- robot positions on part detect sensor were off.
(counter measure)- taught positions 22,23,29,30,and 33.
(re-occurrence)- unknown (what)- robot side door issues
(why)- roller bent top back
(counter measure)- took roller off straighten roller bracket (what)- shot coming out back side of sleeve
(why)- wear shot life 145293
(counter measure)- changed tip and sleeve (what)- slide core s2 5ba leaking
(why)- unknown
(counter measure)- changed slide core s2 (what)- slide cores broke
(why)- unknown, out of spec
(counter measure)- changed op/top p and hp/top s
(re-occurrence)- yes (what)- spec issues
(why)- slide core broke
(counter measure)- change slide core operator bottom s2
(re-occurrence)- yes in time (what)- spray cartridge leaning
(why)- bolts holds main beam assy. 3 out of 4 broke
(counter measure)- drilled out old bolts put in new
(re-occurrence)- unknown (what)- trim issues cavity 4
(why)- cutter broke
(counter measure)- changed r/s cutter (what)- vacuum block stuck in die on operator side
(why)- blew aluminum build up
(counter measure)- took pry bar and tap to break free (what)- water leak
(why)- sprue bushing bad
(counter measure)- changed sprue bushing
(re-occurrence)- yes in time (what)-slide core leaking
(why)- cracked?
(counter measure)- changed rpy cavity 3 slide core * high temp bearing trial for ladle lower unit
Replace ladle lower unit with high temp ceramic bearings during crucible replacement ***No Down Time***
What: Check 13A showed that the Hepa Filter needed changed.
Why: Gauge was reading in the Red.
Root Cause: Dirty filter.
Countermeasure: Replaced Filter.
Will Problem Reoccur?: Yes ***No Downtime***
What: Green light bulb burnt out.
Root Cause: Bulb life.
Countermeasure: Replaced Bulb.
Will Problem Reoccur?: Timing. ***No Downtime***
What: Light bulb burnt out for red light near unloading table.
Root cause: Bulb life.
Countermeasure: Replaced bulb.
Will Problem Reoccur?: Yes. ***No Downtime***
What: Trim-press ball retainer broken.
Root cause: part failure
Countermeasure: Replaced ball retainer.
Will Problem Reoccur?: NO
Cycle Time: No recordable cycle time, machine was a ***No down time they where down for man power.***
What: Changed over to run RPY - 1 Rocker and needed modification to trim-press put in. **No Downtime Machine was down for no card**
What: NG Conveyor belt had holes in it.
Root cause: Part jammed in conveyor, and wear.
Countermeasure: Replaced NG Conveyor Unit.
Will Problem Reoccur?: Y **No Downtime**
What: Broken light cover for red light on die release tank.
Root cause: Not sure.
Countermeasure: Replaced cover.
Will Problem Reoccur?: No.
"NON INVENTORY RED LIGHT COVER"
LR **No Downtime**
What: Red light bulb burnt out.
Root cause: Bulb Life.
Countermeasure: Replaced Bulb.
Will Problem Reoccur?: Yes. **No Downtime**
What: Red light bulb burnt out.
Root cause: Bulb life.
Countermeasure: Replaced Bulb.
Will Problem Reoccur?: Yes. **No Downtime**
What: Upper Aluminum Limit not working.
Root cause: Nuts where loose do to the insulator block being broken.
Countermeasure: Replaced round insulator block, tested Okay.
Will Problem R **No Downtime, was planned down**
What: Scrap Press bearings falling out.
Root Cause: Scrap press was going down too far hitting it's own cutters causing guide shafts in linear bearing to shift creati **No downtime machine was already down.**
What: Holding Burner F-Voltmeter not reading when it should.
Root cause: Wire on Protection Relay must have un-noticeable came up plugged.
Countermeasure: U *Change over*
Problem: Squeeze Master would not go home. -2nd shift. scrap press had wrong cutters on it causing scrap to stick in scrap press on eject chute. they changed to proper cutters and DH touched up robot at scrap press but then it was not cutting -Ingot loader wil not operate.
-The conveyor limit switch bracket had become bent. so the limit switch wasnt being made.
-Re-adjust limit switch bracet, restart.
I will monitor, because I just dont kn -Ladle arm travel alarm 2X .
- Cleaned the senoer -Motor overload alarm -Moving die cooling water not coming on.
-Solinoid for the valve had a broken wire @ the terminal. I beliieve that the wires not being secured and out of the way of the opening or closing the machine -Moving die water not turning off.
-Removed solinoid to check for debris.
-Cleaned out debris and restart. -Pass down from 3rd shift.
Leaking ladle.
-Changed it out with a new ladle. -Scrap conveyor 1 not working.
-Piece of scrap jammed between the conveyor and the frame.
-Cleared and restart. -Trim Press sensor out of adjunment(Not cycling).
-Readjust position, and reteach sensor. 1) 2 vacuum blocks blown on R/B side.
2) Blocks on both R/B and Op side blown, not plugged with AL. 1) Dropped shots & High speed shot alarms, observed over 3 shifts.
2) Check plunger coupler 1) axis alarms channel 1,3, and 4. 2) shots falling out of scrap press before being pressed. 1) ladle electrode break alarm. 2)ladle electrode bar malfunction 1)Collision detect alarms when "Picking" shot from die.
2)blowing operator side Vacuum blocks (V-3) 1)Die lock malfunction.
Loosing hyd. pump.
2)Die open L.S. malfunction
3)Robot malfunction, appears the R/B faulted and stopped the D/C M/C just prior to reaching full open. 1)Fuse blown on O/P module
2)Control holding injection sol. valve "ON" all the time 1)Ladle electrode bar malfunction
2)Further electrode faults 1:00 1)M/C runs 1 cycle then R/B goes home
2)Vacuum system has trouble recovering vacuum pressure in tanks quick enough. 1)PC Malfunction fault
2)PC Malfunction fault 1)Spray cartridge warps when bolted into mount.
2)Squeeze master lines need 90"s removed and "T"s installed due to change over. 1)Vacuum system alarms.
2) Intermittent Robot part detect fault. 1)assisting production with vacuum equipment failures. 2) Hydraulic pump turns off when you close die 3) After starting m/c in full auto it would cycle stop and only run one cycle 1)ingot loader was going past up sensor. 2) pusher 2 was not returning. 1)machine stopped while running. killed robot power hydraulic pump and trim press
2)Part detect #2 not working. 1-Robot is taking shot to offload conveyor instead of to NG conveyor if trim press is off or alarmed.
2-Robot positions for take out, vibrator and stationary jig positions need to be touched up. One o 1.) Okay Conveyor worn.
2.) Helper door limit malfunction. 1.0 Ladle Broken 12,201 SHOTS ON THIS TIP
SHOTS STICKING AND BREAKING 150,000 SHOTS
TOOL LIFE 1RKR TRIM DIE NO.1 1ST SHIFT REQUEST, BROKEN 1st stage filter gauge in Red. 1st. what: Vacuum not operating correctly R/C: Data bit HF4C (Vacuum Start Position) was not made.
C/M: Data bit is set by shot stroke position, Manually operated adv./ret. adv. again to set position. 2 SLEEVES FOR WATER COOLING JOINT TO BE DRILLED
--1 SLEEVE WILL BE PUT IN #3 DIECAST M/C WHEN FINISHED
--1 SLEEVE WILL BE FOR SPARE 2000 HR FILTER CHANGE 2000 HR LIFE UP 2000 HRS 2000 HRS PM 2ND SHIFT PUT DIE IN M/C BUT DIDN'T HAVE IT ALIGNED RIGHT
-PRESS DIE IN AND SMASHED OUTER RING ON SLEEVE.
-1ST SHIFT HAD TO REPLACE TIP AND SLEEVE
SHOT LIFE ON SLEEVE? 41,311
TIP -- 30,000 2nd passed on that top Absolent HEPA filters needed changed. 2nd shift & 3rd shift 2nd shift-Axis 1 problems after changover 5A2 TENS to 59B 1RKR, will not bleed properly. Bled the line at the die, bad hose from die to block. 2nd time blowing vacuum hose and block. 350ton DC machine's TC sleeve don't have cooling line.
We need to lathe cooling line for 59B R/A die cast. 3rd shift down for vaccum faults. 3rd shift left ladle filled, replaced 3rd shift passed on getting blowback. 3rd shift was having trouble with the SQM not working so they had powered off the machine 3 times to see if problem might fix its self. When I come in operator had started up the machine and all SQM r 3rd. stage filters gauge reading in red 59B 1 RKR #1 Spray cartridge Washed /cleaned 59B 1RKR F-18 Blown hydraulic hose on side cylinder. 59B 1RKR F-4 Sprue bushing cracked inside plunger bore. 88,000 shots almost shot life. Replaced with new one from inventory. 59B 1RKR F-4 Cavity 1 squeeze pin has come loose. I had to tear apart the robot side so that I could tighten it. 59B 1RKR F-7 Movable core 2 malfunctions. Reed switch on operators side tested bad, cable connection appeared to be damaged during die installation. Could not find new one in inventory so replaced wi 59B 1RKR F9 Replaced bad thermocouple. 59B 1RKR Tappit pin depth out of spec, Cavity 1 out of spec low , Cavity 2 out of spec high , Cavity 3 and 4 middle of spec. 59B F-18 Spotting die in machine to confirm tie bars need adjusted. 59B tens F-1 Thermocoupler not working. I replaced the malfunctioning thermocouple. 5A2 "SF5" DIE BLOCK 5A2 -S F-5 5A2 BC F-1 Movable side thermocoupler temp reading high.
Thermocoupler must have internal damage replaced with new one, TPS adjusted machine settings also temp now running in spec.
Not likely to reoc 5A2 BREATHER COVER F-1 fixed half. 2810 shots on this run. Pulled die to do change over. Complete teardown to change to 5A2 BC F-2. Replaced all 12 fixed core pins B and all 12 fixed core pins A.(SD) 5A2 BREATHER COVER moveable side. 2810 shots on this run. Pulled die to do change over. Replaced all 12 move core pins B and all 8 move core pins A.(SD) Replaced ejector pin 2,5,7,10,13,14,22,31,38,39 5A2 Breather Covers.
What: Scrap shoot broke on trim die.
Countermeasure: Repaired broken shoot and adjusted the two that were bent the wrong way.
Will Problem Reoccur?: Timing.
Cycle Time: No Chang 5A2 P/M F29 P1 slide core pin broke, P2 also bad, while changing slide core pins found crack in P2 slide core, replaced P2 slide core. JBS
"NON INVENTORY 5A2DM0060 P2 OPSIDE SLIDE CORE 2PCS" 5A2 P/M Die F-16 5A2 P/M F-15 MOVING
F-18 MOVING 5A2 P/M F-16 MOVING
5A2 P/M F-17 MOVING 5A2 P/M F-18 MOVING
5A2 P/M F-15 MOVING
5A2 P/M F-14 MOVING 5A2 P/M F-19 MOVING. General maintenance. 5A2 P/M F-22 Replaced sprue bushing. ( leaking) JBS 5A2 P/M F-22 Movable side broken tappet pi P1. Replaced broken tappet pin. 5A2 P/M F-22 Replaced cracked P2 slide core. JBS 5A2 P/M F-23 Die installed after die rebuild M2 slide core height out of spec. slide core removed measures out of spec to be 50 microns short. replaced with new one out of inventory 5A2 P/M F-24 D/C 6 Replaced cracked P2 slide core, also P2 slide core pin had a lot of alum build up on it, replaced it also. JBS 5A2 P/M F-24 Movable side of the die. The operator bottom M slide core was broken causing a water leak. I replaced the slide core and confirmed there was no leak. (JEFF) 5A2 P/M F-24 Replaced cracked P2 slide core. JBS 5A2 P/M F-24 Cracked P2 slidecore. Replaced cracked slidecore. E/S confirmed squeeze master settings. Settings set to high, readjusted. 5A2 P/M F-24 Movable side M2 cavity slide core height out of spec. Confirmed good condition of slide core. Found fixed side of die was out of alignment, adjusted and part is in spec. 5A2 P/M F-24 Replaced cracked P2 slide core. JBS ( app. 4,700 shots.) 5A2 P/M F-25 Movable side of the die. Replace the P2 slide core and slide core pin. The slide core had a crack exceeding 10 mm. This slide core had about 12,000 shots on it. Replaced the P1 slide 5A2 P/M F-25 Movable Complete assembly of new die from D1 and prep and test for trial. Used slide cores and slide blocks from P/M F13 that is retired. Replaced all water lines behind ejector pl 5A2 P/M F-25 P2 slide core cracked over 10mm.
"NON INVENTORY 5A2DM0017" Confirmed spray points and concentration. Adjusted pressure on squeeze master from 12.5 to 12.0 on both P channels. 5A2 P/M F-26 Replaced cracked P2 slide core with used slide core in DM, used slide core had 6000 shots on it. JBS 5A2 P/M F-26 MOVING
Broken P1 slide core pin. Replacing the P2 slide core and both slide core pins also. Crack of over 9mm with over 21,000 shots on the P2 slide core. Both slide core pins had 43,0 5A2 P/M F-26. Cavity P2 is leaving a burr that is out of spec by .07mm. We found a problem with the slide core being out of spec. 5A2 P/M F-27 D/C 4 Changed P-2 slide core Fri. 2-17-17, Mon 2-20-17,967 shots and 2-21-17, 1630 shots. Confirmed water flow in cooling joints and spray points on spray cart.. 5A2 P/M F-27 Movable side of the die. P1 slide core has a crack at 10 mm. 18,000 shots on this slide core which had no coating...amazing. Replacing with a non-inventory used slide core. (JEFF) 5A2 P/M F-27 Replace the cracked P HP side slide core. This slide core is being replaced with a trial slide core from Matt Kline. OK to run. 5A2 P/M F-27 Replaced P2 slid core on Fri. 2/17/17 2nd shift, put in D1 slide core. 2/20/17 2nd shift needs changed again, with 967 shots and a 10.5 mm crack. 5A2 P/M F-27 Movable side Both P slide cores cracked to 10mm. 5A2 P/M F-28 Cracked slide core exceeding 10mm 48,000 shots on this slide core. Replaced the slide core 5A2 P/M F-28 Movable side of the die. Cracked P2 OP slide core exceeding the allowable 10 mm. Only 2,600 shots on this run and also this die. I believe this is the 3rd slide core on this machine b 5A2 P/M F-28 Movable side of the die. P2 slide core is cracked. 21,000 shots on this slide core. I also replaced the P1 slide core pin while it was down. Confirmed that the spray concentration was 5A2 P/M F-28 Replaced M1 side slide core for slide core height. still n/g 5A2 P/M F-28 Both P slidecores cracked. Replaced both P slidecores and tappet pins. 5A2 P/M F-28 Movable side. Replaced the P2 slide core because of a crack exceeding 10mm and slide core pin. The slide core had over 26,000 shots and the slide core pin had over 41,000. No water lea 5A2 P/M F-28 Replaced broken P2 slide core pin. JBS 5A2 P/M F-29
What- P1 slide core is cracked
Why-Not sure
C/M- Changed the P1 slide core, Darrell changed channel 3 from 12.5 to 11.5
Reoccur-Yes 5A2 P/M F-29
What-Broken p1 tappet pin
Why-Tool life
C/M-Replace both of the tappet pins and both P slide cores
Reoccur-Yes, in time 5A2 P/M F-29 P2 slide core had a crack in it, changed slide core. 5A2 P/M F-30
What- Cracked slide core P1
Why- Unknown
C/M- Change slide core
Reoccur-Yes 5A2 P/M F-30 All four cavities are dropping parts. Spray concentration, spray points, cavity polished did not help. I'm going to change out the plunger tip. No leaks OK to run. 5A2 P/M F-30 Cracked P1 slide core. 3000 shots
Replaced with new one,spray points were adjusted checked squeezemaster settings checked against plex. Channel 2 pressure lowerd from 12.0 to 11.0, let op 5A2 P/M F-30 Cracked P2 slide core out of spec 12.5 19,666 shots.
P1 slide core cracked 6mm still in spec changed per Chad Franks 19,666 shots. Replaced with new ones.
Cause normal wear.
likely will r 5A2 P/M F-30 Cracked slide core op side P2. Changed slide core. Had die tech confirm squeeze master settings. Will confirm temp readings and cooling water cycling when with machine in operation. 5A2 P/M F-30 Movable side P1 slide core cracked past 10mm, quality says must be changed. Slide core did not make 24 hrs.
Channel 3 pressure (P1) was at 12.5 was lowered to 11. Sent 4 piecies from cavi 5A2 P/M F-30 Movable side Quality wants P2 slide core changed for soldering. Slide core had 1,984 shots.
"NON INVENTORY 5A2DM0060" 5A2 P/M F-30 Movable side. P1 slide core cracked passed 10 mm . 1,984 shots Replaced with new one, squeeze master settings checked. 5A2 P/M F-32 Cracked P1 slide core quality says NG. 5A2 P/M F17 Die rebuild. 5A2 P/M f-22 tapprt pin out of spec to deep. replaced pin. 5A2 P/M f-25 Movable side of the die. P1 slide core has a crack exceeding 10 mm. Over 29,000 shots on this slide core. Replaced the P1 slide core and slide core pin. (JEFF)
"NON INVENTORY SLIDE C 5A2 P?M F-27 Cracked P1 (HP side) slide core measuring 10 mm. Quality dept requested the slide core be changed. OK to run , no water leaks. 5A2 P?M F-27 Movable side of the die. P HP side core broke at the base causing a water leak. This was a Matt Kline slide core with about 6,000 shots on it. There was no crack in the normal trouble 5A2 PM 15 MOVING 5A2 PM 22 MOVING 5A2 PM F-24 moveable half. Replaced broken P1 slide core pin. E/S confirmed squeeze master settings, settings to high, readjusted. 5A2 PM F-25 broken tappet pin. Slide core pin had 33,872 shots on it. P2 operator side 5A2 PM F-27. P1 slide core crack over 10mm. Replaced P1 slide core. Checked water flow, die temp, die release concentration, and squeeze master settings. Everything seemed to be normal. 5A2 PM F15 Fixed Side- 0 shots on run, complete teardown to remove P only cavity cores from pm15 die block to send pm15 die to D1. 5A2 PM F15 Movable Side- 0 shots on run, complete teardown to remove p only cavity cores from pm15 die block to send pm15 die to D1. 5A2 PM F18 MOVING 5A2 PM F20 MOVING 5A2 S F-11 Movable side of the die. Broke off the S4 slide core. 24,852 shots on this slide core. The operator had a movable core LS switch abnormal error. When I returned from lunch they had alre 5A2 S F-11 moveable half. Keep getting move core 2 faults. Change out operator side lead switch to slide core unit. Also replaced lead switch extender on operator side.(Not from inventory) 5A2 S F-5 5A2 S F-5
D/C 7 5A2 S F-5 MOVING 5A2 S F-9 MOVING 5A2 S F-9 MOVING. General die teardown. 5A2 Trim Press #2 stripped bolts on a cutter. 5A2 chain tensioner F-2
Normal teardown for maintenance
Die was pulled for shot life (23441 shots)
Replaced ejector pins #1,2,4,8,9,11,19,20,21,22
Movable side 5A2 trim die out of trim press 6 was missing 2 guides 5A2-S F-10 5A2-S F-5 MOVING 5A2/ 59B Spray Cartridge Needs Cleaned and repaired 1 Line not blowing. 5BA MID F-2 Movable side of the die. Robot bottom slide core had a leak. I fixed a couple other leaks that I noticed. 5BA P/S F-15 P2 slide core has chip out of it. 5BA P/S F-7.
What- S1 slide ore had a crack of 10 mm
Why- Possible settings issue
C/M- On time was 0.5 now 0.6
Off time was 4.7 now 4.6
Flow was 55 now 50
Squeeze pressure was changed from 14.7 to 5BA P/S F-8 Movable side S2 slide core chipped out. 14,062 shots Replaced with new one. 5BA "S" Die #1 Issues at Machining line due to parting line. 5BA Die 14 S-1
What: Slide Core needed changed due to spec.
Why: Wear on slide core.
Countermeasure: Replaced slide core. Slide Core Check sheet Paper attached to die 5BA M F-10 Cracked slide core cavity 1 cracked clear out on tip 5BA M F-12 Cracked robot side bottom back up slide core. 5BA M F-14 Taka wants cavity #4 slide core changed chipped out. 5BA M F-4 Fixed side Cracked and leaking spue bushing. 5BA M F-6 Fixed side Cracked and leaking sprue bushing. 5BA M F-8 Movable side Cracked M2 slide core. 5BA MID Cavity 4 Trim Damage. 5BA MID F-2 Lots of flashing after the die was changed. I found that the RPY M slide cores were accidentally installed instead of the 5BA M slide cores. I replaced all four slide cores and confirme 5BA Mid F-5 Fixed side Cracked sprue bushing leaking water. 5BA Mid F5 Fixed side. Replaced broken angular pin, operator side. JBS 5BA Mid F5 Movable side. thermocouple went bad, brought die back to replaced thermocouple. Also freed up both bottom slide cores. 5BA Mid F5 die dropping cavity 2 & cavity 4 parts 5BA Mid F6 Replaced cav. 3 roller groove slide core. (cracked) 5BA P/S #5 S2 slide core was cracked and had a chip out of it. 32,484 shots on it. Replaced with new one from inventory. 5BA P/S F-1. Replace a cracked slide core, position S2. 36,000 shots on this slide core. Replaced two water fittings and snipped lots of lines trying to spot all of the water leaks. 5BA P/S F-10 Movable side Quality says S2 slide core NG , cracked 4,381 shots 5BA P/S F-10 Movable side S2 slide core has small chip in it,quality says NG. 5BA P/S F-12 Broken P2 tappet pin. 5BA P/S F-14 Chipped P2 slide core. Changed slide core. 5BA P/S F-14 Cracked P1 slide core, replaced with new MM slide core. 5BA P/S F-16 Fixed side Replaced thrmocoupler giving eratic readings. 5BA P/S F-16 Quality says P1 slide core NG Changed P1 and S1 slide core 5BA P/S F-18 Movable side Bad P1 slide core from Machining . 5BA P/S F-18 Movable side NG P1 slide core. 5BA P/S F-18 Quality says P1 slide core NG 5BA P/S F-2 Large build up on P-1 slide core. Cleaned slide core once and adj. spray cart. and checked water flow in cooling joints. Start up and 20 shots later same build up, changed slide core. 5BA P/S F-2 Movable side of the die. P2 slide core has a crack exceeding 10mm. Over 32,000 shots on this slide core. Replaced the slide core with a slide core we had previously taken out but only 5BA P/S F-2 Replaced cracked P1 slide core. JBS 5BA P/S F-2 Replaced leaking sprue bushing. JBS 5BA P/S F-21 Quality wanted P1 and S2 slide cores changed. 5BA P/S F-3 Cracked sprue bushing. Replaced the leaking sprue bushing. 5BA P/S F-3 P1 P2 slide cores are cracked but not to 10mm, quality said must be changed.Rplaced with new ones, saved old ones for possible future use as crack is 6-7mm 13,287 shots. Die tech lowerd pr 5BA P/S F-4 Cracked P2 slide core, replaced slide core. JBS 5BA P/S F-4 Movable side of the die. Replaced the P1 and S1 slide cores because of cracks. We found that since the slide core change point in Aug. we have been going through a lot more slide cores. 5BA P/S F-4 P2 slide core cracked again. 593 shots, confirmed cooling joint water flow, die release solution tested. (OK) Die release filter. (OK) 5BA P/S F-4 P2 slide core cracked. 1,011 shots on this slide core. Checked spray points and cooling. ( time not correct, app. .4 ) 5BA P/S F-4 The S1 slide core has a chunk out of it. The P1 slide core has a crack and both of the slide cores pins are worn. Replaced all four of these parts while I had it apart for the S1 slide 5BA P/S F-4 Replaced cracked P1 slide core and S2 slide core pin. JBS 5BA P/S F-4 Replaced cracked P2 slide core. JBS 5BA P/S F-4 Replaced cracked S1 slide core. JBS 5BA P/S F-5 Movable side Quality says all 4 slide cores must be changed because of cracks. 5BA P/S F-5 P2 slide core has a crack and a chip. Tool life was 47,852
Replaced with new one confirmed water flow threw cooling joint.
most likely will reoccur. 5BA P/S F-5.
What-Crack in the P1 slide core 18,699 shots on this slide core.
Why-Slide core life
c/m-changed the slide core and slide core pin
reoccur-yes 5BA P/S F-6 P1 slide core roller grove out of spec. Replaced P1 slide core. JBS 5BA P/S F-6 S1 and P1 slide cores cracked quality says must be changed. P1 might have had just over 3000 shots,S1 had 16,700. 5BA P/S F-6 Slide core that was replaced earlier today (wo39333) quality says has a radius out of spec and must be replaced. 5BA P/S F-8 Movable side Cracked P2 slide core out of spec. 5397 shots 5BA P/S F-8 Movable side P2 slide core changed earlier this morning has radius out of spec. 5BA P/S F-8 Movable side Quaulity says S2 slide core is NG has raised area but go nogo gauge still works must be changed. 5BA P/S F-8 Replace P2, S22 and tappet pins. 5BA P/S F-9 Both new S slide cores installed in die during die rebuild quality says are out of spec. 5BA P/S F-9 Movable side S2 slide core has a chip out of it quality says must be replaced 29,473 shots. 5BA P/S F10 Movable side. replaced S2 slide core that was broke after having a blow out. JBS 5BA P/S F8 S2 slide core chunked out, replsced slide core. JBS 5BA P/S F8 S2 slide core was cracked and chunked out, replaced S2 slide core JBS 3,365 shots 5BA P/S F9 Replaced S1 slide core -- Crack Replaced P1 slide core-- burr. JBS 5BA P/S S1 slide core has smaal crack, quality says must be replaced. Leaving a small raised line that is out of spec. Will reoccur in time. 5BA P/S TRIM DIE 1 5BA P/S f-9 Movable side P2 slide core cracked out of spec. 5BA P2 slide core stress crack (Passed 10mm range) 5BA PS F-4. P2 slide core was cracked measuring over 10 mm. Replaced P2 slide core. Slide core had 15,495 shots on it. 5BA PS F2
Teardown to insert repaired cores from D1
25687 shots
Die was pulled for heavy burr on s cavity 2
Movable side 5BA PS, F-18. S1 slide core is cracked. replaced S1 slide core. 5BA PS, F-23. P1, P2 and S1 slide cores are cracked and chunked out. replaced P1, P2 and S1 slide cores. 5BA S and P Die 14
What: Fixed Side on the die leaking at sprue bushing. Moveable side leaking at fitting (orange hose).
Why: Sprue needed replaced.
Countermeasure: Replaced sprue. 5BA SLIDE CORES, 2PCS OUT OF 12 WERE N/G FROM TEG WHEN SHIPPED IN TO FTP.
2 PCS ARE CHARGED OUT
PO FTP005739 5BA-S/P Die 11
What: Slide Core cracked 5BA-S 11-2 (OB).
Why: Wear.
Countermeasure: Replaced Slide Core.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. 5BA-S/P Die 11
What: Water Leak.
Why: Sprue Bushing leaking.
Countermeasure: Replaced Sprue Bushing.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. 5a2 p/m f-15 6A0 , LADLE BROKE 6A0 F-3 Movable side Quality says Cavity 4 slide core must be changed out for soldring and pitting. 12,354 shots. 6A0 F4 Thermocouple not reading temp. correctly, put new thermocouple in movable side of the die. JBS 6A0 M Bottom slide cores hard to move die is filthy off shift operators not cleaning dies. Took bottom slides apart cleaned and clearance do to damage from not being cleaned at all. 6A0 M F-11 Chipped out corner of slide core. 6A0 M F-5 Cracked sprue bushing leaking water. Replaced with new one likely to reoccur in time. 6A0 M F-5 Movable side Broken slide core leaking water. Replaced M4 bottom slide core. Worked on both bottom slide core holders to help them slide more freely in the die. JBS 6A0 M F-7 Having purosity promblems replacing sprue bushing. 6A0 M F-8 Cracked and leaking sprue bushing. 6A0 Mid F2 DH installed die, while hooking connections up robot side reed switch cable fell between opened die and got smached when they closed die. Replaced reed switch. JBS 6A0 Mid F5 cav. 4 roller groove slide core broke, replaced slide core. Had to do a lot of work on Cav 4 roller groove holder and cap. Also had to free up Cav 3 and 4 bottom slide cores. Cav 3 was real 6A0 P F-7 Cavity 1 tappet pin out of spec. 6A0 P Remove teg slide core install mm slid core for trial. after trial remove mm slide core and reinstall mm slide core. Installed new LS switch and cable to replace damaged one. 6A0 P F-1
What-The P1 slide core got a chip in it
Why-Slide core failure at 27,000 shots
C/M-Replace the P1 slide core and slide core pin
Reoccur-Yes 6A0 P F-3 Fixed side Cracked sprue bushing leaking water. 93,624 shots Replaced with new one likely to reoccur in time. 6A0 P F-3 Fixed side Replaced suspect thermocoupler. 6A0 P F-3 Movable side Broken robot bottom slide core. 26,117 shots. 6A0 P F-3 fixed side Thermocoupler giving eratic readings. 6A0 P F-4 Fixed side Cracked and leaking sprue bushing. 6A0 P F-7 Cavity 1 slide core chip out on corner. 6A0 P F-8 Blow out operator side tear slide apart replace cooling joint orings. 6A0 P F-8 Broken cavity 4 slide core. 6A0 P F-8 Broken s4 slide core, and bent tappet pin. 6A0 S F-4 Fixed side Cracked sprue bushing leaking water. 61,054 shots 6A0 S F-6 S1 and S2 slide cores broke off die possible crashed. 6A0 S F-7 Quality says S2 slide core NG Must be changed 6A0 S F-7 quality said cavity 2,3 slide cores ng must be replaced. 6A0 S F2 Sprue bushing leaking change sprue bushing. JBS 6A0 robot program does not use scrap press. Adding Scrap press to robot program 6A0-S Die 5
What: Water Leak
Why: Sprue bushing leaking.
Countermeasure: Replaced Sprue Bushing.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. 6AO M F-1 Water leaking from bottom slidecore. Slidecore is cracked at base. Replaced with new one from inventory. 6Ao M F-7 Change cavity #3 slide core. 6B2 WP F5 Replaced both squeeze pins and bushings and the squeeze pin cylinder. JBS 6B2 WP F-7 top slide core water fittings leaking. 6B2 WP F4 Fixed side. Replaced fixed slide core A, and the bottom thermocouple. JBS 6B2 Water Passage F2 moveable side. 2378 shots on this run. Pulled die because insert core pin M3 in bent. Replaced insert core pin M3(11,824 shot life) and ejector pins 5,9,11,12,19,20,22. 6B2 Water passage F-3. Movable side of the die.
What-Water leak
Why- Fitting on the top slide core broke.
C/M-Replace the fittings and the squeeze pin and bushing S11
Reoccur-Yes 6a0 P F-5 Movable side Broken cavity 4 slide core leaking water. : 3rd shift DH was told by 2nd shift DH to change Sleeve and Tip if Die was Changed out, Per Craig R. ?? A part of the shot broke off in the lower side of the T-20 moving side of the die. Drilled and tapped the stuck chunk and Used the slide hammer with torch to remove. No damage. A piece of the ok chute broke off causing parts to fall onto floor of trim press. A)Trim press handles NG parts ok
When running OK parts, R/B delivers to press and process stops.
B)1 out of 4 parts being sent to NG chute A,B #24 MOVING A/B F-20 MOVING A/B F-21 MOVNING A/B F-21 moving A/B F-22 MOVING A/B F-22 STATIONARY A/B F-24 A/B F-24 MOVING
A/B 21 MOVING A/B F22 MOVING A/B F22 STATIONARY AB #19 MOVING
AB #22 MOVING AB #21 MOVING AB 22 MOVING AB F22 MOVING ADDING TO PART AIR BLOW AL24 FAULT BROKEN WIRE ALUMINUM BLOW BACK COMING OUT OF M/C CAUSING SAFETY HAZARD ALUMINUM HARDENED IN LADLE , COULD NOT GET OUT
CHANGED LADLE CUP ALUMINUM HARDENED IN LADLE CUP
CHANGED CUP ALUMINUM LEFT IN LADLE ALUMINUM STUCK TO THE BULB SO REPLACED IT WITH THE NEW VERSION ALVIE WANTED TO TY NEW VALVE CAUSE OF VACUUM TROUBLE AXIS 2 ALARMS / PRESSURE HOLE OUT OF SPEC LOW Abnormal noise when Die is closing. Lower slide core cylinder bolts had loosened. Noise was the cotters making contact early. Retightened bolts. Now OK Add / adjust Robot home programs to reduce Robot Crashes/Down Time . Added Mid die air blow to clean flash from bottom slide core pockets Added a switch to select what model is being run. Input is X82. In water passage mode the OK carrier conveyor, flipper, and turntables do not run. This also disables part detect on x87 and x88. X23 fo Added lock nut on the exhaust thermocouple position setting bolt on the melting furnace .
To eliminate the possibility of the bolt vibrating loose. Added output YB4. For cooling solenoid air blow. Japan request. Added program for new fill sensor on the furnace per Camden West. See attached file for changes. Added secondary deadman switch for Robot. Allows second person to be in the workcell. Added small electrical box inside of the cage that has 4 pilot lights to show when the product detect sensors are on. I wired this straight to the output module for Y78-Y7B Adding shim behind #4 cotter fixed side Adjust Tie Bar Tension
See Attachment Adjust line pressure
Before 14.7 after 15.0
Target is 15.0 mpa Adjusting pin hole depth out of spec too deep Adjustment to ingot loader lift did not hold up.
Ingots not able to be pushed into furnace. After Die/model change checked part detect and it was off.
Adjusted so that it was center of parts.
Planned downtime after clean up. After changeover Move core 2 malfuntion alarm and thermocouple 2 disconnect alarm. and smashed spray nozzle.
Thermocouple was plugged into No. 1 receptacle should have been in #2. NowOK.
Read switch c After changing to water passage the part NG signal was not working correctly. Japan requested and sent PLC program modifications. I installed them. See attached file. After having other M/c problems and starting back up robot would come to wait position in front of helper door but when die and door would open robot would not enter and m/c would cycle time over.
Po Air Blow Solenoid (H-46) Was leaking by and not shutting off Air Blow at water tank not turning on Air Canister would not drain due to corrosion Air Gauge missing cover Air Leak on DC #3 Upper Crucible platform area. Air Leak on DC 3 Robot. Air Leak on Spray Cartridge. Air Valve blowing all the time causing output card to stay energized Air blow for sleeve was not working Air blow on spray unit not working. Air blow very weak, solenoid suspect. Air bowl leaking on in line oiler for robot, replaced with new. Air bowl leaking. Air hose melted Air leak
FIX-replaced solenoid air valve to plunger lube line Air leak on Die Cast#8 under ingot loader replaced old line with new now ok Air leak on spray unit replaced line now ok Air line pipe on spray unit leaking from broken pipe. Airblow system faults. Shot Sleeve air blow solenoid valve open constantly. Alarm 01A .Thermo coupler for smelting pot (belly) was alarmed out. Found that wire nut melted and lost connection. Reconnected tested and now ok All 4 Slide cores cracking Aluminum coming out of sleeve on the backside on injection. Aluminum dripped on wires and pipes around machine (Lower Crucible) Aluminum leak caused a dead short tripping the melting furnace equipment main breaker and tripped all three phases fuses on sub panel. Currently assessing the damage Aluminum quality issue. Aluminum splashed onto the doghouse cable. Annual Inspection by Shibaura Company Answered Diecast 8 call. found thermocoupler ceramic cover broken. Arm was bent Assembling Spare spray cartridge At Die change i have to go and remove the bolts from the tie bar nut clamp do to the clamp being broke so had to bolt together to lock in place at next crucible change we will be putting on a new used Auto door or helper door was bounce when trying to close. Auto door or helper door was bouncing when trying to close. Axis alarms Axis 1 and Axis 4 Alarms (AIR IN THE LINES) Axis 3 alarms Axis 3 alarms
Cause :The cavity 3 squeeze pin was found to be bent.
Countermeasure: Die maintenance replaced the squeeze pin and bushing.
The die repair sheet from the last run in die cast 2 stated t Axis 3 alarms .
Cause: die temp low fixed side die because the cycle time is too slow . Currently running at 28.5 seconds for chain tensioner. The target cycle time is 25.4 seconds. It appears to be Axis 4 alarms Axis Faults Axis alarms 3rd shift did not run, so when we come in on 1st operator started up the machine and started getting axis alarms. Plex had shown that 2nd shift had alarms the previous night and got inside Axis alarms Ch2 and ch4 Axis alarms channel 1 and 2
Cause: hose couplers NG - the o rings are worn or torn
Note: these are the new style couplers that were installed to prevent hooking hoses up incorrectly
Countermeasure : Axis alarms when running 6A0 MID. SQM adjustment made while running 59B Tensioner Axis channel 3
FIX-Adjusted flow on channel 3 Axis channel 4 Axis problem after die change Axis problem on channel 1
FIX-Adjusted flow on circuit board Axis problems Axis problems
-Passed down from 1st Axis problems #2 channel (59B- one rocker) Axis problems all axis's Axis trouble after change over to breather baffle. BAD BAD BLOW BACK BAD SWITCH BAD VALVE BAD VALVE
VACUUM FILTER BAD BAD, SHOTS STICKING TO IT BATTERY NG IN PLC, GAVE TO BYRON FOR REPLACEMENT BCU Contractors added Homing Routine to all die cast machine. Grease Program has been changed to no longer run an infinite loop, so that it would have to be stopped and taken home. Instead the program BISCUIT ALARMS BISCUIT STICKING TO THE TIP BISCUIT THICKNESS ALARMS TIP DAMAGED
1ST SHIFT & 2ND SHIFT CHANGED OUT BLOOW OUT OIL LEAK BLOW BACK BLOW BACK
GAVE TO ROGER
TYK0002 returned to cage
TYK0001 charged to DC 7 BLOW BACK ON SLEEVE
CRACK ON SLIDE CORE BLOW BACK PROBLEM/DIE LUBE RAN EMPTY BLOW BACK, SLEEVE WORN BLOW BY, EXTRA FLASHING BLOWBACK BLOWBACK AND ALOT OF FLASHING
REPLACED TIP & SLEEVE
GAVE TO DH BLOWBACK and lots of flashing. BLOWBACK, GAVE TO JOHN C. BLOWING VACUUM BLOCKS
GAVE TO MIKE WARREN BLOWING VACUUM BLOCKS/HOSSES
TIP AND SLEEVE WERE PAST LIFE BLOWN BLOWN HOSE ON DIE BOLT BROKE BOLT BROKEN OFF IN BLOCK BOTTOM BROKE BOTTOM FELLOUT OF OLD LADLE BOTTOM OF LADLE CRACKED BOTTOM OF OLD LADLE BROKE OFF BREATHE COVER TRIM DIE
Repaired the broken plug for the Breather cover trim die top side sensors for sticking parts. BROKE BROKE AIR FITTING ON ROBOT CHUCKS
TIP=49,000 SHOTS, SHOTS WERE STICKING TO TIP BROKE DURING CHANGEOVER BROKE FROM POWER OUTAGE BROKE HALF PIPE BROKE LADLE BROKE OFF GROUND OUT BROKE ON CHANGEOVER BROKE, BROKE, GAVE TO OPERATOR BROKE, GAVE TO ROGER BROKE, LEAKING BROKE/NOT READING
CHANGED BROKEN BROKEN AIR BOWL BROKEN BRACKET CAUSED DAMAGE TO TIP AND SLEEVE BROKEN COOLING JOINT BROKEN CUTTER BROKEN CUTTER TP#1 BROKEN GUIDE BROKEN GUIDE
REPLACED BROKEN LADEL BROKEN LADLE BROKEN LADLE GAVE TO DH BROKEN LEAKING BROKEN MELTING POT BROKEN SPOUT BROKEN SWITCH BROKEN TRIM PRESS CUTTER BROKEN WIRE GIVING AL01 FAULT BROKEN, REPLACE DRAWBAR BROKEN, VACUUM M/C BUILD UP OF ALUMINUM STUCK ON LADLE WOULDNT COME OFF BURNT OUT BUSHING IN SCRAP PRESS NO GOOD BUSTED Back door open close cyl.come apart from door Back door safety Key switch slide handle broken in two pieces. Relace with new handle assembly. The Door switch was OK. Back door slamming
FIX-Adjusted cushions and speed Back door to furnace not sealing
-Removed 1/4 plate some welder on ingot up loader Back door was leaking aluminum. Back door wouldn't close. Had die interlock alarm
FIX- Manually moved robot with pendant from home position and then sent it back to home Back furnace door drifting open
FIX- Replaced open close door cylinder Back furnace door leaking
FIX-Put roll back on Back side helper door cylinder cam loose.
Floating joint striped. Bad advance sensor on the Scrap conveyor flipper. Solenoid wire was damaged and flipper shaft broke the welds at the cylinder.. I rewelded the shaft and the flipper plate and drilled and tapped for Bad o ring on slide core cooling joint. Replaced o rings on S2 top colling joint now ok. Been having a lot of SQM trouble 3rd shift swapped card wiring from 1 to 2 still having trouble. Bent guide on trim die
(RPY trim die #2) Biscuit Thickness Biscuit Thickness jumping after a few shots Biscuit and tree getting stuck and not falling out of the trim press.
Adjusted two bent air lines and now biscuit is removed consistently. Biscuit breaks when the die opens
countermeasure replace tip
life of tip 7100 shots Biscuit not solidified when die opens causing biscuit to explode. 5A2 Breather Cover.
Also sleeve life is very low according to die maintenance . Biscuit size jumping around
countermeasure: tightened slack in upper and lower chains Biscuit size variation NG
No added downtime made adjustment while machine was stopped. Biscuit size varies, out of spec. Blew 2 vac blocks and 2 hoses Blew both Vacuum blocks Blew both vacuum blocks.
R/B side hose incinerated. Blocked t42 from the trim press logic. Causing problems with the breather cover trial. Blow Back
Replace Tip Blow Back
Sleeve was just changed on 2-1-16 2nd shift
"2ND SHIFT Checked into reason of Sleeve change, Decided Only Tip needed changed, Sleeve was returned back into inventory"
"Refer to Work order 8 Blow Back and new tip.
"tip charged out on another WO" Blow Back and sleeve washout. Blow Back causing lube tip to plug up causing no lube to sleeve. Blowback Blowback, worn Blowback. Blowing Vacuum blocks in Low speed shot, R/B side. Blowing multiple vacuum blocks in low speed shot mode. Blowing vacuum blocks (operator side). Verified vacuum system, spray cartridge spray points, and die release. Ended up changing Vacuum LS1 and LS2 from 70.0 to 60.0. Blowing vacuum blocks R/B side during pre-heat. Blowing vacuum blocks on operator side. Blowing vacuum blocks,
-found plunger lube tip was plugged
Per Mike Earnest requested to change tip and sleeve
Sleeve was used and didnt know how many shots was on it.
Gave parts to DH Blowing vacuum blocks. Blown Vacuum block and hoses on R/B side. Blown Vacuum block on operator side, hose damaged. Blown vacuum block, blown hose on R/B side. Blue ok carrier jammed Blue ok conveyor Blue ok conveyor
FIX-Replaced proxy sensor Blue ok conveyor jamming Bolts for upper die components bent, one component missing Bolts holding spray cartridge pivot cyl. broken Bottom Broke on Ladle.
Changed in furnace time to 8.0 from 4.0 to keep ladle hot Bottom fell off
set to furnace setting Bottom half of the operators panel is not working. Replaced IO Module and still not working. Bottom of ladle broke Box of wool for crucible repair Breaking cavity trim cutters Breather Cover
Cavity 1 part stuck in Trim press only 2 pieces being trimmed out Broke Broke bolt on robot chuck Broke cutter on trim die. Replaced cutter. Checked air blow and adjusted Broke draw bar Broke ladle
-Replaced ladle Broke slide core on 1st. (cav #4-2) Broke, happened on 3rd shift Broken Broken 1.0 Ladle Broken Crucible Broken Ladle Broken Ladle wire. Reterminate copper lead and reinstall. Now OK Broken Plunger Spring Broken Roller groove slide core Replace slide core Broken Slide Core problem Broken cable on robot. Broken ceramic sleeve on ladle electrode Broken cutter on bottom trim press die Cavity 1. Trim damage cavity 3 still an issue passed on to 1st Broken lad bar assemble.
Replaced with new one.
Will likely reoccur with normal use. Broken ladle Broken ladle replacement Broken ladle wires at the crimp. Recrimped two broken ladle wires and tested. Now OK Broken ladle, gave operator a new one Broken ladle, gave operator a new one. Broken leak detect probe for upper crucible. Repaired then reinstalled probe. Broken melting Crucible Broken on Pour end, biscuit thickness prob. Broken roller groove slide core. Operator bottom Replace slide core. Broken slide key Broken thermocouple noticed during change over Bucket loader side door mesh screen was pushed out and barely secured. Drilled and put bolts and fender washers to secure mesh screen. OK now. Build a addition Spray Cartridge for water passage. Burr Cav. P-1 NG. P-1 slide core crack. Replace p-1 slide core Burr on P1 slide core. What: P1 slide core chucked out. CC: Replaced P1 Slide core. Burr on part do too broken slide core Byron is doing trials on the safety system and forward limit switch is pulsing on the ladle arm ladle would not run . C/O TO 1 RKR C/O TO 1RKR NEED COOLING JOINT FOR SLEEVE
TRIAL RPY 1 RKR NEED TIP C/O TO BREATHER COVER CAVITY 4 TRIM DIE #3, CUTTER WORN OUT CHANGE OUT FOR SPEC OUT OF RANGE CHANGE OVER CHANGE OVER
TIP/SLEEVE ON CART N/G CHANGE OVER "PART REQUEST",
DRAW BAR HARD TO GET OUT (LOOKS LIKE SOMEONE DAMAGED THREADS LAST DIE CHANGE AND PUT IN ANYWAY).
WILL LET THE OTHERS IN DICAST MAINT. KNOW IN CASE THREADS IN DIE GOT DAMAGE CHANGE OVER FROM 1 RKR TO BREATHER COVER CHANGE OVER LADLE MISSING FROM C/O CART CHANGE OVER ON DIECAST 2 NO 1KG LADLE AVAILABLE FOR THE CHANGEOVER CHANGED OUT THERMOCOUPLE NEW FURNACE PUT IN PLACE CHANGEOVER CHANGEOVER CART FOR CHAIN TENS. CHANGEOVER DIFFERENT SIZE LADLE CHANGEOVER SOMEONE LEFT ALUMINUM IN LADLE CHANGEOVER TO 6A0 FINGERS OUT SPEC AND MISSING CHANGING DIE FOR PART QUALITY ISSUES
TIP BEING CHANGED DUE TO SHOTLIFE 109,000
GAVE TO MIKE WARREN 2ND SHIFT CHANGING OVER TO ANOTHER MODEL
GAVE TO ROGER CHART RECORDER BROKE CHECK #42 OUT OF SPEC CHIPPED OUT CHIPPED OUT NOT CUTTING RIGHT CHUCK FINGER WAS GROUND ON "THIS FINDER WAS JUST REPLACED 4-2-2018. Fingers can not be ground down they are designed for specific specs.
ROBOT WAS HAVING LOADING ISSUES.Replaced chuck finger CHUCK WINTER PUT IN M/C CONTAMINATED FROM HYDRAULIC LEAK/FIRE COULD NOT LOCATE OLD SLEEVE & TIP THAT WAS TAKEN OUT FROM CHANGE OVER COUNTERMEARSURE-= repair uh spray cartridge, so maybe use as test to see if helps with precocity. has more air blow nozzles? CRACK CRACKED CRACKED
GAVE TO JOHN C. CRACKED
GAVE TO KENNY C. CRACKED
Gave to John c. CRACKED
LEAKING CRACKED (S DIE) CRACKED AND LEAKING CRACKED AT START OF SHIFT CRACKED GAVE TO OPERATOR CRACKED LADLE CRACKED LADLE AT START OF SHIFT
POWER WAS OFF ,TURNED ON AND FILTER CLOGGED 2000HR. CRACKED LADLE/BENT CUP CRACKED LADLE/LEAKING CRACKED OIL BOWL FOR DIE RELEASE PUMP CRACKED, GAVE TO ROGER CRACKED, REPLACED CRUBICLE BROKE CRUCIBLE CHANGE CRUCIBLE CHANGE
PM PARTS CRUCIBLE CHANGE BEFORE JANUARY 2015 PM LIFE. FILTER CRACKED. CRUCIBLE CHANGE DUE TO DAMAGED FILTER CRUCIBLE CHANGE PM CRUCIBLE FILTER CRACKED - REPLACED CRUCIBLE OVER FLOWED DURING SHIFT CHANGE, BRICK WAS DAMAGED REMOVING PROBES FROM DOOR TO CLEAN ALUMINUM OFF PROBES CRUCIBLE PM
GAVE PARTS TO ROGER O CRUCIBLE REPLACEMENT CRUCIBLE REPLACEMENT, BROKE CUP DAMAGED CUP NG CUPS DENTED CUTTER BROKE CUTTER BROKE IN HALF CUTTER WORN, (TRIM HIGHT ISSUES) Can not get all home indication on trim press. Cast Pressure Alarms , V-Check light on during operation
(was completed 5/11/16 ) Cav. # P-1 Adjusting pin hole depth is out of spec. Cav. P-1 slide core is cracked Cavity #2 & #4 breather cover parts are falling out of the OK parts carrier.
CM: install cover on the trim press chute to close the gap above the OK parts carrier. Cavity #2 overflows on unloading turn table, causing it to jam up.
CM: adjust trim press down position.
(the cylinder had been adjusted during the WAP run to try to fix a problem with the sub runner Cavity #4 axis alarms Cavity 1 Tappet pin depth out of spec. Cavity 1 cutter shattered. Replaced cutter and verified trim. operator sorted back now ok Cavity 1 parts found to be bent while doing quality check for mounting hole height. Cavity 2 Broken roller groove slide core. Cavity 2 and 3 slide cores are broke. replaced slide cores 2 and 3. Cavity 2 and 3 slide cores out of spec. Cavity 3 Slide core broken off at the base.
Replace Robot bottom slide core Cavity 3 and 4 ok parts table not moving Cavity 3 squeeze pin came loose. Had to tighten squeeze pin. Ceramic insulator broke on one of the ladle electrode probes. Replaced both ceramic insulators on electrode probe. OK Change 2 slide cores and 2 water lines. Change Cav 2 Slide core. Change P1 slide core due to parts out of spec Change P2 and S2 slide cores due to cracking. 5BA P/S F-20. Change P2 slide core. Change S1 slid core for a chip quality says it is NG. 3,365 shots. Change S2 Slide Core. Change cracked S1 slide core. Change out P1 & S2 slide core do too a crack in slide core Change out leaking hydraulic pump on trim press. completely cleaned out tank and refilled with new oil. Change out tip and sleeve during change over.
-Sleeve was worn
-Shot Life 25,910 Change over Change over
Put T's back in hydraulic lines for squeeze master. Due to squeeze pins being on fixed side for this model.
And squeeze master wont start. Fix: was movable core not home. Needed jumper pu Change over
Robot teaching Change over
Axis problems (5BA one rockers). Adjusted Pump pressure up from 14.8 to 15 and adjusted pod pressure and flow
Had operator check pat spec. All good. And took parts in lab to check for poro Change over
-From new 6A0 trial to RYP 1 rocker Change over
Robot needed taught to new model from cable change Change over from RPY 1RKR to 59B 1RKR .The shot colliding with the trim press. Change over given to DH Change over to 59B. Production request to replace sleeve & tip.
put in water cooled sleeve
"These items were charged out of inventory on 10-20-16" Change over, position 6 needed touched up. Change preset of Timer 52 to facilitate ejector pin timer change for production (Craig R.) Change suction strainer filter on trim press hydraulic unit. Changed P2 slide core, it was cracked and contracing showed parts out of spec from lab. Changed Tip Only
Excessive Blow Back, give to DH Changed program so would not get false lube malfunction alarms. Added x202 to T13 and T15. Changed program so would not get false lube malfunction alarms. Added x202 to T13 and t15. Changed the Ladle upper and lower gear box oil during crucible change timing Changed vibrator when changing over. After start up taught for new vibrator position and noticed buiscut was not gripped well. Looked at take out position. Bottom chuck fingers not clamping buiscut. W Changeover, needed 1.5 ladle Changing out the M2 side slide core per Mike Hite for a quality issue to confirm a possible part mislocation issue at the sideface M/C Channel 1 SQM reading no good. Channel 3 squeeze pin will not move Charger lift lowered down into conveyor with Pusher 2 not returned.
Pusher 2 cylinder rods straddled conveyor cradles.
Lift cyl. probably drifted down away from X46 (Pusher UP) after ingots were suc Charging machine was crashed. Loader one and two twisted. Conveyor was jogged forward while loader was down with pusher two advanced. Chart recorder not recording Check #39 reading high Check attachments for tech information and settings
WHAT: line pressure / hydraulic overloads
why: Check condition of Shot sensor for Scot T. (troubleshooting intermittent cycle time issue) Check report of damaged starter Checked Robot chuck fingers during Change over for Breather Cover 60.0mm Found that they were worn out
-0.400 um Chill block runner breaking off when the die opens on the robot side WAP F10 die
Cause: No spray on the overflow runner area on the fixed side die
Countermeasure: adjust spray position Chip on cavity P1 slide core. What: Cracked slide core. CC: Replaced P1 Slide core. used TEG slide core. Clamping safety device L.S. malfunction Clamping safety device limit switch malfunction Clean and flush Die Release units Clean and flush die release unit Clean blowout by operator side vacuum block and P Slide core. Replace tappet pin and cooling joint. Clean soldering off die. Clean up both bottom slide core. Replaced water line on op side bottom slide core Cleaned ,Washed Spray cartridge for # 7 Die cast (#2 5BA/RPY Mid) Cleaned and Inspected spray cartridge. Cleaned and washed Spray cartridge (#1 6BA WAP) Cleaned soldering and grime off 3D4 F-6 while machine was down for other repairs. Cleaning heat exchangers Cleanup hydraulic fluid from hydraulic pumps, check for leaks and tighten fittings. Cleanup hydraulic fluid on hydraulic pump, check for leaks and tighten fittings. Cleanup hydraulic fluid on hydraulic pump, check for leaks, and tighten fittings. Cleanup hydraulic fluid on hydraulic pump, check for leaks, tighten fittings, change hydraulic cooling fan. Cleanup hydraulic fluid on hydraulic pumps, check for leaks and tighten fittings. Cleanup hydraulic fluid on hydraulic pumps, check for leaks, and tighten fittings. Cleanup hydraulic fluid on hydraulic pumps, check for leaks, tighten fittings and replace 2 hydraulic lines. Clogged plunger lube nozzle. Cause - moisture in sleave because of machine setting down. counter measure informed operator to preheat sprue and sleeve with torch. Coding joint broke Collar came loose and stuck the plunger in the sleeve damage the machine end of shaft for plunger . Collision alarm at scrap press Collision detect and axis 5 move error detect faults on R/B. Intermittent issue. Collision detect at scrap press
Retaught P(55) and slowed P(54) down to 300mm/sec Collision detect faults on robot Collision faults on robot at trim press Come in at 245 and Dh told me that die cast 3 was blowing out alot seems to be low spot on die or something but on the older dies possible die spot each time its pulled seems to be lot of problem with Come in on 1st shift machine was down for an aluminum leak out the side door DH said they had shut it down around 5 and jackhammered for me to repair. i also had 1st shift operator and DH jackhammer t Communication fault on Robot Pendant. Completed 8-16-24 Confirm Squeeze Setting for 5BA P/S Confirm all hydraulic lines water lines and fittings for leaks on machine.
Repair replace order parts as needed Confirm chiller operation making 52 degree water.
Hot well level low, add water. No Change
Switch over to East Filter. No Change.
Replace West filter and switch to it. No Change.
Water exiting heat ex Confirm crucible loading sensor - NG will allow the loader to load empty
Countermeasure :adjust sensor Confirm crucible loading sensor - OK is working properly Confirm loading sensor position (11/10/20 during crucible change) Confirm machine conditions after die crash on Water Passage Confirmed furnace loading sensor
Result- NG Confirmed furnace loading sensor
Result-NG will allow for loading empty Confirming 6A0 Mid die for flashing and Die Blow out concerns. Confirming machine Contamination found in K Molds for the month of July Continue investigation of Hyd. Gauge G1 reading 1MPA high, out of spec relative to W.O.7923 during production's P.M. Continuing Issue with Axial Data getting to the DCM. Controller for EXH Temp was not reading correct temp (2420) Conveyor cradles contacting lift. Conveyor was bunching up and jamming, similar to what has been damaging it lately. We backed off the chain tensioners and removed two flights so we would be able to tension the belt to the proper ten Cooling Joint Leaking from sleeve, replaced Cooling joint for sleeve broken
Replace damaged cooling joint Cooling joint to sleeve leaking water. Gave cooling joint to DH. Cord for robot controller damaged
Cord was taped to protect wires Countermeasure
No downtime due to furnace being put into seasoning stage after button replacement.
What: Buttons/ Safety plexy glass melted
R/C: Due to clogged half pipe allowing temperature to get t Countermeasure
No downtime, m/c shutdown due to no cards
What: Scrap falling out back of scrap conveyor, causing buildup
R/C: Open area on back of conveyor
C/M: Added addition on back side of scrap co Countermeasure
Problem: Trim press drifting down when machine is off or waiting to be started
cause: Trim press cylinder bleeding down
countermeasure: Checked for leaks, Replaced trim press cylinder
R Countermeasure
What: faults at scrap press
R/C: Build up on trim press causing reclamp on shot to be off
C/M: 2nd shift installed countermeasure air blow block on rear of trim press, same block used Countermeasure
What: Hydraulic oil around NG robot part unload
R/C: Worn hose leaking oil on Trim press hydraulic tank
C/M: Found leak and replaced worn hose, Tested manually for leak ok
Will it reocc Countermeasure
What: M4 ok table
R/C: M4-2 connector pin configuration different than other machines
C/M: Removed x080 and switched with comm at main electrical panel to allow proper installation of Countermeasure
What: OK table M4 not compatible with extra table
R/C: Pin configuration in wiring pig tail M4-2 does not match other machines
C/M: Rewired m4 table wiring, arranged wiring in electrica Countermeasure
What: Operator having to add extra ingots into aluminum to keep level up to run production
R/C: build up of Scrap falling over side of scrap conveyor after scrap press and trim press
C/ Countermeasure
What: Scrap building up at scrap press, causing r/b to fault
R/C: Scrap pieces getting caught behind scrap press bracket after cycle.
countermeasure: Attached skirt to bracket under c Countermeasure
What: Unable to reach scrap conveyor stop button
R/C: Fwd/stop/rev. buttons located inside new safety system
C/M: Relocated scrap conveyor buttons on outside safety system gate to allow Countermeasure
What: Unable to verify plunger lube in line
Root Cause: Line from pump to 5 gallon bucket of lube black unable to see liquid
Countermeasure: Removed black line and installed clear lin Countermeasure (No downtime m/c down for PM)
What: Ok conveyor worn, needs rebuilt ok tables need repair
R/C: Normal wear
C/M: removed ok conveyor and ok tables, replaced with rebuild and repaired it Countermeasure for upper crucible over heating. Added t65 to M1 and M20. Using input from previously unused temperature controller. Countermeasure work
Problem: High speed injection pressure selector switch (slow, high-on, on) not same as the other machines
Countermeasure: Installed correct selector switch and wired for slow, high Countermeasure(No downtime m/c down to clean furnace)
What: scrap conveyor stop button located inside safety door, ok tables in need of repair
R/C: Wear on ok tables
Countermeasure: Removed stop/rever Countermeasure(No downtime, problem fixed while operator inspecting furnace)
What: Cycle stop button will not cycle stop machine
R/C: X21C input from cycle stop button not hooked up to input from PLC Cover for solenoid on robot come loose
FIX-Drilled and taped holes Crack on P-1 slide core Cracked Cracked Ladle cup.
Replaced Ladle. Cracked Ladle cup.
Replaced cracked ladle. Cracked P1 slide core. Replaced with non inventory slide core that was in die maint area. Cracked Slide Core P1 and P2 both at max 10mm by my measurement and the operators measurement. Cracked air bowl replacement Cracked and leaking Cracked crucible.
Spout of Crucible broke.
Had to Jack Hammer the build up off of the spout which is what broke the Crucible. Cracked into pieces, gave to Roger Cracked laddle
Replaced with a new Laddle Cracked ladle . Cracked ladle cup.
Replaced ladle cup. Cracked ladle cup.
Replaced ladle. Cracked slide core in cavity S2. Replaced with new. Cracked sprue bushing leaking inside causing porosity. Cracked sprue bushing(68,523 shots). Replaced cracked sprue bushing. Cracked sprue bushing. I replaced the sprue bushing and water tested it. Cracking around the 24 squeeze pin channel 4 Cracking slide Cores 5BA F 8 die. Craig Randal requests cable formerly feeding die cooling water temp control unit be removed. Craig had Steve put water passage die back in and he forgot to put the 4x4 under die when closing it causing it to pull the threads off all 4 draw bars Crashed die, multiple pilot lights / valves flickering / chattering Crock in slide core area of 5BA P1 F-23 Crucible Change Crucible Lid Unsecure Crucible Lid unsecure Crucible Lid unsecure. Crucible Replacement Crucible Spout Break Crucible broke Crucible change Crucible change do to melting furnace having a hole in it so Ryan and I come in at 4 to put in so no conflict with Contractors with crane. Crucible change due to damaged filter Crucible change. Crucible change. Got Melting pot, holding pot, stands for both melting and holding pots, half cut pot, and box of wool lining for Darrell so he can do crucible change on 2/13/2016 on die cast machine Crucible change. Needed box of wool Crucible lid unsecured Crucible lid unsecured. Crucible lid will not shut in Semi auto after ingots are loaded. Loader middle position sensor was knocked out of position. I rebent the trip dog arm and reinstalled. and set the distance . The cru Crucible replacement
-Hole in filter, crucible cooled and filter no longer removable. Crucible replacement due to spout breaking on holding crucible from 7/10/2020 Crucible replacement, holding crucible w/damaged filter. Cruicible replacement Cup for Pin tester Cup for pintester Cutter broke on trim press
FIX-Replaced cutter Cycle Start button on operator panel loose. Cycle Time Alarms when running 59B 1RKR Cycle Time and cast Pressure Alarms Cycle Time running slow
Before cycle time 31.0 seconds
After change cycle time 28.2 seconds Cycle time Improvement
PLC change helper door open. Change timer to allow the helper door to open at the same time that the die receives the die open signal. Cycle time before 25.6 seconds after 24.2 Cycle time alarms
Cycle time 28.3 seconds Cycle time over faults on ladle unit and robot. Re-homed ladle unit and robot. Cycle time too slow Cylinder for spray cartridge is leaking. D. CAGNON
BENT, LOW TEMP ALARM D/C #1 Fitting on water line going to plunger shaft leaking, replaced fitting while down to change lot marks. JBS D/C 1 Replaced broken ladle. D/C 3 RPY 1RKR F7 Replaced movable side thermocouple. D/C 4 Replaced thermocouple on the fixed side of the die. JBS D/C 4 ladle broke, got DH a new ladle. JBS D/C 5 Breather cover. Oper. changed vac. block and did not notice thermocouple cable had fell between die, went to start m/c and smashed cable. Replaced fixed side oper. side thermocouple. JBS D/C 6 Cooling joint that is cooling the sleeve broke off, replaced cooling joint. JBS D/C 6 cooling joint broke going into the sleeve. Replaced with new cooling joint. JBS D/C 8 RPY Mid F5 Replaced sprue bushing that was leaking. JBS D/C 8 cracked ladle, got new ladle for DH. JBS D/C M/C lube shortage fault
Die Height lube shortage fault DAMAGE DAMAGED BOLT DAMAGED PLUNGER SHAFT DC #7 having vac. problems, changed 2 air filters. JBS DC 5 needed a new T- slot bolt. JBS DC#1 changed over to UH-SB parts. once m/c starts robot goes in to grab shot and stops in front of product detect sensors and faults out DCM MC5 was dropping parts on 2nd shift they decided on just a plunger tip change because sleeve only had 13,000 shots on it. Ran for about a hour than started dropping parts and had some blow back. L DH AND DIE MAINT. REQUESTED PARTS FOR DIE CAST REBUILD
CRUCIBLE CRACKED DH Needed air fitting DH REPLACING FOR PM ON M/C DH REQUEST NEW ONES DUE TO OLD ONES BEING BROKEN DH REQUESTED DUE TO TOOL LIFE DH REQUESTED DUE TO WORN OUT PART DH SAID TIP & SLEEVE ARE BURNT & HAS BLOW BY SAFETY ISSUE DH changing dies, was running hydraulics with cooling water valves off.
Overheated oil , burned up pump DH fell during die change and broke old light fixture DH reported the ingot loader drifted up and hit the furnace door and melted the pusher forward limit switch. DH, MIKE REQUESTED PARTS DUE TO OLD ONES ARE WORN OUT, DUE TO TOO MUCH ALUMINUM AND EXCESSIVE HEAT ACCORDING TO DIE MAINT. DIE CHANGE OLD ONE SNAPPED DIE CHANGE, BROKE BAR
GAVE TO TOMMY DIE FELL OUT OF MACHINE
REPLACE T-BOLTS,NUTS AND L CLAMPS DIE LOCK FOURCE MALFUNCTION AFTER INJECTION FAULT DIE REPLACEMENT PARTS DIE TRIAL , SHOT STICKING TO DIE DIRTY DIRTY FILTER DIRTY FILTERS DIRTY, PART REQUEST DIRTY, VACUUM FAULTS DOING A CHANGEOVER
28,000 ON TIP
REPLACE TIP ONLY CAUSE OF BLOW BACK DOOR SWITCH AT CRUCIBLE DOOR WAS BROKE
REPLACED DRAW BAR BROKE DREW C.
P/M 19 STATIONARY Damper on the stack of the upper crucible drifting shut when the request entry button is pressed Darrel reports this M/C loosing Nitrogen. Darrell and I replaced the defective air/oiler assembly that feeds the upper crucible tower lid cylinder. No Leaks Dent on inside of o-ring groove WAP F 1 die Dh had to do a Die Change from RPY 1 RKR to 59B 1 RKR. Dh requested t slot bolt for die Diaphragm pump is hesitating and not fully pumping. Replace pump and gauge was not working either. Replaced gauge. all working properly. Diaphragm pump is not working. Did Model changeover and needed this style of cup Die 11 5BA-S/P
What: S-2 slide core cracked out of spec.
Why: Had quality check crack and was in spec - went out of spec around 9pm.
Countermeasure: Replaced OB 5BA-s 11-2 slide core.
Will Problem Reo Die Cast #4
PM F-21 stationary Die Cast #5 machine check #26 Vacuum Pressure reading -87.1 the spec calls -90 kPa min. Die Cast 1 crucible overflowed damaging molten metal detect probes. Die Cast 3 shot NG conveyor electrical box is broken and conduit pulled away from the box. See attached picture. Die Cast 4 trim press door. Safety interlock not attached properly. Die Cast 5 gate at holding crucible. Safety interlock not attached properly. See attached. Die Cast 6 Trim Press Air Blow not blowing the overflow off of the die and causing miset. Air Blow starting before the down stroke. Die Cast 6 motor on scrap conveyor. Conduit has pulled away from motor. See attached. Die Cast 6 still having issues with blowback Die Cast PM Confirmation Die Cast# 2 6A0 Mid Die blow out Die F-1 leaking water back up and running by 10AM Die F-3 Partial teardown o remove debris from blowout . Cleaning . Readjustment to upper slide core. to align better with the upper mounting block Die Lab reporting an abnormally high amount of porosity off die cast # 8 . Also die cast # 8 reporting a lot of vacuum down time . Die P/M F-18 Die Rebuild
5A2 P/M F-13 Die Rebuild
APR P/M F-14 Die Rebuild 5A2 P/M F-21. Die Release Tank cleaning Die Release pump no good Die Release system cleaning
-Drained and cleaned die release tank and filter
-circulated hot water and cleaner (purple power 2 cups)
-flushed system with water only
-refilled with water and set dilut Die cast #3 has a crucible hood that dose not retract as it should. This is causing problems at the end of Fridays or anytime the upper needs scraped Die cast #4 broken ladle, got new ladle for DH. Die cast 4 broken ladle Die cast 4, valve no good Die cast machine cycle time is near maximum spec (28.0 s)
Robot is out of sync with die cast machine Die cast machine is intermittently calling for v-check during operation. Difficulty obtaining correct casting pressure range following v-check. Casting pressure near maximum spec (55 MPa) during ope Die cast machine not recognizing spray cartridge home position will not run in full auto. Found a loose connection on mode selector switch on main panal on machine operator controls. Die change over: Replace drawbar that snapped during a run cycle. Die change, R/B requires touching up at trim press Die change, they had some broken switches. Die close solenoid malfunction alarm Die flashing on bottom half of all 6A0 dies. Die height adjust switch partially melted, operational. Die is Blowing aluminum out from excessive flashing Die is blowing out on operator side ( spotted the die in the machine and found no contact on the chill block)
Countermeasure: replaced chill block on operator side and added a .100 um shim on the oper Die lock force change after injection alarms,
- pulled covers and cleaned area where sensor is. Also cleaned sensors seating surface, cycled power on machine. Monitored, OK Die lock malfunction
Die lock force malfunction
no output for die open. G440 loses position reference, data should be 1 resets to 0. Die lock malfunction
Die lock force malfunction alarms Die lock malfunction /Die lock force malfuction Die lock solenoid valve malfunction Die lube concentration out of spec
reading 1.54 Die lube not functioning correctly Die lube pump does not move fluid. Die not opening all the way during preheats and/or full auto. Die rebuild (5A2 P/M F15) Die rebuild (P/M F-16) Die rebuild parts. Die rebuild. 5BA P/S F-1 Fixed side. 15,698 shots on this run. Die release Die release Tank cleaning Die release agent concentration does not regulate well, % constantly dropping. Die release concentration out of spec reading high 70:1
countermeasure: adjust upper float position for more water. Die release diaphragm pump not holding prime during machine operation Die release loosing prime Die release not spraying Die release pump Die release pump failure. Replaced with new pump.
Test ok. Die release pump not functioning. Replace Die release pump Test OK Die release pump not pumping. Exhaust filter was plugged and air inline oiler had been turned off. I reset the oiler to 3 clicks. Pump now pumping. Die release pump not working Die release pump output pressure high, out of spec. Check #23 Die release solution % low, on all D/C machines. Die release spray does not spray Die release spray head will not come go up or down. Die release tank cleaning Die release trouble Die release unit PM
Clean and flush system with hot water and purple power cleaner
Confirmed that spay cassette is not leaking
Refilled and set die lube concentration (reading 1.882 on Lamotte tester Die release unit PM
Clean and flush system with hot water and purple power cleaner
Confirmed that spay cassette is not leaking
Refilled and set die lube concentration (reading 1.940 on Lamotte tester Die release unit PM
Clean and flush system with hot water and purple power cleaner
Confirmed that spay cassette is not leaking
Refilled and set die lube concentration (reading 1.949 on Lamotte tester Die release unit PM
Clean and flush system with hot water and purple power cleaner
Confirmed that spay cassette is not leaking
Refilled and set die lube concentration (reading 1.964 on Lamotte tester Die release unit PM
Clean and flush system with hot water and purple power cleaner
Confirmed that spay cassette is not leaking
Refilled and set die lube concentration (reading 1.966 on Lamotte tester Die release unit PM
Clean and flush system with hot water and purple power cleaner
Confirmed that spay cassette is not leaking
Refilled and set die lube concentration (reading 1.976 on Lamotte tester Die release unit PM
Clean and flush system with hot water and purple power cleaner
Confirmed that spay cassette is not leaking
Refilled and set die lube concentration (reading 1.981 on Lamotte tester Die release unit PM
Clean and flush system with hot water and purple power cleaner
Confirmed that spay cassette is not leaking
Refilled and set die lube concentration (reading 2.201 on Lamotte tester Die repair. Die temps running high after change over to RPY 1 Rkr Die trial install, during trial run TC Sleeve and plunger tip with excessive wear. appears plunger tip not true with the sleeve during shot timing causing wear in sleeve and flashing issues. Die wand air/liquid sprayer wouldn't work.
FIX- Replaced wand Die was changed to another Model on m/c and Sleeve TOOL LIFE was close so sleeve was changed
98,500 Die will not lock into the closed position. Machine cycle time over alarm faults.
OE-san contacted Toshiba - possible cause die close cylinder is leaking internaly
I confirmed tie bar strain load per Diecast 5 trim press. Added logic for part detect on the trim press. When scrap was left on trim press the press would stop but not alarm. Added x88 to t10. Also added M900 to the alarm horn y7f. also Diecast DH attempted to repair molten metal level probes, was unsuccessful and requested assistance. Diecast machine would cycle stop after one cycle. The die is not opening quickly enough. Changed timer T3a from 2.5 seconds to 4 seconds so that the machine could run and maintenance could troubleshoo Diecast needed chart paper Dog House cable wires fraying Dog House door crank wire is Fraying. Door located between crucible and operator control box missing two bolts for hinges. Down for filter. So not running. Down for trim damage from Saturday.
Countermeasure: Adjust robot at the Tab Remove Trim Press. Downtime is planned, not running on our shift.
6A0-M trail parts, Type09. Draw Bar broke by trying to thread it into the m/c Draw Bar was crossed threaded.
Replaced Drew C.
S-9 MOVING Dropped shots, each dropped shot shows no sign of plunger lube on biscuit. Dropping #2-3 cav out back from flipper Dropping 6A0 mid cavity 4 part also dent and rub mark on all cavity 4 parts
Confirmed spray, SQM both OK and replace plunger tip. did not improve
Cause: was burr on the MV side die
Countermeasure r Dropping P Cavity 2 Part Dropping cavity #1 part (8-17-16) Dropping cavity 4 part 5A2 Breather cover Dropping chill piece on the operator side . Dropping ok parts at trim press Dropping parts Dropping parts around the OK conveyor. Needs investigated. Dropping shot Dropping shot
FIX- Adjusted temp on movable side of die Dropping shot
FIX-Replaced tip and injection collar Dropping shot and blow back
Replaced tip Dropping shots tip has over 92,000 shots on it. Dropping shots, Die release concentration low, (1.3) Dropping the S1 cavity. During a die we change i got in to measured the housing that the sleeve sits in OD was 94.7 mm bot front and back, and the plunger cylinder rod tip OD was 65.2 mm and the cylinder rod was 50.2mm also E-stop button broken on Melkeeper furnace control cabinet E-stop button missing see attachment ELEVATOR DOOR HANDLE BROKE ELEVATOR DOOR LATCH BROKE END BROK OFF ENGINEERING REQUEST
FOR DIECAST M/C'S 5 AND 6
NEW MODEL FOR N/G CONVEYOR CHUTES THAT RIALTO IS FABRICATING.
CYLINDERS FAILED TO BE ORDERED IN ADVANCE FOR THIS PROJECT EX A,B F24 EXCESSIVE BLOW BACK. SHOTS STICKING TO DIE,PLUNGER LUBE PUSHING PAST TIP AND SLEEVE CAUSING BUBBLES IN SHOT
TANAKA ENG. REQUESTED FOR PROD. DH TO CHANGE EXH A/B F-24 MOVING Ejection pin encoder replaced with encoder from D/C#8 Ejection stroke abnormal Ejector NG Ejector pin Height reading below 25.00.RPY 1 RKR F-15 Cavity 1 , Adjusted Spray cartridge travel distance. It was overtraveled and spray was not spraying correctly on Cavity 1. We ran the ejector p Ejector pins not moving because dummy plugs not installed at change over. robot product detect not seeing part. Adjusted product detect and verified with Taka. Part hitting entering trim press, Not Electrode Bar Malfunction Faults Electrode Bar Malfunction faults Emergency stop error on trim press and robot End of Arm tooling bent on robot, the mounting plate for the chuck specifically. Eng. scott T. requested part due to old one no longer holds a concentration Engineering request that a new Shot control Module be installed. Excess soldering Cavity 4 In Roller groove.
Replace Cavity 4 slide core Excessive flame coming out from under the furnace cover door located above the crucible filter. Melting the plexi glass and switches on the control panel. Excessive flame coming out of melt furnace exhaust stack Excessive flame coming out of melt furnace stack Exhaust temperature controller SD26 not signaling to fire the melting burner.
No output from controller even when its calling for it to fire.
Replace exhaust temp controller and teach all parameters.
Exhaust temperature not reading correctly. Exposed Cable to scrap conveyor 1 motor Safety requests ran in flex conduit.
Placed M10 motor cable in flex conduit installed and tested. ok. F 22 STATIONARY F-16 F-18 MOVING
P/M F-15 MOVING F-22 MOVING FILTER BROKE FILTER BROKE/CRUCIBLE REPLACEMENT FILTER CHANGE FILTER CHANGE
HOUR 2000 FILTER CHG 2000 HR FILTER CLOGGED AND DIRTY CAUSING VACUUM PRESS FAULTS FILTER CRACKED IN HOLDING CRUCIBLE, REPLACE HOLDING CRUCIBLE WITH 'non inventory" crucible FILTER DIRTY FILTER GAUGE IN RED FILTER IN RED FILTER LIFE FILTER LIFE UP, CLOGGED FILTER OUT OF SPEC FILTER OUT OF SPEC (HIGH) FILTER PLUGGED (VACUUM FAILURES) FILTER PM FILTER REPLACEMENT FILTERS CLOGGED WITH OIL/DEBRIS (VACUUM TROUBLE)
"NON INVENTORY VACUUM UNIT EXHAUST FILTER" FILTERS CLOGGED, VACUUM PROBLEMS FILTERS DIRTY
"NON INVENTORY NP2DIECAST EXH FILTER"
0532-140-156 FILTERS GAUGE IN RED FILTERS IN RED FILTERS OUT OF SPEC FILTERS READING OUT OF RANGE FOR 6AO TRIAL FULL OF ALUMINUM FURNACE DOOR REPAIR FURNACE SIDE DOOR REPAIR Fabricate and install a deflection panel for the inside rail on the Large scrap conveyor. Due to the installation of the small Tab press we are no longer using the scrap press after the trim press du Fabricate and install new mounting unit with new pulley and mount outside the safety gate. mounted new doghouse door lifting/lowering winch and new cable. Fanuc Robot Annual PM,see hard copy for details.
PM Not Complete. Fanuc Robot Semi-Annual PM, see hard copy for details. Fanuc Robot Semi-Annual PM, see hard copy for details.
PM COMPLETE. Fanuc Robot Semi-Annual PM, see hard copy for details.
PM Complete. Fanuc robot controller not working Fanuc robot needs taught/touched up. Fanuc robot semi-annual PM, see hard copy fir details.
PM COMPLETE. Fanuc robot semi-annual PM, see hard copy for details. Fanuc robot semi-annual PM, see hard copy for details.
PM Complete. Fanuc robot semi-annual PM, see hard copy for details.
PM Complete. No parts needed. Fanuc robot teach pendant not working and has all black screen. Filing on Cavity P1 and S1 (Trim Die #2 )
Countermeasure: Shim guide blocks 0.200 um for P1 and S1 Filter Filter DC #4 Filter broke on holding furnace. Filter changed Filter had 3 holes in it
Lab checked Aluminum and it had Inclusions Filter in Crucible broke beyond filter repair
Replace Holding Crucible Only Filter on Holding Crucible broke on 11-23 2nd shift.
Replacing with non inventory crucible
Crucible stand cracked
Half Pipe Cracked while chiseling the aluminum off around it Filter on crucible broke (2-22-17, 1st shift).
Cause: Unknown
Replace crucible Filter ONLY Filter request Finishing changing ingot loader lift cylinder.
1st shift w/o# 6912 Finishing repair to Trim Press Flipper. First Stage filter gauge reading in Red. Fixed die not heating up to specified temp..
Solanoid valve not closing all the way, dur to debris in the plunger.
cleared and restart. Fixed side die running hot, sight glass shows low flow of cooling water. Fixed side die temp A too hot. Fixed side of die running too hot. Causing temperature alarms Fixed side of the die. Replaced the bottom side thermocouple, slide core A and the W3 cooling joint. (JEFF) Fixed side thermocouple NG Fixed side thermocouple failure.
Replace fixed side thermocouple. Flame out alarms on the melting furnace
Cleaned the photo eye Flame out not resetting Flame out, replaced ignition rod non inventory Flame out, will not reset Flex hyd. hose was leaking, replaced hose. JBS
What: Flex hose hyd. hose leaking inside M/C
Why: Time
Countermeasure: Replaced hose
Reoccur: Yes Flipper #1 is not working correctly and faulting out. Flipper #3 jamming Flipper 2(trim press diverter 2) sticks. Causes robot to crash. Flipper 3 allowing a part into the NG conveyor periodically. Adjusted speed controls on the cyliner and lubricated the joint mechanism. So far OK I will check back with him in 1/2 Hour Machine is ru Flipper 3. Bracket that holds the flipper to the shaft broke. After a lengthy disassembly to be able to access this flipper. Removed and repaired the bracket that holds the shaft in place to the fli Flipper 4 broken Several shift worked on removal and rewelding all the flipper plates. Reinstall all of flipper unit and conveyors and test and adjust for position. Tested OK. Flipper 4 on trim press allowing preheat shots into ok conveyor Floor Plug by robot safety cover is peeling back Follow up to confirm die . ( BENT TENSIONER 59B ) cavity 2 parts dropping when the die opens and falling in the pan. the squeeze pin not returning Follow up to replace missing trim die part on RPY/5BA P/S trim die #1
operators are filing P1 and P2 Follow-up Request for W005601: Monthly Die Cast MC PM Follow-up Request for W060133: Monthly Die Cast MC PM Follow-up Request for W070674: Monthly Die Cast MC PM Follow-up Request for W073107: Monthly Die Cast MC PM Follow-up Request for W075785: Monthly Die Cast MC PM Follow-up Request for W075839: Monthly Die Cast MC PM Follow-up Request for W081184: Monthly Die Cast MC PM Follow-up Request for W084165: Monthly Die Cast MC PM Forgot to dump ladle cup when hydraulic line blew
bottom fell off, set to furnace setting Frame around ingot lift table that hold skirting in place is broken. See attached request form. Full of Contamination in bottom of air bowl Full work alarm on trim press Furnace Damage Due to Corundum build up. Major repairs needed. Furnace Low Temp Furnace corundum build up beyond save point. Air hammered out and rebricked for repair. Furnace has flames coming out around the cover.
Cause: Melting burner is rich
Counter measure : adjust the pilot burner gas down . adjust main burner down from 13.0 m3/h to 11.8 m3/h Furnace loading door not closing , gap at the bottom Furnace loading sensor allowing for loading the crucible empty Furnace not making temperature to melt Furnace not melting right Furnace repair Fuse blown on TR80DID0PT Dispersion I/o MODULE in D/C M/c operator control enclosure. GAUGE BROKE GAUGE IN RED GAUGE IS BROKEN GAUGE OUT OF SPEC GAUGE OUT OF SPEC FILTER CLOGGED GAVE TO AMANDA F.
BLOWBACK GAVE TO AMANDA F.
BROKE GAVE TO BYRON
CONVERTING PLC FROM A SERIES TO Q SERIES GAVE TO CRAIG HINGER GAVE TO CRAIG R. GAVE TO CRAIG R.
ADDING COLLANT JOINT TO SLEEVE WHILE RUNNING BREATHER COVER. TRIAL RUN GAVE TO CRAIG R.
BROKE, WATER PASSAGE ROBOT GAVE TO CRAIG R.
PREP WORK FOR WATERLINE PASSAGE IN TC SLEEVE MODIFICATION FOR IMPROVEMENT GAVE TO CRAIG R. AND CAMDEN W.
11-25-19 GAVE TO DAN K. GAVE TO DARELL C. GAVE TO DARRELL GAVE TO DH GAVE TO DH
1ST SHIFT INSTALLED NEW TIP & SLEEVE, FAILED TO PROPERLY TIGHTEN CAUSING CRASH GAVE TO DH
BROKEN THREADS GAVE TO DH
FLASHING AND BLOW BACK GAVE TO DH
This was replaced on 1-3-2017, but replaced with UHDIECAST0043
This Cooling Pipe Assy that was changed on 1-3-17 was to short GAVE TO DH (MIKE)
OLD ONES ARE WORN OUT GAVE TO DH FOR TRIM PRESS, OLD ONE HAD BEEN GROUND ON GAVE TO DH STEVE W.
EXCESSIVELY CRACKED GAVE TO DH, OLD ONE LEAKING ALUMINUM ALL OVER GAVE TO DIE LAB GAVE TO ENG. GAVE TO ENG.
ADDING TO CRUCIBLE AS A COUNTERMEASURE FOR MELTING CRUCIBLE.
LEVEL DETECT OF CRUCIBLE. GAVE TO ENG. FOR CHANGE OVER CHUCK REPLACEMENT
1 CHUCK WP
1 CHUCK BC GAVE TO JAPANESE ENG. GAVE TO JESS
BROKEN GAVE TO JESS P.
MODEL CHANGEOVER GAVE TO JESS P.
VACUUM ISSUES
"NON INVENTORY BUSHCH EXH. FILTER" GAVE TO JESSICA P.
PM PARTS, FILTERS DIRTY AND AIR BOWL NG GAVE TO JOHN C. GAVE TO JOHN C.
BLOW BACK GAVE TO JOHN C.
BROKE GAVE TO JOHN C.
BROKE, OPERATOR ERROR GAVE TO JOHN C.
CRACKED GAVE TO JOHN C.
DOING MODEL CHANGEOVER AND THERE WAS NO SLEEVE TO PUT IN FOR THIS MODEL GAVE TO JOHN C.
NOT SPRAYING GAVE TO JOHN C.
PART FELL OUT OF TRIMPRESS GAVE TO JOHN C.
REPLACE SIDE DOOR WOOL GAVE TO JOHN C.
SPRAY UNIT VALVES GAVE TO JOHN C.
TIP CHANGED ONLY, TIP WAS WORN AND CAUSING HEAVY FLASHING ON BISCUIT WITH WAS ALLOWING SHOTS TO DROP GAVE TO JOHN C.
TRIALS ON NO. 1 , 1.5 LADLE GAVE TO JOHN C.
VACUUM ISSUES GAVE TO JOHN C.
VACUUM VALVE JOINT LOST
REPLACED GAVE TO JOHN C.
WEAR GAVE TO JOHN C.
WORN GAVE TO JOHN CHOPSON
WORN GAVE TO JOSH
PM RELATED GAVE TO KENNY
BROKE GAVE TO KENNY C.
BROKE ON MANUAL OPERATION GAVE TO KENNY C.
SHOTS STICKING AND DROPPING PARTS GAVE TO MIKE W. GAVE TO OA FOR SPRAY CARTRIDGE GAVE TO OE, NEW MODEL START UP GAVE TO OPERATOR GAVE TO OPERATOR
BROKE GAVE TO OPERATOR
DRAW BAR WAS BENT, OPERATOR ERROR GAVE TO OPERATOR
NO LADLE AT CHANGEOVER CART GAVE TO OPERATOR
WORN GAVE TO OPERATOR JOSH
P.M'S, DIRTY FILTER
FILTER WAS LAST CHANGED ON 7-29-16 GAVE TO OPERATOR, CLOGGED GAVE TO OPERATOR, LEAKING GAVE TO OPERATOR, WORN GAVE TO ROGER GAVE TO ROGER
BROKE GAVE TO ROGER
CRACKED GAVE TO ROGER
BLOW BACK GAVE TO ROGER O GAVE TO ROGER O
VACUUM ISSUES GAVE TO ROGER O. GAVE TO ROGER,
BROKE GAVE TO S.FURNIS GAVE TO SCOTT T & DARRELL
CHANGING TO COPE WITH "HIGH SPEED POSITION SHOT ALARMS, SLEEVE GOUGED" GAVE TO SETH D.
CRACKED GAVE TO SETH D.
LEAKING SPRAY VALVE GAVE TO SETH D.
This Ladle Cup is for Model 5YK , Eng. is doing Trial on machine. GAVE TO SHANE F.
"NON INVENTORY EXHAUST FILTER VACUUM UNIT" GAVE TO SHANE, OLD FILTERS PLUGGED WITH OIL
"NON INVENTORY NP2 DIECAST VACUUM UNIT EXH. FILTER" GAVE TO STEVE W. GAVE TO STEVE W.
BLOWBACK GAVE TO STEVE WAGNER
PLUNGER ROD BENT GAve to Operator GETTING ALOT OF BLOW BACK, BLOWING VACUUM BLOCKS GIVE TO ROGER
BLOW BACK , VACUUM PROB. GUIDE GROUND DOWN/LEAVING MARKS ON PARTS CAVITY #2 Gas checks are out of spec for material Hydrogen gas amount Gauge reads over limit
Replaced HEPA filters Gave Vacuum Block to DH to install
Machine was having Vacuum trouble continued from 2nd shift
Once New Vacuum Block was changed out the faults went away. Gave new ladle to operator Gave operator a ladle to replace broken ladle. Gave spray nozzle tip to operater Gave to Amanda F.
Cracked Gave to Craig R.
Setting up Spray Cartridge for 1RKR Gave to D.Cagnon
Broke Gave to Darrel C.
Oil not rising Gave to Drew C.
Furnace No.6 Gave to Japanese assoc.
Sensor added on to m/c Gave to Jessica P.
Restock Gave to John C and Operator
broke Gave to John C. Gave to John C.
3rd ran without plunger lube which caused tip to be bad "CHANGED TIP ONLY" Gave to John C.
Bent Gave to John C.
Blow Back Gave to John C.
Blow Back past the crucible
Plunger lube trouble Gave to John C.
Blow back Gave to John C.
Blow back, dropping shots Gave to John C.
Blowback Gave to John C.
Broke Gave to John C.
Cracked Gave to John C.
Goes to Crucible that is for Emergency Breakdown Gave to John C.
Ladle broke Gave to John C.
Ladle cracked Gave to John C.
Machine Dropping SHOTS
Coupler is tight and shaft is bent Gave to John C.
Previous shift did not check Plunger Lube bucket and it was empty when 1st came in.
Which caused TC Sleeve to be bad Gave to John C.
Put Trial sleeve in also "non inventory" Gave to John C.
Replaced Tip only, Blowback Gave to John C.
Shot sticking Gave to John C.
Sleeve and tip worn. Gave to John C.
Tip was changed yesterday cause of Blowback on 1st shift
Still having blowback on 1st shift today, changed sleeve and tip Gave to John C.
Tunnel broke Gave to John C.
m/c red lighted and had to do manual operation to get back in home position,
Ladle broke on side of crucible Gave to John C.
wear, trim height-spec issues Gave to John C.
worn Gave to John C.
worn, almost life Gave to John c.
Cracked Gave to John c.
Cracked on 3rd shift, ran all night till 1st shift Gave to Josh F.
Ladle cracked, build up in m/c caused crack.
cleaned out m/c Gave to Josh F.
Won't fit in vacuum block after die change, maybe got pinched. Gave to Kenny C.
Bent Gave to Kenny C.
Plunger Shaft over heated Gave to Kenny C.
cracked Gave to Kenny C. , cracked Gave to Operator Gave to Operator
Broke Gave to Operator Josh
Cracked, Gave to Operator,
Blow Back
Operator brought Sleeve back said this does not need replaced "per Darrell ."
Charged Sleeve back into Inventory. Gave to Operator,
Cracked Gave to Operator, worn Gave to Roger Gave to Roger
Cracked Gave to Roger
End of Draw Bar snapped off Gave to Roger
Sleeve Worn "Trial Sleeve , water line added to keep sleeve cool" over 100,000 shots
Sleeve charged out to give to Die Maint. to prepare for next sleeve change Gave to Roger
cracked Gave to Roger O
Low shot speed alarms
vacuum trouble Gave to Roger O.
doing model change over to "59B" this sleeve has the hole pre-drilled in it. Gave to Roger, LADLE CRACKED
Put 1.5 LADLE CUP IN M/C "NON INVENTORY MARUKA0002"
This was just changed on 1-28 Gave to Scott Gave to Steve W.
Cracked Gave to Willie W.
Ladle Cup cracked, Aluminum got cold Gave to operator
Cracked Gave to operator
Ladle cup got broke during manual operation Gave to roger , worn Get a thermocoupler for the movable side of the brand new die that D1 is making for us. 5A2 TENS F-3 Getting Mov Cor 2 Limit Switch Fault. Switched reed switch box twice, changed main wire, cleaned slide cores, bled hydraulic system. I didn't notice a lose wire clamp on one of the reed switches, but Getting blow back from bad tip and sleeve. Not sure if it is up for shot life according to our records its up on shot life but according to production sleeve only has about 15,000 shots. Also on secon Getting die lock force error. Told that the shot sensor causes this problem. Getting excessive Blow back, also high speed shot alarms
Old tip severly scarred.
Gave to Steve Wagner Getting high speed shot alarms, maximum cast pressure alarms and biscuit thickness alarms. Found that high speed shot sensor was covered in oil giving false readings. Cleaned sensor and cylinder and p Getting high speed shot and biscuit thickness alarms. Shot stroke varying position when returned to zero. Getting ladle arm electrode bar alarm. Electrode had cracked insulator. Getting ladle electrode bar alarm, could not reset. Getting ladle electrode bar alarms. Insulators cracked and burned on existing electrode bar assembly. Getting ladle electrode bar malfunction alarms, re terminated wire ends into probes with no results. After that we changed the whole electrode wire harness with no change either.
Fix: Changed the ele Getting ladle traveling limit switch alarm. Aluminum flashing all over arm and holding furnace. Getting trim damage mainly on cavities 2 and 4, shot is getting warped coming out of the die. Good parts conveyor cam roller fell off. Got spray valve for spray cart, D/C 5 JBS Gouge in the tip. Replacing the tip and sleeve. I replaced the cooling joint for the sleeve because it was bent. No water leaks. Ready to complete the die change. Green light on tower burnt out.
Replaced light bulb. Greg Blanton believes that we have a problem with the P1 slide core creating issues with his side face process. We are changing the slide core to confirm that there are no issues with our die. Our P Guard from scrap conveyor lying on top of squeeze master. Guarding by Crucible is not secure and the post moves. Guarding by crucible is not secure and the post are moving. Guarding by crucible is not secure and the post is moving. Guarding by crucible is not secure and the post moves. Guarding by crucible is not secure and the posts are moving. Guarding by the crucible is not secure and the post are moving. Guards sitting on top of electric panels. HELPER DOOR STICKING HIGH SHOT SPEED HIGH SHOT SPEED IS TOO LOW
TIP & SLEEVE DAMAGED HIGH SHOT SPEED. INTERIOR OF SLEEVE HEAVILY WORN HIGH-SPEED SHOT ALARMS HOLDING CRUCIBLE COVER REBUILD HYDRAULIC FILTER READING OUT OF SPEC TO HIGH, REPLACE FILTER HYDRAULIC LEAK HAD TO STOP M/.C DUE TO FIRE FROM OIL ON LADLE-LADLE FULL OF HARD ALUMINUM & OIL Had 2 Axis alarms pin would come out but not return changed lines from cavity 2 to 1 and moved in and out ok so we replaced the fittings on both ends of hydraulic hose now ok. Had Kepple Sheet Metal make a Bracket for inspection lights on DCM # 5 & 6. I need those brackets mounted & lights installed. Had a leak at the hydraulic tank steel braided line so it was down when i come in so i changed it out with a new one that we had ordered. Had big air leak on main air valve on the spray unit. Had to get into side panel of squeeze master to adjust pressure and flow on cavity 1 and 3 cause breather baffle runs at a way lower pressure then 1RKR. now ok Had to replace the cracked ladel. Had trouble with 2 scrap cutters 1 broke off the bolts the other bent the bolts cause of problem scrap from shot being left behind Had trouble with high shot speed looked at the cast pressure it was out of spec to much nitrogen so let some out and now ok Had trouble with over pour with ladle. Had vacuum faults looked at profile and it showed plunger rod movement Half Pipe Cracked Half Pipe broke Hard hydraulic piping leaking for die open, close cylinder Has blown 2 vacuum blocks. Have a work request for air leak on the robot found the leak cut the bad section out went to get a connector for the line come to find out its not a 8mm and not a 10mm its an oddball 9mm which we dont Having axis alarms channel 3 Having issues with die blowing out aluminum on helper side top slide core filling slot with aluminum. Replacing plunger tip to see if that helps. Tip has 16,000 shot life. Needs replaced at 18,000. Sl Having pressure build up time alarms. Having trouble with flame outs Off shift had changed out the photo eye on the melting burner but still having the flame outs. So i decided to change out the Protection Relay for the melting burner.FRS Heavy Aluminum build up on wire causing ladle electrode malfunction Heavy Flashing on the last four dies RPY 1 RKR confirmed clamping tension on tie bars and it is out os spec on top two tie bars Helper Door open L/S Helper door cover came loose. Helper door is closing/opening/closing during the closing motion. Helper door is to slow effecting the cycle time . Helper door repair Helper door slamming open
FIX- Adjusted cushion and speed up Helper door will not stay shut Helper side door L.S. 2 error Helper side door LS fault. Helper side door PM Helper side door auto malfunction alarm Helper side door came loose from the cylinder and the bracket bolts were loose. Put bracket back on cylinder and re tightened bracket bolts. Helper side door close limit switch malfunction. Helper side door does not open Helper side door hitting outer door when Opening/Closing Helper side door limit sw. error Helper side door not opening or closing by operator panel switch. Discovered the cylinder for the helper door had came unthreaded from the door. I also repaired several melted switches on the operator High aluminum sensor is not working and alarming out when the aluminum touches all the probes. High spd shot alarms
Trial Tip larger O.D. High speed shot alarm.
Trouble shoot this issue High speed shots
FIX- Replaced tip and sleeve High speed shots and blow back
FIX-Replaced tip and sleeve High speed shots and ton of blow back Holding Burner flame out
Cause: Ignition coil / wire
Countermeasure: replace coil Holding Crucible Filter broke in half
Replace Filter ONLY Holding Crucible Filter broke on 11/17/2016, Replaced Filter only.
On 11/18/2016 1st shift Bracket that holds Crucible Filter in place broke.
Replace Holding Crucible Crucible
11/18--Upon removing H Holding Crucible Replacement, FILTER CRACKED Holding Crucible changed only, Hole in filter Holding burner flame out alarm metal temp out of spec Holding burner flameouts
w/ aeronica H Holding crucible Temp probe ceramic cover came loose and floating in the Aluminum. It is a new probe but appears the set screws were not tight that hold the cover in place. Reinstalled the cover and Holding crucible burner not firing Holding crucible has been overflowing lately. The operators noticed that the melting furnace melts material much faster than DC 1 & 3
I adjusted the melting burner flame - before 12.9 m3/h after 11.6 Holding crucible is overflowing the filter
Cause: aluminum not flowing through the filter fast enough
Countermeasure : scraped the surface of the inside of the filter And adjusted the loading sensor Holding crucible leak detect alarm going off
-Took wires off of leak detects and alarm is still going off. Also as the leak detect light was on the holding burner failed to shut off, I believe there Holding crucible temp not reading. Replace holding crucible thermocouple. Holding temp overheat 1600f
Cause: thermocouple wire is NG
Counter measure: cut back the conduit and taped the bare wires(temp fix) will run new conduit and thermocouple wire. Hole in Holding furnace filter changed out holding crucible and halfpipe Home program not working correctly when the robot faults when it returns to the trim press at PR64.
countermeasure: added a macro in the home home program to unclamp before moving.
Home program hits t Hood is difficult to open and close Hose check and o-ring replacement on DIXON coupler Hose check and o-ring replacement on DIXON hydraulic couplers Hose leaking water at sleeve.
Hose was long enough to cut out hole and reinstall. Hyd oil temp running 111 degrees.
Cleaned heat exchanger. Hyd pump tripping the thermal over load on contact relay . Hyd. cylinder cable for DC5 Hyd. leak from squeeze master hose on the back of the die. Replaced hose. JBS Hyd. leak, hard /line connected to rear of movable die cylinder. Hyd. leak, in solid line to injection Cylinder. Hyd. pump does not start. Hyd. pump shuts off Hyd. pump shutting off. Hyd.. pump will not run Hydraulic Leak to Trim Press Cylinder
Floor Anchor Brackets bad Hydraulic Leak/ Possible blown Line. Hydraulic Temperature running high on machine 110 deg f
Cleaned during scheduled down time Hydraulic filter in red zone. Replaced filter with new. Hydraulic fitting under back of machine for main hydraulic line cracked spraying oil. Removed fitting and welded. DC Reinstalled welded hydraulic line fitting. JBS Hydraulic fluid leaking on the floor. Hydraulic gauge G1 reading 1 MPA high, (16 instead of 15). Out of spec.
The check sheet I saw indicated the reading has been out of spec for 4 weeks. Hydraulic hose
-Fix replaced hose Hydraulic hose bad leak. Robot side slide core out hose had a hole burnt into it and was leaking , Replaced with new hose. leak test ok Hydraulic hose had a hole in it causing major hydraulic leak. Hydraulic hose leaking at accumulator. replaced hose, air bowl, inspected machine for damaged cables.
found no cables or wires damaged. checked for hyd. leaks, none found.
Turned over to production fo Hydraulic leak Hydraulic leak at trim press. Hydraulic leak coming from a line above the die.
-Found: Hydraulic hose for the slide core had busted.
-Fix: Replaced hydraulic hose with a new one. Hydraulic leak on die open/close ram. Leak is located at connection of hardline to advance side of ram.
Fix:Swapped line from DCM 1 to reduce downtime, repaired leaking pipe that was removed from DCM Hydraulic leak on hard line behind mounting plate for die release pump. Hydraulic leak on the Trim Press
Cause: fitting leaking on a hose (fitting NG)
Countermeasure: replace hose Hydraulic leak on the squeeze master.
Late entry due to forgetting to clock into job. Hydraulic line to die close/open cylinder spraying fluid out of connection block. Removed line, welded , line and block need to be replaced. Hydraulic pipe leaking. Remove and repair by welding Hydraulic pipes connecting the pump and cooler were not connected and fittings were off, causing a big spill of hydraulic fluid. Hydraulic pump shuts off.
Root Cause is bit G440 is flickering and or going off while die is open and die locks are engaged which causes Die Lock Malfunctions which terminates the hydraulic pump. Una Hydraulic pump shutting off
(5BA P/S #3 die) Hydraulic slide core steel line on robot side leaking Hydraulic temp on die cast machine was up to 111 degrees. Hydraulic temp on machine was at 113 degree. Hydraulic temperature running high on die cast machine 110 deg f
Cleaned during scheduled down time for robot PM Hydraulic temperature running high on die cast machine 112 deg f
cleaned during scheduled down time I had clocked in under this work order. Had Rick D. come to help fix problem. He didn't know I had a work order open so he opened one too. His work order has all the info WO28495. I had 1.25 hrs dow I need to pin for water passage trimming.
Could you please make pin. IGNITION ROD FOR CRUCIBLE ALUMINUM LEAK DETECT
2PCS "NON INVENTORY" INGOT LOADER PUSHER NO.2 PART DETECT SENSOR INGOT LOADING CYLINDER DRIFTING ITEMS BROKE Ingot Charger Conveyor will not move forward nor back.
-Also frequently tripping overload. Ingot Elevator safety door switch snapped the mounting bolts off. Repaired the mounting nuts on the slide handle and replaced bolts. Reassembled and tested for alignment . Now OK Ingot Furnace door issues. Ingot Loader lift cradle badly bent and several broken welds. Drew Caynor and I Replaced with New Cradle., including new studs and mounted the roller table with slight modification to the bolt patter Ingot cart jammed in lift. Ingot charger conveyor attempted to advance with pusher not Down and pusher 1 not Returned. Ingot charger conveyor will not Adv. or Ret. Ingot conv., in the past, has run ingots into the pusher assy.
This as well as another issue related to crashes thought to be related to the lift and pusher cylinders drifting during fault conditions Ingot conveyor Flights bent Ingot conveyor "locks up" Ingot conveyor cradles bent. herb and Nolan took over Ingot conveyor crashed Ingot conveyor fails to advance, overload relay tripped.
Production thinks a clutch might be slipping, they also noticed tension of chains is not equal, they also said the overload relay for the conve Ingot conveyor sensor loose, realigned and tightened. Ingots loaded on conveyor upside down causing error alarm.
operator corrected loading, machine running. Ingot conveyor will not advance, operator can not manually load ingots. Ingot conveyor will not run. Ingot elevator lift motor overload relay tripped. Ingot elevator motor starter overload relay tripped. Ingot loader Ingot loader alarms out during load cycle.
Fix: Believe the loading process was separating the safety door from switch just enough to cause a safety alarm. Adjusted door Latch and tested. OK Ingot loader came down on top of ingot conveyor. Straightened out brackets on ingot conveyor and checked and verified all limit switches and cylinders on ingot loader. Ingot loader conveyor crash. Ingots loaded on conveyor upside down by operator.
This work order was left open from Thursday. Ingot loader crashed into conveyor and got jammed wasn't getting down light Ingot loader crashed, Operator loaded ingots wrong. Ingot loader crashed. Ingot loader crashed.
Kept die cast machine running. Ingot loader crashes. Repaired while machine was running. Ingot loader door open, will not close, all functions dis-abled. Ingot loader door switch destroyed. Ingot Loader ingot advance for loading sensor bracket was broke off and laying in the bottom of the conveyor causing the ingot to continue forward and raising the Ingot loader going up to high hitting door Ingot loader is not going back to start position in auto.
Die cast machine ran the entire time. Ingot loader light curtain post anchors stripped / post must be moved to accommodate new guarding. Ingot loader loading problem Ingot loader not finishing cycle
-Weld broke for limit switch. Welded Ingot loader pusher limit switch sticking on do to aluminum on switch.
FIX- made guard for #2 forward limit switch. Ingot loader pusher up/down chain came off of the sprocket. Nothing got damaged, discovered 50mm nut was loose for sprocket bracket allowing it to spin sideways. Got chain back on sprocket. Tested, ok Ingot loader roller for loading in furnace broke. Welded broken
No down time Ingot loader safety door switch no good Ingot loader spacer project. Completed and tested.J.R. and Michael Ingot loader stops in auto, after pushing ingots into furnace. Lift will not lower in auto. Ingot loader will not load in auto Ingot loading conveyor crashed. Begin repairs.
no down time. machine ran while did repairs Ingot scissor lift does not operate. Ingot scissor lift not working . Communication cable from the lift to the pendant was smashed repaired damaged cord now OK Ingots not detected on conv. at pusher Ingots were dropped into an empty crucible on 2nd shift
Replace Melting Crucible Only Injection Hydraulic pipe weld repair.
Cleaned and Ground down area for welding Rewelded, Reinstalled on DCM and Tested for leaks. Not leaking at time of testing. Injection Rod Seals Leaking. Injection Servo Valve closed position Malfunction Injection cover door open on toscast screen. All covers were closed. Found that spray cartage was in manual. Should be off. Injection dosing valve not working properly on Die spray unit. Injection hard hydraulic pipe is leaking, pulled off and gave to Die Maint to tig weld. Welded and reinstallled, tested OK Injection hydraulic line is leaking from the flange that the steel braided line threads into. Found that o-ring was damged, replaced o-ring and tested. OK Injection pipe leaking oil
Cause: leaking around the pipe flange ( has been welded several times)
Countermeasure: replaced with flange assemble from ( Blubaugh's) The hose was used previously on anot Injection rod seal was leaking, replaced packing. Injection servo valve closed position malfucnction Install 200 ohm, 120 watt LHR resistor for ladle drive. Original removed and installed on D/C #8. Install HMI in Squeeze master unit Install I/O reconfigured module board. (Parameter changed in module from Toshiba) Install float switch for plunger lube. Install new product detect sensor type from 4 sensors to only one laser type.
countermeasure for crashing dies. Install pressure gauge on diecast 7 as shown per picture. Picture represents gauge shown on diecast 8. Installation of squeezemaster manifold base complete. Removed guarding and fabricated to allow fit for new manifold base. Welded base to moving die side. Also removed rear safety door .. Removed li Installed Trial shoulder bolts for Robot secondary gripper for running Water Passage.
This is a countermeasure for breaking shoulder bolts.
Bolts size went from M6 to M8 Installed both new Trimming presses air manifolds and solenoids and associated air piping Installed hydraulic manifold for Squeeze Master on movable side. Also installed color coded hydraulic lines from manifold to manifold. Installed new design secondary gripper
The gripper uses a different contact point than the original design to reduce the amount of movement when the robot is placing parts in the trim press. Installed new laser sensor for scrap loading.
Setting N1950mm F2600mm Installed new manifold for squeeze on movable side. Also made a new set of hydraulic hoses from manifold to die. Installed new scrap conveyor rear cover/gaurd
also installed a conveyor brush to prevent trim pieces from falling into the bottom of the srapp conveyor and jamming it up. Installing new couplers and color coding for easy, hassle free connection. Installing new couplers, color coding manifold couplers to couplers on die for quick no hassle connections. Insulator broke on one of the ladle probes Investigate Melkeeper Temperature chart recorder (paper style) availability. Investigate cause of loader crashes which occurred after changing ingot arrival sensor type Investigating why 5A2 P1 and P2 slide cores are cracking at very low shot life Issued to Drew C.
PM #21 Issued to John C. for Crucible Change JR Otto and Craig Randal. Adjusted ingot lift up advance down 1 inch Adjusted and rebent approx 15 ingot paddles replaced 1 paddle that was missing and several missing paddle bolts. Jam nut on trim press cylinder rod will not move. Jam sensor X9F being flagged by scrap conveyor, shutting down m/c. Japanese engineer wanted solenoid valve DG15 change for "No Casting Pressure Reading" Just for information holding temp running way high over 1500 degrees so if possible crucible break that could be part of reason the upper limit probes were in wrong position so the thermocouple was in Keeps getting a "ladle pour inverter fault".
-Found the bearings were bad in the whole ladle arm assembly.
-Fix: Replaced the ladle arm unit. Kept machine running no down time.
What: Ingot loader crashed.
Why: Extra ingot set on top.
Countermeasure: Bent ingot holders back and replaced missing bolt.
Will Problem Reoccur?: If too many ingo Key switch not working properly. Key to robot on the controller for auto/T1/T2 is broken. LADLE BROKE LADLE BROKE
BEARING HAD FLAT SPOT LADLE BROKEN LADLE CAUGHT FIRE AND ONE OF THE OPERATORS GOT SAND IN LADLE PUTTING FIRE OUT LADLE CRACKED LADLE CRACKED
CUTTER BROKE LADLE CRACKED ON BOTTOM LADLE CRACKED, UNKNOWN REASON
M/C IS CLEAR OF BUILD UP LADLE CUP BROKE LADLE CUP CRACKED LADLE CUP CRACKED FROM PREVIOUS SHIFT, 2ND,3RD SHIFT
*OPERATOR STATED M/C WAS NOT CLEANED OUT WHEN SHIFT STARTED,
THAT CAUSED LADLE TO HIT THE ALUMINUM BUILDUP AND CRACK LADLE HAD A HOLE IN IT LADLE HAD HOLE IN IT LADLE HIT UNCLEANED ALUMINUM BUILD UP WHICH CAUSED IT TO CRACK LADLE LEAKING LADLE WAS CRACKED LADLE WAS CRACKED WHEN 3RD SHIFT GOT HERE LEAKING LEAKING SPRAY VALVE LEAKING VALVES LEAKING WATER LEFT FULL OF ALUMINUM LID CLOSE LIMIT SWITCH STUCK ON LIFE LIFE ON FILTER
SPRAY VALVES NG LINE FILTER TROUBLE LOADER ELEVATOR SAFETY SWITCH BROKE
VACUUM FAILURES "FILTER" LOADER MAIN AIR BOWL LOOSE LOST Lab said K-molds had inclusions. Ladle Ladle Bar Electrode Malfunction. Ladle Broken, New one given to operator Ladle Cracked & Dripping Ladle Cup Broke
Fix: Replaced ladle Cup Ladle Cup Request Ladle Electrode Wire Break Alarms. Ladle Electrode wire broke at copper connections. Ladle Fwd Limit Switch was flickering on/off while unit was in the molten aluminum Ladle LS Malfunction Faults
Travel LS Malfunction Faults Ladle LS malfunction fault.
Ladle fwd. traveling LS fault.
Ladle FWD. LS probable failure. Ladle Limit Switch faults when ladle is coming out of the crucible. Ladle Lower unit chain master link broken and the chain is jammed in the sprocket
Replaced lower unit with spare Ladle PM Ladle Unit Locked up "inverter faults" Ladle arm assy PM Ladle arm cable Break alarm will not clear. Checked all connections OK. Ended up relacing the Ladle wire. Old cable must have had some internal damage. 1 wire reading open. Ladle arm lower section locked up Ladle arm making noise when coming out of crucible and into sleeve Ladle arm rebuild Ladle arm stopped
Lower unit was covered with aluminum.
Machine didn't run due to man power Ladle arms lower bearing issues Ladle bar malfunction
FIX- replaced tip and sleeve. due to blow back on ladle bar Ladle bar malfunction. Ladle broke Ladle broke
-Replaced ladle Ladle broke
FIX- Replaced ladle Ladle broke
Fix-Replaced ladle Ladle broke Operator Error Ladle broke, gave operator a new one Ladle broke, gave operator a new one. Ladle broke, gave operator new ladle. Ladle broke, put wrong size on replaced with correct size JBS Ladle broke. Replaced Ladle broken, gave operator a new one. Ladle broken. Gave operator a new one. Ladle chain tension not right Ladle changed from 1.0 kg to 1.5 kg
Need to adjust ladle timer settings to maintain cycle time, biscuit size
Verify ladle pour into shot sleeve is OK Ladle cracked Ladle cracked and leaking, gave operator a new one. Ladle cracked and leaking, gave operator a new one.
No downtime. Ladle cracked causing biscuit issues replaced ladle. Ladle crashed in to crucible. (Proto type ladle) Ladle cup broke Ladle cup broke.
Replaced Ladle cup. Ladle cup broken. Tried to replace could not drive cup holding pin out. Ladle cup cracked, replaced by production. Ladle cup is cracked, replaced ladle. Ladle cup replacement Ladle cup request Ladle elecrto wire break
FIX-Reattached wire to ladle bar Ladle electro bar wire break Ladle electro wire brake
FIX- Replace wire connector at probe Ladle electrode alarms . Ladle electrode aluminum upper limit faults. Ladle electrode bar malfunction Ladle electrode bar malfunction. Ladle electrode bar malfunctions, found that ceramic insulator on electrode was gone causing short in circuit. Also noticed ladle had golfball sized hole in back side of it so we got operator a new on Ladle electrode bar malfunctions. One of the ceramic insulators is broken. replaced with new. Ladle electrode break Ladle electrode break alarm Ladle electrode break alarm . Ladle electrode cable caught and broken Ladle electrode came disconnected. Ladle electrode had 1 broken wire broken at the crimp. Made new copper connector and reconnected wire.. tested and OK Ladle electrode wires burnt and shorting out to each other from blow back . Ladle for D/C 5 Ladle forward limit switch
FIX- adjusted limit switch Ladle forward limit switch alarm. Ladle forward limit switch malfunction Ladle forward traveling L.S. malfunction
Ladle L.S. malfunctionInitially these faults would not reset. Ladle hitting tie bar cover when returning. Tabs for mounting were slightly bent . Rebent the mounting tabs and straightened cove. Remounted and Now OK Ladle inverter fault
FIX-Replaced lower ladle assy Ladle is broken, gave operator new one. Ladle leaking, gave operator a new one. Ladle limit switch alarm each time door is opened to check 1/2 pipe Ladle limit switch malfunction
Ladle traveling limit switch malfunction.
Will not reset.
this occurs when ladle is either in the crucible or has just come up out of it. Ladle limit switch malfunction alarms. Ladle limit switch malfunction and ladle travel limit switch malfunction Ladle limit switch malfunctions.it also throws a forward limit switch malfunction. Ladle lower unit locked up. replace with rebuilt lower unit. Ladle over and under pouring Ladle over pour Ladle pouring inverter protect on fault. Ladle pouring over the back side of the sleeve. Ladle probe missing bulb. Found it floating in aluminum .let it cool and reinstalled and tightened. Ladle probes all bent causing ladle malfunctions and submerging lower ladle unit into the aluminum. Ladle traveling electrode faults. Ladle traveling forward limit sw. malfunction.
Ladle Limit Sw. malfunction. Ladle traveling switch malfunction Ladle unable to move from operator control. Ladle unit locked up. No arms rebuilt, pulled to rebuild. Ladle unit upper gearbox not showing any oil in site glass
Drain upper and lower gear box oil and refill .
Capacity upper gear box 2 liters
Capacity lower gear box 5 liters
Use Mobil Gear 600 XP150 Ladle was cracked Ladle will not Move "Back" to crucible. Ladle will not return out of M/C Ladle wire break Ladle wire break crimp new end and fasten in holding block. now ok Ladle wiring had a kink causing ladle to malfunction. Ladle wrong size for 1RKR parts Ladles dunking into aluminum, suspect bad relay
-replacing relay to see if this is the problem Large hole in 3/4 inch Air supply line over the spray cartridge. Replace hose with new hose. Large scrap conveyor is jammed and wont move forward. Ran it backwards and replaced all broken or missing cotter pins. Appx. 15 . reset several link caps. Large scrap conveyor jammed up. Replace several missing cotter pins on the chain pins x25 Leak Detect not working. Leak Detect probes too short. Leak detect probe wires fraying.
C/M: Re-terminated wires Leak near cooling joint at sleeve. Leaking Leaking Valve spray cart Leaking hydraulic line on the slide core pins cylinder, Robot side. Replaced the hydraulic line. No leaks. Leaking machine side fixed side sprue bushing hose, also spray wand air line side needed replaced. all ok Left full of aluminum Level probe conductor wire connector broken Lid for Crucible not staying open Light housing on the Die release tank is broken Light on Die Release broken Line Pressure Malfunction Alarm B-54D.
Line pressure dropping below -.5 MPA Line pressure malfunction alarm Liquid tight conduit connector pulled out of terminal box, R/B side of M/C Liquid-tite conduit pulled loose from thermo couple / terminal box R/B side. Loading furnace door not sealing Loading sensor allowing loading when crucible is empty Loading sensor not working correctly , it will allow for dumping into empty crucible Loading sensor position moved
Countermeasure: Readjusted sensor position Logged in wrong machine. Lot Mark Damage from Trim Press P1 cavity (2 lots on hold after lathe for lot mark flaking) Low Shot speed alarms, High speed shot alarms possibly shot sensor module took over from first shift. Low aluminum , melt furnace not keeping up.
Melt Furnace Temperature is actually too hot Low liquid metal level alarms
Furnace melts slow. Low shot speed alarms Low speed shots and trim press height
Ladle broke too and die #2 (RPY-M) has spot in cav #4 Low vac. pressure. Low water pressure on fixed side of die. Pulled solenoid valve, cleaned inspected and reinstalled. Same results, ended up changing solenoid. Lower Crucible Replacement, cracked filter
Filter has been cracked since 1-6-2017,
No information as to how filter cracked Lower crucible temp erratic readings. raeplace lower crucible thermocouple. Now OK Lower crucible upper limit probe is too short. Replaced probe and adjusted to 8 Inches. Lower crucible was left full and hardened Lower ladle arm is locked up . The electrodes for the ladle were all bent up letting the end of the ladle to go right into the molten aluminum . Lower unit on ladle arm locking up
Bearings worn inside lower unit or Al contamination.
replaced lower unit with rebuilt one.
likely to reoccur in time. M F-20 M/C P/M leak detect not working, replaced probes
"NON INVENTORY" M/C PM
NON INVENTORY NP2 VACUUM EXH. FILTER M/C START UP FOR TENSIONER M/C does not Divert under temperature shots to NG conv. M/c doing Model Changeover to 59B Tensioner.
M/c was running 6A0 , when changing over took Sleeve out and noticed it was bad.
Sleeve Life ONLY 39,000. "Not sure why such low life on sleeve, had wash M/c faulted out with aluminum in ladle cup.
M/c down 2hrs , aluminum got hard in cup while m/c was down.
Replace ladle cup M1 Cavity cutter broke/guide broke M2 slide core broke(32,115 shot life). Replaced M2 slide core. MACHINE CHANGING OVER
DRAWBAR THREADS ARE STRIPPED, CHANGED MACHINE COUNTER MEASURE MACHINE DOING CHANGEOVER
WHILE DOING CHANGEOVER NOTICED SLEEVE IS BADLY WASHED OUT ONLY 13,500 SHOTS ON THIS
SLEEVE IS GETTING SHORT SHOT LIFE
FOLLOWING DATES OF SLEEVE CHANGE: 7-18,6-23,6-6,5-23 MADE A SPARE SHAFT & TIP ASSY TO HELP MAKE CHANGEOVER BETTER MAIN AIR BOWL ON FURNACE LEAKING MAIN HYDRAULIC FILTER 2000HR SERVICE MAKE NEW SPRAY CASSETTE FOR 1 RKR PARTS MC #1 MIST COLLECTOR
REPLACED BEARINGS ON MIST COLLECTOR MOTOR MELTING BURNER RELAY BAD MELTING FURNACE, FLAME OUT METAL FOUND IN ALUMINUM, CHANGE UPPER CRUCIBLE BY DH 1ST SHIFT JOHN CHOPSON MISSING MISSING FROM CHANGEOVER CART MISSING WERE MISSING ON M/C MIST COLLECTOR FILTERS MIST COLLECTOR OUT OF SPEC, CHANGED FILTERS MODEL CHANGE MODEL CHANGEOVER MODEL CHANGEOVER TO 59B CHAIN TENSIONER MOLD HEATER INTEGRATION Machine blew a vacuum block and die maintenance is not here today, gave operator a non inventory block from cage. Machine blowing vacuum blocks on robot side. Checked all hoses and filters, also condition of chill blocks all good, increased air pressure slightly. Machine blowing vacuum blocks, operator made us aware that the machine was running with the hose off of the block when he got here. Also when we were troubleshooting we noticed that the vacuum units m Machine doing Model Change over to 5A2 Breather Cover.
No sleeve to put in for this changeover, Replaced with new sleeve. Machine down for manpower at 3:15, I am ladling out the crucible and removing the filter for a replacement tomorrow. Machine down for refractory rebuild. Performing PM Work. Machine down for refractory repair. Machine down(No downtime)
What: Hydraulic oil leak, rear left side of machine
R/C: Hydraulic oil filter lid seal not installed properly
C/M: Removed lid and fixed seal to allow correct seal on filter Machine dropping parts Machine getting axis 3 alarms (low).
Fix: Replaced female fitting on fixed side of the die. Machine getting blowback and shot is sticking to die, tip and sleeve both at over 100,000. Machine getting die lock malfunction before injection faults, cleaned and verified condition of load sensor. Reset die height. Machine getting major blow back due to worn tip and sleeve. Replaced with new Machine moving Machine new drive shaft for die cast Ok conveyor per sample. Machine not getting any plunger lube. Machine out for refractory rebuild. Perform pm activity on vacuum system. Machine scheduled down for refractory rebuild. Machine scheduled down for refractory rebuild. Replacing Metal leak probs. Machine side Advance hydraulic hose to the Die leaking. Replaced hose Now OK Machine side squeeze master hose channel 1. Hose failure leaking badly. Installed fittings on a new hose and replaced. Now OK Machine was down for low aluminum had some parts stick in trim press as operator was pressing parts out. Machine was down when come in for cracked filter on holding crucible Machine will run with a blown vacuum block Main Hydraulic pump motor sounds NG. reinstalled pump shaft key. reset and reinstalled chain coupling and tested.
Root cause was inadvertant removal of the motor end armeture by inexperienced E/S indi Main Pressure hose from hyd unit to trim press manifold was loose and dripping . Was able to tighten and get the leak to stop. Cleaned up all oil on the trim press and both scrap conveyors. Main control HMI looses squeeze master 4 axis data Main hydraulic injection line leaking removed line, welded and replaced lin . will reoccur in time. Main hydraulics filter change. Main panel buttons melted. Down for crucible change. Maintenance check # 12 reading out of spec high. Spec 7.5 to 9.5 Kpa actual reading 10.3 Kpa. I adjusted Blower dampers on holding and melting furnaces . Current reading is 9.5 Kpa when checked with t Maintenance requst,
Install temperary guarding on scrap chute Many cycle time alarms, operator improved this dramatically by adjusting ladle speed. Still seeing intermittent cycle time faults.
M/C not down more than 10 minutes today due to my work . Melt furnace melting slow , Machine running low on aluminum. Melt furnace running too hot the damper lid is glowing red Melt furnace slow to melt ingots. Ingots not fully melted in 30 min. causing loader to jam when loading the next set of ingots. Melt stack glowing red Melting Burner had Flame Outs Melting Burner not lighting. Melting Burner, Frequent Flameouts Melting Crucible Broke "spout"
Holding Crucible changed, corundum around top of crucible Melting Crucible Changed for Inclusion Melting Crucible Cracked on 11-19-16 Melting Crucible PM Melting Crucible broke around spout area during operation (11-19-16)
Non Inventory crucible nippon0008, Non Inventory Nippon0010 half pipe Melting Crucible cracked, Replaced Melting Furnace Door handle latch threads damaged and unable to be released properly. Melting Pot Temp Controller showing AL01
Fix: Found melting pot thermocouple to be NG. Replaced melting pot thermocouple and tested ok. No additional downtime crucible being seasoned.
"NON INVENTOR Melting burner fails to ignite, flame out. Melting burner flame detection fault Melting burner flame out alarms . Melting burner flame out fault after having turned melting burner selector switch off to clean out furnace. Would not re-set. Melting burner flame out faults Melting burner flame outs
Holding burner flame outs Melting burner flame outs. Melting burner flameouts Melting burner not keeping up with demand.
Operator says flame does not look right. Melting burner will not fire Melting burner will not fire, flame out Melting crucible thermo couple issues.
Holding crucible re-melt thermocouple failure. Melting furnace burner flame burning rich Melting furnace charging door askew, East roller out of track. Melting furnace has a low air pressure alarm, not igniting. Melting furnace is not melting fast enough Melting furnace melting too fast/temperature too high
Cause: gas flow too high
Countermeasure: adjust gas flow down. 16.5 m/h down to 15.2 m/h ( match dc9) Melting furnace temp too high ,Damaged upper loading door,burnt through the perforated steel ,DCM to replace .Wires for thermocoupler were burnt,removed the bad section of wiring Melting furnace, flamimng out Melting stack lid is rusty Metal Leak Probes stuck I aluminum holding burner will not fire. Metal leak alarm. Metal leak on 1st shift. Found that the half pipe was cracked. Replaced half pipe @10:00am Passed on to John Chopson to have 2nd shift remelt so that 3rd shift can run Sunday night. Metal shortage alarms
exhaust temp reads high shutting off the melt burner
replace exhaust thermocouple
Also the setting for the furnace temp controller was set at 1452 should be set at 1652 Missing Missing Spring at shot sensor Mist Collector Filter Change Mist Collector filters. Mist collection filters Mist collector Mist collector filter Mist collector filter change Mist collector filter in red, out of spec-replaced Mist collector filter out of spec. 600 and 606 replaced 4 no downtime Mist collector filters in red Mist collector filters out of spec. Mist collector middle stage filters reading in red. Mist collector, Third stage gauge reads in red. Mist filter in red
Fix-Replaced 1 filter 606. Other filter replaced on 3/3/16 Model C/O parts request. Model Change on Dies Modification of the RPY 1 RKR Type program requested by engineered. Modify air blows on trim press. See attached file for changes. Modify logic for upper crucible lid. Made lid come up if the lower crucible level was high. See attached file for changes. Modify program so that breather cover type is recognized by the PLC. M202 coil logic- equal statement changed from K2 to K4. Modify robot pendant switch. C/M for production using wrong selection switch. Modify trim press air blows. See attached file for changes. Mold heater is overheating Mold heater overheating running 47 deg celcius. Molten Metal High Limit
Temp Detect Molten Metal Leak alarm, but not leaking. Molten Metal Upper Level alarm stuck on due to broken insulator on probes.
Fix: Replaced insulators and installed tested OK. Molten meltal High Alarm. Insulator bad on level probes . Could not find new insulators. Cut furnace brick to make new insulators. Confirmed that probes are working correctly. Molten metal probe moving Molten metal upper limit Monthly Die Cast MC PM Monthly Die Cast MC PM 650t Motor Over load.
Main scrap conveyor had parts jammed in it at the end.
Unjammed parts, ran conveyor. Motor over load on scrap conveyor. Motor starter for mist collector damaged. Movable side of the die. Changed the P1 and S1 slide core because they both have a crack over 10 mm. I changes both of these slide cores yesterday also. I am checking the spray points, spray conce Movable side of the die. 5A2 P/M F-28 Have to replace the P2 slide core Made in house because the roller groove it to wide. Replacing with a slide core from D1. Movable side of the die. 5A2 P/M F-24 Both P slide cores has cracks at 10mm. Both slide cores had around 7,000 shots on them. Replaced both P slide core and both slide core pins. Confirmed water to Movable side of the die. 5A2 P/M F-24. P1(10,000 shots)and P2(8,000 shots)slide cores have cracks that measure 10mm. Movable side of the die. 5A2 P/M F-27 Replaced both P slide cores for cracks exceeding 10mm. At the beginning of our shift it was found that all of the settings for the squeeze master were incorrec Movable side of the die. 5A2 P/M F24 The P2 slide core has a crack all the way at the tip. 10, 000 shots on this slide core. Very odd location to have a crack. Replaced the P2 slide core, confirm Movable side of the die. 5BA P/S F-2 The hot water manifold crashed. I will have to make up a new manifold. I found that the hex stock supporting the slide cores got bent when the manifold crashed Movable side of the die. Dropping the M parts. I found that both bottom M slide core holders were locked up and unable to move my hand. I removed both holders cleaned, clearance and reassembled the Movable side of the die. The P1 slide core (Produced by Matt Kline) that was changed by Drew an hour ago is out of spec for roller groove width and visual defects in the slide core.
Later confirmed Movable side of the die. 6B2 water passage F-2. Pin broke in the machine. Replaced M1.M2,M3,M5,M6 insert core pins.(SD) Replaced ejector pins 3,4,8,9,11,12.(SD) Movable side of the die. P1 slide core has a crack in it at 10 mm. 13,000 shots on this slide core. Checked for water leaks. OK (JEFF) Movable- 5BA P/S F1 Die Rebuild 15,698 shots ran on this run. Move core 2 malfunction. Extender cable for moving slide core was smashed. Replaced extender cable . Now OK Moveable Die Thermocouple wire was damaged/Melted Needs Die change to replace Moveable core 2 malfunction. Replace leaking Robot side hose to move core. Adjust read switch for light. Moveable core limit switch error Moveable side bottom thermocouple was pulled apart at the plug when the die closed. Replace thermocouple Moveable side cooling water valve stuck open causing inconsistent water temperature. Also found a couple other leaks in fittings/piping after reinstalling. Moveable side exhaust cavity is plugged with aluminum.. Remove debris. Moveable side on T-20 Die upper slide core had an exploded cooling water line. This is caused by running without the cooling water on. We verified that the valve was not turned on. Replaced 2 coolin Moveable side upper slide core with excess flashing. Removing Die to clean out relief pockets that are full of aluminum. Removed upper slide core. Removed upper cotter on the fixed side and cleaned an Moveable side upper squeeze pin fitting broken and leaking water
Remove and replace fitting Multiple issues after model changeover. N/G conveyor not moving. Verified belt is in good condition and not binding up. Conveyor moves slowly if it is helped. Checked motor voltage at motor relay HH54PW-L. Reading single phase power . NEED IT FOR MACHINE NEED NEW RUNNING ON M/C 1RKR NEED WOOL FOR UPPER CRUCIBLE NEW MODEL NEW MODEL SPRAY CARTRIDGE NEW MODEL, SENSORS FOR NEW N/G CONVEYOR CHUTE FLIPPER NG NG Metal mesh conveyor belt jammed. Removed many knock off tabs from the belt from running Water passage. The Belt is now functioning and running without stopping. However it is damaged and needs r NG conveyer chain broken on trim press NG conveyor at the bottom of the trim press is not rotating, chain conveyor is broken and tore. Replaced conveyor with new. Tested OK. NG conveyor chain mesh belt too damaged to run. Waiting on parts Belt 0151 that has already been ordered and should arrive Jan 23..
Install temporary countermeasure conveyor unit from used parts . T NG conveyor gearbox locked up. NG conveyor repair. Machine down for refractory rebuild. NG conveyor sticking NG scrap conveyor for trim press locked up and popping. NG temperature parts not kicking out back
Modified PLC program to allow proper reading of NG and good parts. ok NG temperature. Parts not coming out on NG conveyor
FIX-Set ejector time from 1.0 to 0.5. NIPPON0011
NON INVENTORY CRUCIBLE WOOL NO GOOD NO GOOD BEEN GROUND ON TO MUCH. NO INFORMATION AS TO WHERE THESE PARTS WENT ON WHICH DIE. NO LUBE NON INVENTORY
AF40P-060S BOWL FILTER NON INVENTORY "FILT-0081, 0532.140.156" NON INVENTORY 0532140156 FILTER NON INVENTORY FILTER, AFM40P-060 A5" NON INVENTORY NP2 DIECAST VACUUM EXH FILT. NOT RECORDING NOT WORKING Need Electrical out let installed at unload table so we can plug in dremels to repair parts. Currently have extension cord running from shot blast to the unload table. Need both left and right chain sprocket guarding replaced. Needed 4.0mm washers for DCM 4,5,7. Gave these washers to Darrell Cagnon to be milled down to 3.8mm. Needed Lot marks Needed a 1.5 ladle after change over. Needed a spray cartridge valve. Needed cooling rod for new model. Needed ladle for machine requested by Craig Randall Needed lot marks for 5A2 and 1 rocker Needed new springs for spray cartridge, old one very worn New TCPDIJ-1 module produces B-549 (Shot back pressure sensor is down) alarm. Next attempt countermeasure for CPU malfunction error. Installed new Communication Module TCRMT (Master I.O. Module)
At initial start up with new module there were no faults and now running. Still i Nitrogen gauge not reading
FIX- Replaced gauge Nitrogen regulator gauge broke for wand they use to clean out impurity's out of aluminum. Replaced gauge. No Communication No Die Lube To the tip and sleeve No Down time.
Replaced top filters because filter gauge was in the red. No Information as to why these were changed out No Sleeve was in M/c
Was running 5ba model No Vacuum pressure
Vacuum No1 was getting vacuum pressure as long as vacuum no2 was not on No data from squeeze master showing on main control screen of Die cast m/c No down time.
Problem: Operator called because flames were coming out the dog house when door was opened. No downtime
What: #20 on check sheet middle guage reading out of range
R/C: Filter clogged
C/M: Replaced both stage 2 prefilters, gauge reading correctly in range.
Will it reoccur: Timing No downtime
What: hepa filter reading out of range on check sheet #20
R/C: filter clogged reading out of spec
C/M: Replace top hepa filter
will it reoccur: Timing No downtime machine down for squeeze master relocation
What: Replace Robot covers Broken
Why: Wear from dropped parts/shots onto cover
R/C: Axis covers made out of plastic not to with stand a load
C/ No downtime, machine PM
What: Melted plexi glass
R/C: From plugged half pipe
C/M: Removed and installed new plexi glass
Will it reoccur: Timing
Cycle time: No change No downtime: Machine in planned downtime for PM
What: Trim press bearing worn needing replaced.
Why: Buildup of chips on top of trim press allowed chips to become in contact with bearing.
R/C: Prematu No information as to why ladle cup was changed No plunger lube and too big of biscuit. No water going into movable side of die Not all parts falling in ok bucket(blue conveyor). Ladle was leaking too
FIX-Replaced bolt and spacer. Replaced ladle Not setting in trim press Not working correctly Noticed that I forgot to do a work order to replace the Replace ladle lower unit ( was replaced on 12-4-23)
Changed the upper and lower gear box oil on the lade unit at crucible change timing. Number 4 shot detect sensor does not see part OFFSHIFT DAMAGED SLEEVE WITH HAMMER
M/C IS DOING MODEL CHANGEOVER "NO DOWNTIME"
SLEEVE LIFE - 15,431
LAST CHANGED 2/27/2018 OK CONV. OK Carrier stops before reaching return (down) position. OK Chain Conveyor Damage replaced. OK Conveyor Gear box and motor have sheared drive gears Replace 5GU15KB with 5GU25KB Gear box which was in inventory. The speed difference between these two is minimal and should run within time para OK Parts Table Stopping OK carrier Sensor abnormal. OK carrier Stops at top of travel OK carrier hangs up returning. OK carrier hitting prox sensor OK carrier jammed, will not move up or down.
Same issue, jams on upward movement. OK carrier jamming OK carrier jams after tipping, does not return. Intermittent issue. OK carrier jams before reaching tipping point OK carrier jams going up OK carrier jams when traveling up. OK carrier stops on the way down. OK conv. jams up OK conveyer jamming up at the top. Retimed chains and adjusted tension ok for now. OK conveyor binding OK conveyor bolt to sensor bracket sheared off OK conveyor box coming apart OK conveyor chain off OK conveyor chain tension not balanced, jams at top and will not return OK conveyor getting stuck OK conveyor is not going all the way up. OK conveyor is not working correctly. OK conveyor jammed up OK conveyor jamming OK conveyor not moving up OK conveyor not running OK conveyor part box is jamming. Support bearing shaft lost snap ring to hold carrier in position. OK conveyor parts transfer bucket fell apart. Replaced bottom plate and replaced all bolts. Drilled and tapped two bolts that were broken off. Replaced front dump plate and all new bolts. Heli coil OK conveyor table #2 not turning OK conveyor was getting a motor overload, discovered the slow down sensor for the up was NG causing the conveyor to slam and get jammed at the top. Replaced with new. OK conveyor will not move OK incline conveyor chain slipped disengaged from two sprockets. OLD CUP DAMAGED OLD CUTTER BROKE WHILE ADJUSTING OLD DRAW BAR BROKE OLD LADLE BROKEN, HIT BUILD UP OF SPILLED ALUMINUM OLD LADLE CRACKED OLD NUT THREADS N/G OLD ONE BENT, LADLE CUP PINTESTER OLD ONE BROKE OLD ONE CHIPPED OUT OLD ONE DIRTY OLD TIP PULLING SHOT OUT OF DIE OPERATOR DOOR LOCK BROKE OPERATOR ERROR. dh pulled air bowl apart from regulator stripping the lock down mounting bolt hole OPERATOR REQUEST OPERATOR REQUESTED NEW FILTERS FOR VACUUM SYSTEM DUE TO OLD ONES SATURATED IN OIL AND CONSTANT VACUUM FAULTS
GAVE TO GARY F.
"NON INVENOTRY VACUUM UNIT EXH. FILTER" OUT OF INK OUT OF RANGE OUT OF SPEC OUT OF SPEC "YELLOW" OUT OF SPEC ON CHECK SHEET OUT OF SPEC ON MIST COLLECTOR Oil Change
Gave to Darrell C. Oil leak coming from trim press. Oil leak on a single squeeze master Hyd. line. Ok Conveyor not moving, jumped a tooth on the front most chain. Skipped a tooth and tested it, OK. Ok Conveyor stuck at tipping point Ok belt not turning Ok conveyer not moving. Found set screws on motor clutch/coupler had come loose and key had slipped. Disassembled and replaced and tightend set screws and keys. Ok conveyor Motor gear head has a damaged keyway and damaged key and spins inside the clutch . Replaced the gearhead and key. The clutch keyway was not damaged. Ok conveyor bucket jamming up at top of conveyor Ok conveyor bucket not traveling all way up. Ok conveyor getting stuck part way up the track Ok conveyor jamming . Ok conveyor not traveling all the way forward Ok conveyor problems chains stretched . Ok conveyor will not move the motor is not trying to lift it . Ok parts turn table shaft broke. Okay bucket running at angle. Okay conveyor blue tub far side fell off, all bolts fell out. Okay conveyor is not working.
-Found: Key fell out of the shaft on the motor for the ok conveyor.
-Fix: Removed motor, replaced key, installed motor. Okay conveyor was uneven due to part making bucket skip chain. Old Punch worn and chipped Old cup was damaged while trying to remove"muffin" (vacuum hardened alluminum). Old one had hardened aluminum stuck inside Omron trim press safety door lock would not always unlock when pushing enter button due to a faulty relay On 5/29 operator come to me at the end of day for the reservoir on the trim press clamp pressure unit was leaking i had seen jeremy's work order which is fine but the oil reservoir was leaking so i ch Op bottom slide core is broke. replaced op bottom side core. Operator adding lube oil frequently. Operator blew a die block , which caused filters to be full of oil
"NON INVENTORY EXH. FILTER" Operator called for collision detect at trim press Operator door drain fitting missing. Operator door limit faults. Door switch hit during die change. Operator found Maint. check 27 out of spec Operator is doing a PM, vacuum filter needs replaced. Operator maintenance check no. 36 Trim press hyd. Press loo\w.
Reading 11 MPA acceptable range 12 - 14 MPA. Operator noticed that the die release usage was abnormal the bucket is always low . When I checked the concentration the meter read overrange. Operator noticed the wire for the probe level holding tank was loose and the wire fell off. Operator observed that the exhaust temperature was running low @ 450 Deg f and that flames were coming out around the furnace cover. Operator panel selector switch damaged Operator requested lot mark pins Operator requests ingot loader pusher be adjusted to travel not as far up. Operator says ingot loader not working in auto mode Operator says squeeze pin #3 is out of spec by 4 mm (too deep). Discovered that squeeze pin had came loose, retightened. Operator side Read switch N/G.Replace read switch that was damaged. Operator side vacuum block hose coming off fitting.
Vacuum block failure on low speed / pre-heat shot. Operator/DH having noticed air leaks @ die release lubrication pump.
-Found air fitting near pump leaking along with lub pump itself leaking air. Replaced air fitting and trimmed airline. Replaced D Overflow sub runner remains on the WAP part after trimming
Cause: Trim die press #1 tray bent allowing overflows to pile up inside the trim press. Robot position P63 at trim press take out NG teaching Overload relay for ingot charger elevator tripped, ingot cart not properly seated in lift. P F-9 MOVING
P/M F-19 MOVING P&S NO2 TRIMPRESS
BALL RETAINER MISSING OUT OF TRIMPRESS P-1 Trim height close to out of spec. and operator filing.
Adjust P-1 Cutters and remove part hold plunger that was stuck. Cleaned part hold plunger ,now ok
Test Shots for correct dimension .. Now P-2 Slide core cracked in roller groove. Length =26.191 N/G
Change P-2 slide core P/M #20
DREW P/M #20 MOVING P/M #23 MOVING , STATIONARY
DREW P/M 14 P/M 14 MOVING
DREW C. P/M 17 MOVING P/M 18 P/M 18 MOVING P/M 20 MOVING P/M 20 STATIONARY P/M 22
DREW P/M 23
DREW P/M F-13 P/M F-13 MOVING P/M F-14 P/M F-14 MOVING P/M F-14 STATIONARY P/M F-15 MOVING P/M F-15 MOVING
P/N F-17 MOVING P/M F-16 MOVING P/M F-17 MOVING P/M F-18 MOVING P/M F-18 MOVING
P/M F-16 MOVING P/M F-18 MOVING
P/S F-20 MOVING P/M F-18 MOVING "JEFF S"
P/M F-19 MOVING "JOHN S" P/M F-18 STATIONARY P/M F-19 MOVING P/M F-19 MOVING
P F-9 MOVING P/M F-19 MOVING
P/M F-20 MOVING P/M F-20 MOVING P/M F-21 MOVING P/M F-6 P/M F-9 P/M F-9 MOVING P/M F14 MOVING P/M F14 MOVING
P/M F-18 MOVING
P/M F-17 MOVING P/M F14-MOVING
S#10 MOVING
PM#15 MOVING P/M F15 MOVING P/M F17 MOVING P/M F19 MOVING P/M RELATED P/M-11 MOVING P/S 2 STATIONARY
DREW P/S F-15 MOVING P1 Slide core is chipped. replaced p1 slide core. P1 and S1 have cracked slide core need replace P1 and S2 slide cores cracked. P1 part dropping
Cause: axis 2 has air in the line
Countermeasure: replaced damaged o-ring on hydraulic hose P1 slide core P1 slide core NG. changed P1 slide core crack was over 10mm. Replaced P1 slide core. Checked die release filter and concentration. Check water flow through cooling joint and spray points. Also checked squeeze master settings. P1 slide core is cracked. replaced P1 slide core. P1 slide core is cracked. replaced p1 slide core. P1 slide core leaking water. Replaced P1 slide core P1 slide core replacement P1 slied core. Replaced P1 slide core P4 Squeezemaster hose blown. Replace Hose Now OK PART REQUEST PART REQUEST
GAVE TO DAN K PART REQUEST
MACHINE WAS DOING CHANGEOVER
THEY WERE PREVIOUSLY HAVING BLOW BACK BEFORE CHANGEOVER.
CHANGED TIP ONLY PART REQUEST
SB DIE 15 PART REQUEST FROM OPERATOR PART REQUEST TRIM PRESS PART REQUEST, CRACKED PARTS REQUEST PARTS REQUEST
VACUUM PROBLEMS PARTS STICKING
JAPANESE REQUEST FOR CHILL BLOCKS TO BE CHANGED PATCH SIDE DOOR PC Malfunction water passage part is stuck in the die
Cannot return the side cores or eject the part PC malfunction alarm on Toscast PIN BROKE PISTON VIBRATOR NOT WORKING PM PM #13 MOVING PM #14 MOVING PM #15 MOVING PM #15 MOVING
PM #16 MOVING
PM #13 MOVING PM #16 MOVING PM #17 MOVING
PM F-13 MOVING PM #18 MOVING PM #18 MOVING
PM #13 MOVING PM 12
DREW PM 13 MOVING PM 16 MOVING PM 17 MOVING PM 18 PM 18 MOVING PM 18 MOVING
PM 17 MOVING PM 21 MOVING PM Die release spray system
1- cleaned tank, strainer, and floats
2- flushed system with hot water and 16 cups purple power degreaser
3- removed and cleaned spray cassette
4- flushed system with water PM F-13 MOVING PM F-14 MOVING
PM F-18 MOVING
PM F-15 MOVING PM F-15 MOVING PM F-18 MOVING PM F-20 PM F-20 MOVING PM F14 MOVING PM F15 MOVING PM F17-MOVING
PM F14-MOVING PM F18 MOVING PM F19 MOVING PM FILTER CHANGE PM FILTER CHANGE
"NON INVENTORY" FILT-0073 PM PARTS
"2PCS IGNITION RODS" ALUMINUM BUILD UP ON BOTTOM, IF CUT WOULD BE TO SHORT PM RELATED PM VACUUM UNIT
FILTER NG IN AIR BOWL
CHANGED TO NEW STYLE FILTER PM for Diecast Hydraulic Unit. Squeeze master and Trim press. Group effort. PM on wiring on squeeze master and hydraulic leaks PM turntable conveyor. Machine scheduled down for refractory rebuild. PM'S PM-18 MOVING PRESSURE GAUGE AT FILTER READING IN RED
GAVE TO CRAIG R. PREVENTIVE MAINT. PREVENTIVE MAINT.
"NON INVENTORY BUSCH 0532.140.156" PROJECT WORK
OILER FOR DIECAST 5 VIBRATOR PUMP FAILURE PUSHER NO.2 FORWARD LIMIT SWITCH NO GOOD, CHANGED SWITCH Part Request Part Request for Ladle Cup Part Request gave to DH/operator Part Request. Part hitting vibrator Part kicking out cavity 4 but all readings good SQM and DCM. Part remained in the Die and ejectorpin broken.
Spray concentration was off the chart below and injection cylinder not injecting properly.
Replace injection unit. Part request Part request for machine modification work. Part request. Part stuck in die WAP F7 die
When the operator started the machine the first time the temperature controller and water valve were off/closed. On the second attempt to start the machine the operator s Parts Request Parts Request. Parts bucket hanging up as it goes into dump guides. Operator side bucket bearing needs replaced. We dont have one in stock. machince side of the bucket had enough space to accomadate a slight lean, s Parts carrier not moving. A loose set screw allowed the shaft key to move out of position. Parts getting hung up on scrap press after cut, made an airblow that feeds off of an existing solenoid and rewired N06f to fire with N06E. Parts not trimming out completely (Breather Cover) Parts request Parts request Die Cast 4, leaking Parts request die cast #5 Parts request for model changeover. Parts request. Parts sticking to die caused by excessive tip wear, replaced tip and adjusted plunger lube to ensure corkscrew in sleeve. Parts wedged into NG Conveyor. Chain belt wont move.
Removed NG COnveyor and removed the jammed parts and tabs Now OK Passed down from 1st shift W006177. Passed on form 1st shift.
Robot needed retaught/finger bent. Passed on from 1st shift. Patch Loading Door on furnace / repair half pipe Patch furnace side & loader doorway Patching back and side door. Pin controlled by #1 channel of squeeze master sticks in the "out" position.
MACHINE IN SETUP FOR NEW MODEL, NO DOWNTIME. Pin tester cup Piston vibrator is not working
No replacement parts. - temporary countermeasure is to leave on continuously until a replacement arrives. Planned project for trim press air blows, air blows now controlled by solenoids. Water passage support cylinder now controlled by solenoids also. Please cancel this WO Plexiglass in door broken. replaced with new. Plugged causing water shortage Plunger Lube Air Supply Filter Bowl leaking.
Fix: Replaced Air bowl. Plunger Lube Spray tip bracket piping came loose. 1o mm bolt that holds the piping in position was too short to hold the piping tightly. Installed a longer 10 mm bolt and reinstalled . ended up help Plunger lube fails to be applied Plunger lube in crush parts in the lab Plunger lube in parts after crush test in the lab Plunger lube line Plunger lube lost prime Plunger lube not being applied Plunger lube not holding prime Plunger shaft Poka-yoke for cooling line flow direction Plunger shaft cooling Poka-yoke for cooling flow direction. Plunger shaft extension broke. Plunger shaft stuck in the sleeve Plunger tip is sticking to the biscut pulling shot apart.
Replaced plunger tip and confirmed proper plunger lube operation. Polish 30B F-1 ribs due to thick soldering. Polish and clean 3D4 F-6 die before shift change. Porosity 5A2 tensioner cavity 4 Porosity NG section H-H found at X-Ray Porosity cavity 2 squeeze pin area RPY 1RKR
Countermeasure: put settings back to match PLEX
Fix Core On Time was 1.3 change to 1.5
Blow time was 2.7 change to 3.0
Blow time up was 1.0 change to 1.5
Ad Porosity found in start parts in the die lab 5A2 Tensioner cavity 2 Porosity in P1 and P2 parts
Confirmed plunger lube, die release, die temp, vacuum,
Adjusted die release from .7 to .6 ,turned die spray pressure down from .4 to .35 , adjusted die temp up fix side 31 Porosity problems all cavities Preperation to run new part for QAV not going into scrap press properly. Teach robot positions. Pressure Build up Faults/ Blow Back Pressure gauge for top set filters reads out of spec. Previous shift reports R/B stopped at trim press, low, still holding shot. Previous shift reports Vacuum block being changed shortly before M/C was shut down for P.M. Previous shift reports melting burner running constantly, does not reach set point. Previous shift reports multiple issues, Hyd. pump shutting off.
Informed production that base bolts where loose and tighten back up and after their PM robot positions need checked. Problem - Trim depth NG
Temp countermeasure - Lengthened the timer on the robot so the part would stay in the dunk tank longer.
Long term countermeasure - Still investigating
recur - not sure Problem at part detect. Problem at trim press. Leaving mark on part when setting into trim press. Requested to fix scrape mark on part. Problem: 59B Parts jamming in ok part bucket and track
Cause: 59B chain tensioners to long to fit down track
Countermeasure: Building new ok bucket and unloading conveyor to allow 59B parts to fit Problem: 59B Parts jamming in ok part bucket and track
Cause: 59B chain tensioners to long to fit down track
Countermeasure: completion of new ok bucket and unloading conveyor to allow 59B parts to fi Problem: After Change-over they keep getting either biscuits alarms or high shot alarm. Problem: After change over Axis alarms, and having vacuum issues.
Added shim to cooling block for vacuum issues. Problem: After change-over from RPY to 59B-1RKR. Problem: Air hose came loose.
Cause: Air fitting failed.
Fix: Replaced air fitting.
Reoccurrence: NO Problem: Air leak at trim press.
Replaced regulator bowl. Problem: Air leak in the vacuum cabinet.
Fix: Replaced the compression fitting, due to old one missing seal. Problem: Air pressure drop fault on trim press
cause: Main air bowl leaking out top
countermeasure: replaced main air blow and set air pressure to correct setting
reoccurrence: No Problem: Aluminum build up on sleeve.
Root cause: 90 set wrong.
Countermeasure: We set 90 and bent sleeve bracket so sleeve could not move.
Will Problem Reoccur?: With 90 set right no problem. Problem: Aluminum not melting
Cause: The connections for thermo couple on the back of furnace were bad.
Fix: Reterminated thermo couple
Reoccurrence: No Problem: Axis 1 alarms(to low). Problem: Axis 3 Alarms.
Added Nitrogen. Problem: Back left cutter broke
Cause: Unknown cause found due to trim hiegth issues
Fix: Used a none inventory cutter from a spare trim press by die maintenance.
Reoccurrence: Yes on going issue with Problem: Biscuit size alarms
Cause: Ladle unit is bad
Fix: Replaced hole ladle arm and bearings
Reoccurrence: Timing Problem: Blew Robot side vacuum block.
Ran for an hour blew another block but this time it was operator side this time Problem: Blew vacuum block on robot side. Problem: Blowing vacuum blocks both sides
Cause: Oil in vacumm over full, air pressure on low side
countermeasure: all lines were replaced, filters cleaned, adjusted air pressure. Drained 2 gallons oi Problem: Blown Vacuum Block (operator side).
Root cause: Dirty Filters.
Countermeasure: Cleaned filters.
Will Problem Reoccur?: Yes. Problem: Blown Vacuum block (robot side). Problem: Blown vacuum block (Robot Side).
Cleaned filters. Problem: Blown vacuum block on operator side. Problem: Blown vacuum block operator side.
Replaced hoses. Problem: Blown vacuum block. Problem: Blue Okay bucket was not able to advance. Problem: Blue bucket on okay conveyor was coming apart.
Replaced missing bolts in bucket. Problem: Broken sensor (the scrap detect sensor) on scrap press.
Fix: Replaced Sensor. Problem: Burnt water line on die.
Replaced water line. Problem: CP4 tripped, sensor relay power source. Problem: Channel 3 on squeeze master isn't working properly.
Fix: Replaced leaking fitting on manifold not being used and bleed channel 3 at squeeze pin cylinder. Problem: Circuit protector 4 tripped. Which is Sensor Relay Power Source.
Fix: Replaced sensor X087 at the end of the scrap conveyor. Problem: Cooling joint at plunger leaking.
Fix: Replaced cooling joint. Problem: Cooling joint in sleeve is leaking.
Cause: Ring build up on sleeve
Fix: Replaced cooling joint and cleaned build up off shaft.
Reoccurrence: yes- if pour time is changed to pour longer this p Problem: Cracked ladle cup.
Replaced ladle cup. Problem: Die Lock Force change after injection. Problem: Die Release Pump not cycling.
Replaced Pump. Problem: Die release floats(passed on from 2nd Friday)
cause: Build up on floats
countermeasure: Removed floats and cleaned, tested ok turned on water, air and confirmed die release. Hand wand and spr Problem: Die release over flowed. Problem: Die release pump is leaking at base.
Fix: Replaced the bottom manifold on pump. "NON INVENTORY" Problem: Dropped part. Problem: Dropped shot. Problem: Dropping part. Problem: Dropping parts. Problem: Dropping shot. Problem: During crucible change. Problem: Filter for hydraulic pump gauge was in the red.
Replaced filter, no down time was already down. Problem: Fixed side no water flow in auto.
Fix: Valve was sticking, freed up valve and tested no further issues. Problem: Flow alarms on MV side die reading below 28l/m usually reads around 41 l/m
Cause: Drain valve partially open. The operator opened and closed the drain valve and the flow rate returned to nor Problem: Head damper closed on charging machine bucket. Problem: Helper door not closing.
Adjusted sensor strip on door. Problem: Helper door pressure sensor not hooked up, wires broke off and pipe in door unthreaded and dangling causing broken wires.
Fix: Repaired wires and rethreaded and reinstalled pipe Problem: Helper side door not moving.
Bolted Helper side door to cylinder. Problem: High casting pressure alarms. Problem: Hydraulic leak Problem: Hydraulic leak. Problem: Ingot loader crash
Die lock force change after injection checked and cleaned probe - completed at shift change. Problem: Ingot loader crashed. Problem: Ingot loader jammed. Problem: Jack-hammer plate from modification was causing loading issues with ingots. Problem: Ladle Equip. Key missing/lost.
Fix: Replaced key. Problem: Ladle Traveling Limit Switch Malfunction (B-064).
Root cause: Bad cable (x60) ladle limit switch
Countermeasure: Replacing cable on Ladle Unit.
Will Problem Reoccur?:
Replaced ladle unit ass Problem: Ladle arm locked up and crashed/broke ladle.
Took ladle unit apart.
Passed on to 3rd shift. Problem: Ladle broke.
Fix: Replaced ladle. Problem: Ladle cup broken at spout.
Replaced ladle cup. Problem: Ladle electrode problems, ladle going to deep in aluminum.
Fix: Replaced ladle electrodes and wire.
Also had to coat the electrodes with titanium dioxide. Problem: Ladle electrode wire break. Problem: Ladle limit switch malfunction/Ladle traveling forward limit switch and Die lock force change before injection all at same time. Problem: Ladle lower unit dunked it's self into aluminum. This has happened several times tracked down to 2nd shift. Found when DH is operating machine they are opening the door before cycle finish ca Problem: Ladle not working properly. Problem: Ladle was faulting out. Problem: Line pressure Malfunction
Cause: Hydraulic pump not coming up to pressure correctly
Countermeasure: Manually cycled pump several times and pressure working properly.
Reoccurrence: unsure of Problem: Lube filter leaking.
Tightened fitting, replaced o-ring. Problem: Main conveyer alarming out because it thought it had parts in front to the conveyer sensor. Problem: Molten Aluminum Upper Limit. Problem: Molten Aluminum Upper limit. Problem: Molten Metal Upper Limit Alarm.
We replaced cables. No down time, kept machine running. Problem: Molten metal low temp.
Cause: Probes had aluminum build up on them not allowing aluminum level to reach thermo couple.
Fix: Knocked build up off probes.
Reoccurrence: NO Problem: Molten metal upper limit
Fix: Electrode wire was grounding out on conduit, pushed insulation down over wire Problem: NG conveyor not moving.
Ran new cable and replaced M6 relay. Problem: Not enough adjustment in the robot part detect sensors.
Fix: Rotated sensors to allow for more adjustment with different models. Problem: Ok conveyor getting stuck on return.
Fix: Tightened chains and replaced bolt on conveyor flag. Problem: Okay conveyor chain fell off of sprocket.
Adjusted chain. Problem: Okay conveyor not moving.
Fix: Loosened motor and put the chain back a link and tightened the chain on the adjusters. Problem: Okay parts conveyor had hole in it causing it to jam.
Replaced mesh conveyor. Problem: Okay parts conveyor not moving. Problem: One pin (S1-part) squeezing too deep. Problem: Operator side blown block.
Replaced black vacuum hoses, cleaned filters. Problem: P1 trim height out of spec.
Countermeasure : added .150um shim to ingate cutter total thickness .350 um Problem: Part detect.
Fix: Adjusted lower left part detect. Problem: Parts getting stuck in trim press.
Fix: Replaced cutters. Problem: Plunger lube not always coming out.
Cleaned plunger lube piping. Problem: Pressure Build-up Time alarm.
Did a V-check. Problem: Production was trying to run die trials and ran wrong program and crashed robot bending end of arm tooling bracket,
Fix: Replaced bracket. Problem: Pump not continuously pumping.
Replaced pump. Problem: Replaced base plates for bottom trim press so that die cast 3 could change over to run RPY 1RkR. Problem: Robot Collision detect at trim press
FIX: Touched up P23 Problem: Robot collision detect faults in die. Problem: Robot fault. Problem: Robot faulting out at trim press. Problem: Robot faulting out at trim press.
Fix: Taught points in trim press. Problem: Robot is having collision detect alarms.
Cause: Robot isn't setting shot in trim press correctly.
Fix: Touched up pos. 24 and 25
Reoccurrence: No Problem: Safety sensor On light, could not manually move trim press
Cause: Y06E air blow solenoid shorted
countermeasure: Replaced air blow solenoid
Reoccurrence: No, Solenoid shorted out causing sev Problem: Scrap Conveyor 1 (smaller scrap conveyor) motor overload alarm.
Swapped out conveyor with rebuilt conveyor. Problem: Scrap conveyor 1 jammed. Problem: Scrap conveyor motor over load.
Fix: Cleaned out scrap inside under conveyor. Problem: Scrap press alarming out
cause: Product detect sensor not working, extra shot got caught on sensor and broke.
countermeasure: replaced product detect sensor on scrap press, Ran wires thru air Problem: Scrap press not crushing shot.
Adjusted bottom sensor. Problem: Scrap press not working.
Adjusted sensor. Problem: Scrap press stuck down.
Replaced relay, cutter, bearings and rods. Problem: Screw broke in part detect rail for sensors.
Drilled screw out, re-tapped. Aligned part detect sensor. Problem: Sensor X017 on Okay Carrier Advance was staying on.
Replaced sensor. Problem: Settings Shortage Warning faulting machine out due to loss of vacuum. Problem: Shot bisect coming off of sprue before robot is coming in to pick up (happening random), this causing robot to pick shot up badly and fault out at trim press or scrap press. Problem: Shot getting crushed and left behind causing robot to crash.
Brought trip press up so that it would not crush shot. Problem: Shot was getting crushed at trim press leaving part of shot behind causing collision with robot.
Tightened nut on top of trim press. Problem: Sleeve rotated causing ladle to over pour.
Re-bent bracket that keeps sleeve in place. Problem: Sleeve turning allowing aluminum to pour outside of sleeve
cause: Sleeve holder did not have a bolt hole to allow holder to be stationed correctly
countermeasure: Drilled and tapped new hole Problem: Slide core damage. Problem: Slide core issue
Cause: Aluminum is way to hot causing coating to come off slide core and stay on part, thermo couple was melted in half
Fix: Changed thermo couple.
Reoccurrence: Timing. Problem: Spot cooling line for slide core broke.
Fix: Replaced cooling line. Problem: Spot cooling line to sleeve broke. Problem: Spray cartage leaking.
Took pipe off and thread taped it. Problem: Spray cartridge not spraying or blowing
Cause: It is over shooting it's down light.
Fix: Adjusted sensor checked spray points all looks good.
Reoccurrence: No Problem: Spray cartridge sloppy.
Fix: We tapped bolt holes and replaced bolts. Also, centered cartridge. Problem: Spure bushing leaking.
Replaced spure bushing. Problem: Squeeze master hydraulic pump wont turn on
cause: overload tripped on motor starter
countermeasure: reset tripped overload, checked overload on machine #2 found overload setting not same on s Problem: Squeeze pin chunking out part. Problem: Squeeze pins would not move. B-433 Moveable Core 2 operation malfunction. Problem: Tappet depth out of spec on cavity 2 (die #3)
Cause: Tappet not returning completely, Tappet loose or broken on die
countermeasure: Tried cleaning with all clean to get tappet to return compl Problem: The Upper limit probes where too short.
Replaced probes. Problem: Tip and sleeve are at life.
Cause: Normal wear of parts.
Fix: Replacing parts
Reoccurrence: Timing Problem: Tip/Sleeve life
cause: tip/sleeve at 117924 shots
countermeasure: Removed and installed new tip and sleeve
Reoccurrence: No, not until shot life Problem: Trim damage cavity 2 RPY-1RKR parts.
Adjusted cutters for cavity 2. Problem: Trim damage on cavity 2.
Adjusted cutters on trim-press. Problem: Trim press had parts stuck in it. Problem: Trim press having too much trim on parts or chunking out parts. Problem: Trim press keeps alarming out.
X99 scrap press part detect sensor, replaced reflector. Problem: Upper crucible lid dcv valve broke.
Fix: Replaced valve. Problem: Upper furnace temperature not correct (Too hot)
Cause: Build up off extra material around thermocouple
Countermeasure: Removed top exhaust stack, jackhammered build up out off machine to read Problem: Vacuum block blew, die release pump bad. Problem: Vacuum block blew. Problem: Vacuum block blown on robot side (No. 2). Problem: Vacuum block blown robot side. Problem: Vacuum block on operator side blew. Problem: Vacuum block on robot side blown. Problem: Vacuum blown block (Robot side). Problem: Vacuum fault but vacuum blocks are not blown. Problem: Vacuum faults
cause: blowing vacuum blocks both sides
countermeasure: operator replaced all lines, I cleaned filters and checked air filters ok. Replaced vacuum ejectors due to no date on the Problem: Vacuum faults
cause: main air pressure regulator up to high, causing 1 and 2 pressure out of spec
countermeasure: adjusted pressure regulator down to allow preshots to be in spec.
reoccurrenc Problem: Vacuum issues both sides. Problem: Vacuum issues. (Running 5BA P/S). Problem: Vacuum problems
FIX: Added die release
Problem: Dropping shot too
FIX: Replaced tip and sleeve and moved thermo coupler to bottom Problem: Vacuum problems
FIX: Swapped #2 valve to #3 on vacuum pump Problem: Water hose leaking.
Replaced hose. Problem: Water leak.
Fix: Replaced blue hose on moveable die. Problem: Water leak.
Replaced fitting. Problem: Water leaks on die.
Trimmed hoses. Problem: die release tank overflow
cause: float sticking allowing valve to fill
countermeasure: Cleaned float and verified floats on/off ok
reoccurrence: No Problem: high speed shot alarms, all 4 axis alarms high, bisket thickness alarms
cause: worn tip 49,591 shots
countermeasure: replaced tip, honed sleeve
reoccurrence: No, will reoccur once tip and sl Problem: ladle isn't getting any aluminum.
Cause: Ladle unit is bad
Fix: Replaced ladle unit
Reoccurrence: Timing. Problem: ok conveyor jammed
cause: snap ring came off of cam roller allowing roller to come out jamming conveyor
countermeasure: Installed new snap ring on cam roller. Manually worked ok conveyor ok
r Problem: ok conveyor would not return to position
cause: Broken bolt in tub allowed bucket to jam
countermeasure: Replaced broken bolt and checked clearance under bracket.
reoccurrence: No Problem: unload table motor overload
cause: build up of small material from trim press
countermeasure: removed all plates and covers to expose under the table, cleaned all material and reinstalled. Ve Product detect Product detect sensor 1 not seeing part Product detect sensor inserted wrong by DH. DH cross threaded the threads into the wrong hole. Repair as needed. Product detect sensor not working. Tried several sensors. Root cause was loose wiring in robot cabinet. now OK Product detect sensors not registering on robot extraction system control panel Production PM. Production Parts Request. Production attempting a 100 shot trial unable to complete due to robot issues. Production parts Request. Production reports Lube unit using excessive mount of oil. Production reports spray cartridge not spraying in center Production request for TC Sleeve and Tip, dropped parts trouble. Production request for plunger joint assembly. Production to install. Production requests D/C units 1,2,3 be equipped with trim press lights.
Beginning with D/C #1 Production requests fluorescent light be installed at trim press.
(Same as installed on D/C M/Cs 1,4,5,6,7&8.) Production requests replacement ladle. Production tree light not working see attachment Project for relocating azbil flame controller to side of cabinet. Project work of moving location of Azbil Protectorelay inside the cabinet. Pull cutters 1,3 &4 off upper trim press die and deliver them to Scott T. to have drawings made. Pull scrap conv. #2
M/C down for Furnace P.M. Pulled E-stop out of machine by helper side door to check with D/C #6 problem. Ok now Pulled die for major water leak Moving side. Upper slide core right pocket full of aluminum and melted water lines behind the ejector plate. Replaced all melted water lines cleaned both sides of di Pump making noise
Fix-Welded pipe Pump stopped working Punch press sensor detecting overflow that is not present
Cause: shot slipping in the robot gripper
Countermeasure: Adjust P75 and P45 lower Pusher 2 Limit Switch not positioned properly.
target fails to contact limit switch arm. Pusher assembly collides with furnace door when loading ingots. Pusher lift not low enough to allow conveyor to advance ingots. Pushers coast off return sensors, dropping out "Auto" light. Auto loading process is interrupted. Put RPY 1RKR F-3 in machine. Die didn't have chill blocks. Got 2 chill blocks for die. Quick disconnect of hose reel air line leaks, will not seal off when gun is removed. R/B chuck fingers need changed out. Note: machine has been sitting awhile. R/B collision alarms at trim press and scrap press. R/B collision detect alarm at trim press G:1 A:5
Fix: Replaced main robot harness. R/B collision detect alarms R/B fault Servo 037 IMSTP Group one R/B faults at scrap press R/B has crashed several times on off shifts, Craig R. working to confirm R/B has no issues. R/B making tumbling noise as it moves from trim press to scrap press. R/B run up against Helper door.
SRVO 46 OVC alarm R/B waiting for Hand Un-chuck signal R/S SIDE CUTTER BROKE RAN OUT
THERMOCOUPLE BLOWNOUT RB not setting shot in chopper correctly READING HIGH OUT OF RANGE
MAINTENANCE CHECK SHEET READING IN RED READING IN RED, OUT OF SPEC READY LIGHT NG REBUILD LADLE ARM REBUILD TRIMPRESS REBUILDING FURNACE TO PUT CRUCIBLE IN RED OUT OF SPEC REPAIR LADLE ARM ASSY'S
PUT 3 UNITS BACK IN INVENTORY AS "NON INVENTORY" REPLACE 2 WORN DRAW BARS REPLACE CRUCIBLE FILTER ONLY REPLACE FILTER
GAVE TO JOHN C. REPLACE HALFPIPE REPLACE PAPER CHART RECORDER REPLACE WOOL IN SIDE DOOR REPLACED AIR GAUGE ON DIE RELEASE TANK REPLACED HALF PIPE , BROKE REPLACED T BOLTS AND FLANGE NUT REPLACED THERMOCOUPLE AT FURNACE CHANGE REPLACEMENT
"GAUGE0029" REPLACING RPY/5BA TRIMDIE WORN PARTS TO IMPROVE TRIMDIE CONDITION
GAVE TO CRAIG R. REQUESTED AT C/O REQUESTED BY SCOTT TAYLOR REplace Stage 3 and Stage 1 hepa filters (reading in red) RIBBON NOT READING ROBOT AIR PRESSURE GAUGE BROKE ROBOT CHUCK LOST ROBOT CHUCK REBUILD WHILE M/C CHANGEOVER TO DIFFERENT MODLE ROBOT CHUCK SENSOR ROBOT CHUCKS FINGERS WORN, GRIPPING TROUBLE
GAVE TO CRAIG R. ROBOT FINGER WORN ROBOT PANEL RPY P/S F-1 Movable side. Leaking O ring. I had to tear apart the top cylinder to get to the cooling joint for the slide core and replace the o ring. RPY 1RKR F-1 Movable side Multiple blow outs on robot side. RPY 1RKR F-1 Hydraulic leak. I had to make a new hydraulic line for the operator side cylinder. OK to run. RPY 1RKR F-12 Movable side. Thermocoupler not reading proper die temp. Replaced with new one. RPY 1RKR F-19 Machine stops with no alarms when opening slide cores. RPY 1RKR F-3 Cavity 3 squeeze pin came loose. Took the die apart far enough so that I could tighten it. RPY 1RKR F4 cavity 1 trim area 4 scraping the part to deep RPY 1RKR die is blowing out aluminum from operator top side of die
Confirmed settings and found the temperature was out of spec too high and also biscuit size was out of spec too big
Changed settings RPY M Die 7, RPY 5BA M Trim 1.
What: High trim cavity 3.
Why: Cutter needed adjusted.
Countermeasure: Adjusted cutter block.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. RPY M F-8 Movable side Blown hydraulic line on side cylinder. RPY MID F-3 3,633 shot Broken helper bottom slidecore, snaped off at base. Replaced with new slidecore. RPY MID F-3. Flashing on the die. I found that there was a burr inside the robot bottom slide core pocket. Both bottom slide core were bound up. I took both bottom slide cores apart to clearance t RPY Mid F-1 A lot of flashing around cavity 2 from side slide core, replaced slide core. RPY Mid F6 Replaced sprue bushing. Forgot to clock out. Sorry RPY Mid F7 Replaced sprue bushing that was leaking. JBS RPY Mid F7 Sprue bushing leaking water inside the bushing. This did not take .53 hours. Started clock, then waited for the fixed side of the die to be taken out of the D/C mach. JBS RPY P/S F7 Replaced P2 slide core for soldering. JBS RPY P/S F-1 Sprue bushing leaking, replaced sprue bushing. RPY P/S F-2
What: Water leak
Why: The P1 slide core broke at the base.
C/M: I replaced the P1 slide core. Only 7,000 shots on this slide core. I clearance the slide core, it was extremely tight to RPY P/S F-2 Replaced both P1 and P2 slide cores, because of soldering. JBS RPY P/S F-2 Sprue bushing has a leak. Replaced the sprue bushing RPY P/S F-4
What:Broken S2 slide core,Broke off at base.
Why:unknown
CM:Replaced and checked for proper cooling.
Reocurr: Possible in time but not likley RPY P/S F-4 Replaced cracked P2 slide core. JBS RPY P/S F-5 Broken S2 slide core. and tappet pin 2,500 shots RPY P/S F-5 Cracked P1 slide core quality says NG S2 also cracked NG. RPY P/S F-7 Movable side Replaced broken tappet pin P1. 31,686 shots RPY P/S F-8 Quality say P1 P2 slide cores out of spec for soldering, tried cleaning but they say NG must be changed. Installed 2 new MK slide cores. Likely will reoccur. RPY P/S F-8 Broken tappet pin cavity 1 Replaced s1 ,p1 slide cores for wear. RPY P/S F-8 Fixed side Cracked and leaking sprue bushing. Replaced with new one reoccur in time. RPY P/S F-8 Quaulity says P1 slide core is NG, go no go gauge does not fit properly. Replaced with new MK slide core. RPY P/S F-9 Operator thinks s
S2 tappet pin is out of spec. Replaced tappet pin. RPY P/S F1 Sprue bushing leaking water, replaced sprue bushing. JBS RPY P/S F3 Replaced P1 slide core and slide core pin. JBS RPY P/S F3 P2 slide core cracked, replaced slide core. JBS RPY P/S F8 Replaced leaking sprue bushing. JBS RPY PS F1 fixed half. Had a cracked sprue bushing causing porosity in parts. Replaced sprue bushing. Re-plumb gauges for checks 37, 38 & 41 Rebuild Rebuild Fanuc Robot Hand Assy Rebuild helper door Rebuild ladle unit arm assembly for spare unit. Red,Green and Yellow light on the machine were burnt out.. Regular Crucible Filter Replacement.
Machine scheduled down for part sorting. Reinstall Ingot loader Door safety device. Hanging next to the loader door. Now OK Remove all 4 New Machine shop Roller groove slide cores and Replace with New TEG slide cores to confirm difference between the makers and why we are seeing so much flashing in the roller groove featur Remove and repair all damaged or bent ingot loader flights. Repair furnace back door refractory and side door refractory Remove and replace holding crucible Remove old Vacuum Tank and reinstall new tank Remove rear safety door, remove door linear slides and install fabricated swing hinges. Now OK Remove soldering from die around holes and grooves. 30B F-1. Remove top slide core cylinder and tack weld threaded post that was turning and causing move core malfunctions. Removed and cleaned spray cartridge to counter measure vacuum issues.
Operator had crane training I don't know what their status on the work center was but there was no maintenance down time. Removed upper crucible lid . Removed old screen , repacked lid and welded a new screen on it. Reinstalled and tested Removed upper crucible lid . Removed old screen . Repacked the lid and welded a new screen on it. Reinstalled and tested Repack furnace side door Repair EHS Audit items see attachment in work request Repair Furnace Loading door. Sunday 9/27/15 Repair Hydraulic Leak. Repair Part Repair broken Ladle wire Repair broken Plunger shaft cooling line fitting Repair discharge conveyor flipper #1 loose/broken bolt Repair leaking water pump on the mold heater.. Replace worn mechanical seal. Repair robot chuck fingers. (Broken mount bolt) Repair trim press ok conveyor, jamming up. Repaired damaged refractory at ingot loading furnace entry and side door Repaired holding crucible Metal leak door refractory and verified metal leak probes Replace "scrap conveyor belt assembly. Also replaced drive shaft and drive sprockets. Removed two sections of conveyor, too long to tension properly. Attached drag plates and motor assembly. Herb Sapp Replace (P2)Primary operator side slide core, cracked w/approx. 3,900 shots on F-20 die. Cause possible from squeeze pin pressure to high. Adjusted from 13 Mpa to 12 Mpa on channels 2 & 3. Note: 13 Mp Replace 1 inch water cooling hose to new type of hose GATES PLANTMASTER HOSE Replace 1st stage mist collector filter gauge reading in red. Replace 2 filters in dust collector. Replace 35A and 35C Hepa filters that are reading in the red Replace AC spindle motor on squeeze master unit with US purchase style motor. Cost down countermeasure. Replace Cavity 4 Roller groove slide core. Chipped and reading above .500 Replace Conveyor Chute Divider Sensors Replace Crucible , spout broke. Replace Crucible due to possible breakage Replace Die Cast Crucible Filter only Replace Diecast Crucible Filter only Replace Discharge Chute Sensor Replace Fixed side #1 Thermocoupler. Temp is reading high and robot is kicking out parts as scrap. Will also drop chiller 2 Degrees, currently at 34C down to 32C.. Replace Holding Crucible Filter Replace Holding Crucible Only, Filter Blocks Broke Replace Holding Crucible because required air gap is clogged for the heat to rise up through
Half pipe cracked, leaking in behind crucible . lack of skimming behind filter
Melting Crucible replaced, Replace J1 Axis servo motor. Motor brake failure found during PM. Replace Ladle Cup Replace Ladle lower unit at crucible change timing
Changed the upper and lower gearbox oil on the ladle unit Replace Lower Holding crucible Replace Lube pump unit leaking. Replace Melting Crucible ONLY
Reason for Change: Inclusion Replace Mist Collector Hepa Filters Replace N/G conveyor chain and test Replace O-rings on DIXON hydraulic couplers and inspect 1 inch water lines. did not replace water lines the condition was good. Replace P-1 Slide core. CHunked out at roller area Replace P1 & P2 slide core do too cracks in slide core. replace cooling joint on robot side Replace P1 slide core do to it being cracked Replace P2 Slide Core (OP Side) Cracked, Die Rebuild 5A2 P/M F-22. Replace P2 slide core do to crack in slide core Replace RPY Trim Press Cutter. Replace S-1 Slide core Replace SW14 cooling joint on top slide core of 3D4 F-6 due to nozzle blowing out of the old cooling joint. Replace Scrap Conveyor Replace Scrap conveyor run detect sensor. Replace Spray Cartridge Cylinder Air Muffler
Bled all airlines (water in lines) Replace Spray Cartridge Diaphram Pump, "was not working" Replace Spray Cartridge Swing Knuckle Replace Spray Cartridge valve due to leak. Replace Stage 3 Hepa filters
Top filters Replace Top RB Slide Core and tappet pin due to cracking, shot was closed in die. 6A0 P F-10. Replace Trim Press Linear Bushings Replace bad thermocoupler. Replace broken bolts in Spray Cartridge Cylinder Replace broken ladle Replace broken ladle,1.0 Replace broken ladle. Replace broken roller groove slide cores op side. Replace op side hydraulic cylinder and read switch. Replace broken safety latch
JR Otto. Replace chipped P3 slide core Replace crucible while machine is out for refractory rebuild. Replace cutter 59B 1RKR 3 Replace damaged NG Conveyor wire mesh belt. Replaced and tested. OK Replace digital temperature chart recorder with paper print out type. Replace holding & melting crucibles due to crack in filter and half pipe during 3rd shift. Replace holding/melting crucibles. Operator error in operations caused crack. Replace ingot loader motor drive chain Replace ingot loader motor drive chain. Replace ingot loading Advance return solenoid with correct configured valve. VFS3300-1FZ was installed previously because of failure of the previous valve and allowed push cylinder to bleed off from t Replace ladle cup Replace ladle cup (Production) cracked. Replace ladle cup, broke. Replace ladle cup, cracked. Replace ladle cup, cracked.
GAVE TO KENNY C Replace ladle cup, damaged during manual operations by DH. Replace ladle cup, major aluminum build cause of break. Replace ladle cup. Replace ladle lower unit during crucible change Replace leaking sprue bushing Replace malfunctioning spray metering pump. Adjust settings and test. Replace melted water line. test ok Replace mist collect filter B Replace mist collector filters. Replace movable side thermo couoler. Replace oil gauge. Replace part detect sensor on scrap press, broke. Replace plunger tip & sleeve by production. Replace plunger tip (Mike Warren) due to wear causing blowback and vacuum issues. Replace plunger tip (Production) due to tip worn and sticking to shot. Replace plunger tip sleeve + plunger tip. Blow back alarms. Replace plunger tip sleeve, Blow back alarms. Replace plunger tip. Replace plunger tip. No D/T changed during changeover. Replace prefilter stage 1. Now OK Replace robot top slide core. Cracked at base. Replace sleeve & tip due to blow back. Replace sleeve and plunger tip due to Blow back and dropping shot. Replace slide core & Slide cooler primary (5A2 P/M F-18) Replace slide core in cativly 2 Replace slide core. Replace slides and shoes Replace spray cartridge up/down cylinder Replace sprue bushing (SA/P F23) Replace sprue bushing, sleeve & tip, cause unknown. Replace squeeze master monitor, cracked. Replace stage 3 hepa filters. Gauge reading N/G Replace stage one hepa filters..reading N/G Replace suspect TCRMT module (communication module) Replace the SMC air bowl
What-air bowl is leaking air
why- Crack in the plastic
c/m- replaced the air bowl
reoccur- No Replace tip & sleeve, confirm plunger rod assembly. Replace tip and sleeve during change over. Sleeve has over 125,000 shots on it. Replace trimpress hydraulic cylinder Replace trimpress part detect lazer sensor, damaged. Replace trimpress upper punch. Replace upper crucible lid cylinder while machine is not running. Upper crucible lids drifts down when pushing the Request to enter button. Tested after replaement . Crucible lid stays up. Now OK. Replace upper crucible, starting to leak aluminum Replace upper limit float. Tank was overfilling several inches above the float. Replace upper limit spray tank float switch. old switch allowing the upper limit to vary when filling.. Now level fill is consistent. Replace vacuum ejector (Production) Replaced top and bottom ladle chains lubricated the turn buckles with wolfrakote paste and set the 90 deg position. Replaced 1nch water cooling hose on operator side only to GATES PLANTMASTER HOSE Replaced Draw Bar cause of Stripped Threads Replaced Ignitor and spark rod Replaced Ladle Arm Lower Unit during crucible change Replaced Ladle electrode bar with improvement of insulators over the sensing probes . Replaced Ladle- full of aluminum Replaced M1 cutter on trim die. JBS Replaced Main Hydraulic System Filter Replaced Oil Drip Main Air Bowl, broke Replaced P1 and P2 slide cores with trial slide cores from Matt C. 5A2P/MF27 Replaced P1 slide core and slide core pin Replaced P2 slide core for chip and slide core pin for build up. Dustin helped change slide core for training. Japan slide core 6,919 shots. Cracked and chipped. Replaced Stage 1 filters. Filter reading in red.
No Down Time. Replaced Thermocouple
PM Related Replaced Trimpress hydraulic cylinder, leaking oil from top seal polluting remelt aluminum all over trimpress
" non inventory cylinder" Replaced bad thermocouple. Replaced both P slide cores that were cracked. Replaced both cracked P slide cores (5A2 P/M F-23) Replaced broken P1 slide core pin. Replaced broken S1 slide core. JBS Replaced broken cavity4 bottom slide core.
SHOT LIFE: 4,500 Replaced broken cooling joint in shot sleeve Replaced cracked P2 slide core Replaced cracked P2 slide core and also replaced the slide core pin. JBS Replaced crucible and set furnace rebuild + assembly. Replaced dirty vacuum filters due to vacuum problems.
"NON INVENTORY NP2 DIECAST VACUUM UNIT FILTER" Replaced gauge for sleeve air blow while they where down changing their lot marks. Replaced hyd. hose fitting on op. side of movable die. JBS Replaced injecton rod hard hydraulic line with new. Replaced melted switch to squeeze pin 4 on manual operation panel Replaced robot cable with new . Old cable had temporary wiring for end of arm tooling also put 4 new battery's in battery box Replaced spray valve in spray cart. Replaced squeeze pin RB side Replaced squeeze pin bushing in catvily 2 Replaced the ladle lower unit during crucible change timing
Changed the ladle upper and lower gear box oil Replaced the top squeeze pin and bushing. Replaced thermocouple that got smashed behind die while puting die in machine. JBS Replaced vacuum block "bad" getting vacuum faults Replacement of Crucible
Filter broke, then DH broke crucible while trying to hammer out aluminum Replacement of Crucible, Spout broke Replacement of Sensor on ladle arm assy. Replacing air oiler due to adjustment knob being broken and being unable to control oil drip. Replacing ingot lift hydraulic pump Replacing the plunger tip for a trial with the new sleeve style from Tonaka during the scheduled die change. Die being put in will be RPY 1-RKR F-2 Replacing worn push buttons and switches Request for ladle cup 1.0kg (Per Rodger), cracked. Request for lot mark pins. Request for plunger coupler and trim press spring. Request for vacuum blocks. Requested filters for vacuum pump for P/M Requested new ladle, due to old one leaking. Rerouting the conduit for the furnace door safety locks so that they don't run directly under the back door of the furnace. We had a problem on diecast 4 where a partially melted ingot fell out of the Reset request button lens is missing. Returned Sleeve Rigged damaged spray cartidge in position with straps and the crane for removal of the damaged pedestal. Robot Robot Bad pick up. Way off
Model change (RPY 1 RKR) Type 04 Robot Collision detect fault when using the home button
Cause: when the robot was returning from the OK parts conveyor the shot would hit the edge of the conveyor on its way to the scrap conveyor.
Co Robot Crashed into door. Robot Data Backup Request:
TYPE04 - RPY 1RKR
TYPE05 - 59B 1RKR
Changes made due to collision detect alarms at trim press Robot Faulting at the Trim Press Robot Faults at trim press Robot Faults could not start. Robot Gripper Rebuild PM
Condition OK no parts replaced only tear down and clean up Robot Gripper rebuild PM Robot Gripper rebuild PM
Replace worn parts Robot Loading and Unloading Issues. Re-Teach Positions. Robot Position NG at trim press Robot Stopping (Waiting For Space) Robot battery alarm and pc battery alarm
FIX- Replaced Plc battery Robot chuck claw was missing when doing model changeover. Robot chuck plate bent after crashed.
MACHINE STILL IN TRIAL STAGE, NO D/T. Robot chuck sensor had the wires pulled out from the micro plug. Disassembled plug and reterminated the sensor leads. repair requires a special tool. .5 Allen wrench kept in the Diecast maint area. Robot collision alarms Robot collision detect faults at trim press Robot collision detect. Robot collision fault after it already trim pressed. Robot collision faults Robot collision faults. Robot collisions at trim press. Robot collusion faults at die Robot crashed at trim press. Robot crashing due to missing knock down bar in scrap press. Robot crashing into the side of the scrap press Robot crashing into the trim press Robot double stacking shots in the trim press(Breather Cover)
Missing spring ,spring stopper, and locate pin (Cavity #2)
Could not detect if part remained in trim press Robot dropping the shot
Cause: shot bent sticking to tip PLUNGER LUBE NOZZEL OUT OF POSITION
Countermeasure: adjusted the lube nozzle Robot end of arm tooling aluminum bracket is bent. Replace bent bracket with new. Robot clamp arm on left side had loose bolts allowing too much play in the clamping. Adjust trim press height up app Robot fault Robot fault at part detect Robot fault at trim press Robot fault at trim press
Adjust robot pick up position at stationary jig P73
adjust set down position at trim press P60
adjust pick up position after trimming P63 Robot faulting at take out position running RPY. Robot faulting out at trim press after changeover on d/c machine to 5BA, retaught robot pos 24 & 25. Shot stabilizer was locked up causing it to hit the shot before the die even touched the shot causi Robot faulting out when picking the part up in the trim press after the part has been trimmed.
Countermeasure: taught P64 Robot faulting while trying to proceed to the scrap conveyor. Robot faults Robot faults at product detect sensor Running WAP Robot faults at scrap press Robot faults at stationary jig.
Cause the pick up position was off.
Countermeasure: touch up robot pick up position at stationary jig, also touch up P60 , P63 in the trim press. Robot faults at the trim press
cause: product detect NG and set down position NG at trim press
C/M : adjust product detect sensors and touch up position 24 and 25 at trim press
Note that the robot chu Robot faults at the trim press
cause: set down position NG
c/m : taught P3 and P4 Robot faults at the trim press (TRIM DIE 2) Robot faults at the trim press/Axis 3 alarms / Trim damage Robot faults at trim press
Cause: robot is drifting intermittently when the trim press raises . Seams to have something to do with soft float. It will run several shots with no movement and will cont Robot faults at trim press after the shot is trimmed out. intermittently
Cause: robot not waiting for press to cycle finish before removing shot runner from the press.
Countermeasure : added a wait (1 Robot faults at trim press passed on from 3rd shift E/S Robot faults shot sticking to the tip Robot faults, vacuum faults Robot faults/Robot collision at trim press Robot getting excess movement alarms.
Robot speeds to fast from trim press to scrap press. Robot gripper # 1 finger broken
Countermeasure: replaced gripper with the spare one used for PM's Robot keeps faulting out for soft alarm. Robot keeps getting collision detect alarms while going into the scrap press. Robot leaves shot runner in the trim press / cycle slow time 28.0 sec Robot leaving shot in trim press and faulting out. Robot needed touched up a trim press. Robot needs retaught at the trim press position. Robot not able to deliver scrap to scrap press Robot not communicating with pendant, not able to home robot. Robot not moving when machine is put in auto.
Found that com. wire was grounded in cable from plug on back of robot to junction box. Wire broke at plug end. put new end in plug. Passed to 3rd Robot not putting shot into trim press properly. Robot not setting shot in trim press correctly Robot not setting shot into trim press properly. Robot not using the scrap press/Collision when going home from trim press Robot or machine killing hydraulic pump.
Getting a die close interlock. Robot outside left clamper continues to loosen while running. Replaced clamper mounts and specialty bolts. all were very worn. Right side has been OK no need to replace them. Now running Robot parts pick up N/G. Robot pick up point bad
Fix-Put chuck fingers on flush and touch up positions Robot point too low at scrap press. Robot position was off in trim press causing 2 out of 4 of the parts to not be sitting in trim press cavities. Parts were getting into press sideways, this may also have been a cause for breaking cutt Robot ran into helper door Robot side chill block and upper slide core blowout. Complete teardown , Cleaning , Welding of damaged areas. Robot side door not making advance limit switch. Door was not returning while checking advance limit swtch. Switch was working OK on Door screen. Door was not advancing and returning consistently and Robot stopping after Trim Press Robot stopping at trim press after initial unclamp. Robot stops at the helper door (message on the pendant reads waiting for space to clear) this occurred after the DH touched up the product detect positions. I could not correct the problem so had to u Robot stuck inside die cast m/c wouldnt return at all was down when i come in . Robot trouble at scrap press Robot waiting until helper door opens for the next shot before it moves to the tank. Also trim press was set crooked by someone on first so when the DH on our shift repositioned it correctly the robo Robot was getting a collision detect in multiple areas, (biscuit removal, and Trim Press) Also Vibrator leaving mark on the parts. Robot was running shot into trim press leg. Robot was taking parts chucked to home and crashing. Rod seal leaking Running 59B 1RKR Trim 1, Die 12
What: Cavity 1, 3 and 4 trim.
Why: Trim damage near tappets.
Countermeasure: changeover
Will Problem Reoccur?: Timing.
Cycle Time: No Change. Running 59B 1RkR Die 11. 59B 1RkR Trim 1.
What: Trim on cavity 2.
Why: Trim too high on cavity 2.
Countermeasure: Adjusted cutter between tappets.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. Running 59B-1RKR
What: Soldering Cavity 3.
Why: Build up.
Countermeasure: Cleaned Cavity 3 on Die 13.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. Running 59B-1RKR Die 13
What: Soldering Cavity 2 and 3 on die 13.
Why: Build up.
Countermeasure: Polished Cavity 2 and 3.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. Running 5BA-PS
What: Axis 1 Faulting out.
Why: Axis 1 running high.
Countermeasure: Verified setting via plex. Changed Flow and Off time to match plex. Tighten loose fittings. Running Breather covers.
What: Only trimming out two of the parts on the shot.
Why: Part (cavity 2) stuck on top of trim die.
Countermeasure: Removed part, cleaned up pins. Running RPY 1RK
What: Cavity 1 part getting chunked out.
Why: Tab not getting blown off.
Countermeasure: Adjusted air so that it blew off tabs. Running RPY 1RkR
What: Trim damage all cavities.
Why: Build up in trim die.
Countermeasure: Cleaned trim die. Running RPY-1RKR
What: Spray cartage leaking.
Why: Valve leaking by.
Countermeasure: Replaced valve.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. Running RPY-M Die 7. RPY/5BA M Trim 1.
What: Trim out of spec.
Why: Cavity 2 and 4 broke inward.
Countermeasure: Adjusted blocks. Replaced cutter on cavity 4.
Will Problem Reoccur?: Timing.
Cycle Ti Running RPY-M Die 8
What: Flashing build around bottom two parts.
Why: Bottom Slide cores not moving.
Countermeasure: Removed slide cores, cleaned area. Replaced leaking fitting. Running Water passage
What: Temp C and D outer signal Temp alarms.
Why: Cycle time to slow causing die to cool down/ thermocouples could not be set right or they are bad
Countermeasure: made cycle ti Running Water passage Die 5.
What: Soldering
Why: Build up.
Countermeasure: Cleaned die up.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. S 5 MOVING S 6 MOVING S 7
DREW S 7 MOVING S F-10 MOVING S F-10 MOVING
PM #18 MOVING S F-5 MOVING S F-5 MOVING
PM F-STATIONARY S F-5 MOVING "JOHN.S"
S F-5 STATIONARY "SHANE.D" S F-7 MOVING S F-8 MOVING S F-9 S F-9
MOVING S F-9 MOVING S F8 STATIONARY S-1 Slide core was cracked at the base and leaking. Replace S-1 slide core S-1 slide core change to replace NG Judged previously installed slide core. S-5 MOVING S-5 MOVING,STATIONARY S-Die F5 S-F-5 MOVING
P/M F-14 MOVING S-F5 MOVING S-F7 STATIONARY S1 slide core cracked. replaced S1 slide core. S1 slide core is cracked. replaced S1 slide core. S1 slide core is cracked. replaced slide core s1. replaced s1 tappet pin as well. S2 has a chip replaces S2 slide core S2 slide core cracked out of spec. changed S5 MOVING SA/P 20 SA/P 21 STATIONARY SA/P 22 MOVING SA/P 23 MOVING SA/P F-20 SA/P F-20 MOVING SA/P F-21 MOVING SA/P F-22 MOVING SA/P F-22 STATIONARY SA/P F-23 MOVING SA/P F23 STATIONARY SAFETY DOOR ELECTRIC LOCK ON INGOT LOADER SAFETY DOOR SWITCH REPLACEMENT SB 16 MOVING & STATIONARY
DREW SB F-12 MOVING & STATIONARY SB F-16 SB F-16 MOVING SB F-17 MOVING SCRAP CONVEYOR MOTOR OVERLOAD SCRAP CUTTER MISSING SEIZED
Gave to Craig R SHOT SPEED ALARMS, CANT CONTROL BISCUIT SIZE SHOT STICKING SHOT STICKING TO OLD ONE, DROPPING PARTS SHOT STICKING TO TIP SHOT STICKING TO TIP
TIP CHANGED ONLY SHOT STICKING TO TIP/DROPPING PARTS SHOTS STICKING TO TIP
GAVE TO JOHN C TO CHANGE SHOTS STICKING TO TIP CAUSING SHOT TO PULL OFF SPRUE PIN AND NOT ALLOW ROBOT TO GRAB IT SIDE DOOR SIDE DOOR WOOL REPLACEMENT SLEEVE COOLING TRIAL SLEEVE HAD T/L SLIDE KEY BROKE SLOT BOLT BROKE SPOUT BROKE OFF CRUCIBLE
"NON INVENTORY CRUCIBLE STAND, NP2DIECAST0010" SPOUT PLUGGED UP COULD NOT GET ALUMINUM OUT, LEFT ALUM. IN LADLE WHILE M/C WAS DOWN SPRAY CARTRIDGE NOT SPRAYING SPRAY VALVE BODY HOLES ALL STRIPPED OUT SPRAY VALVE LEAKING SPRAY VALVE NG, REPLACED SPRAY VALVE NOT WORKING SQM Setting found to wrong setting ( 250 Ton ) SQM Trouble Axis Alarms SQUEEZE NO. 4 SWITCH MELTED SQUEEZE PIN WAS STICKING OUT/VALVE NOT WORKING TL REPLACED SRVO-046 OVC alarm (Overload) Axis 5
SRVO-050 Collision detect alarm Axis 5 STAGE 2 FILTERS IN RED ZONE SWITCH WAS STICKING Safety Device Malfunction Safety gate falling over. Safety hook cylinder faults. Replaced cylinder assembly Safety switch for ingot loader bucket came loose nd fell off. Realigned switch bracket and re installed. Now OK Scale damaged, Trim press faulting out. Weight scale company scheduled Wed,4/20 for repair. Scheduled Filter Change Scott requested removing the operator check light function. This is not on any other diecast machine. Removed R67C from two rungs. see attached changes. Scrap Conveyor Flipper Issue.
Robot Position Issue. Scrap Conveyor has numerous broken flight and damaged flights, drive sprockets damaged/ broke. Conveyor jamming. Scrap Sticking in Trim Press. Scrap chute diverter has broken free from its mounting. Remove diverter mount rings and reweld all parts back in place. Now OK. Scrap conveyer #1 jammed, tripping ol's. Removed covers cleaned tramp iron out of conveyor. Scrap conveyer belt loose adjusted up okay for now. Scrap conveyer fixed one spot moved about 3 ft found 2 more. Scrap conveyor #1 motor overload Scrap conveyor 2 belt blocking photo eye Scrap conveyor 2 jamming motor overload
Cause: missing cotter keys on conveyor
Countermeasure: replace 6 missing cotter keys Scrap conveyor PM
Replaced chain and repaired conveyor
Swapped conveyor back from DC #5 Scrap conveyor PM.
Repaired. Replaced chain. Swapped conveyor from 6 to 5 so that original conveyors were in place. Scrap conveyor Rebuild. Scrap conveyor Welded paddle broke and was hanging low enough to make the jammed conveyor sensor go off. Removed the damaged part of the paddle with cutoff wheel. Now OK. Scrap conveyor alarming
Sensor wire disconnected in terminal. Scrap conveyor belt need replaced. Scrap conveyor hanging up Scrap conveyor is jammed, cotter pin broke on one of the links allowing the shaft to float about an inch and jam up. Scrap conveyor jammed Scrap conveyor jammed.
Removed the jam/ restart. Scrap conveyor jammed. Multiple areas that needed to have cotter pins and rollers replaced Tested OK after repairs. Scrap conveyor jamming up Scrap conveyor jamming up Replaced a couple missing links and about 8 cotter pins. removed about a gallon worth of overflow tabs from inside. Scrap conveyor jamming.
Repaired 15 flights with new cotter keys Now OK Scrap conveyor motor wires are exposed need ran in conduit. Scrap conveyor not running. Scrap conveyor not working
FIX-Tightened motor wires Scrap conveyor not working.
Scrap pieces were wedged in between the conveyour links and the conveyor frame.
Removed, and restart. Scrap conveyor was jamming up and faulting out.
-Found 2 of the pins were backed out and missing cotter pins on the right side.
-Fix: pushed the pins back in place and replaced the missing cotter pi Scrap press "T" bar tabs broke off due to wear. Scrap press and trim press stopped down 3rd: scrap press still jamming. NOT ENOUGH OPERATORS MC WOULD HAVE BEEN DOWN ANY WAY. Scrap press coupler broke. Replaced with new all in one piece style coupler.
"NON INVENTORY " Scrap press does not advance far enough to contact shot. Scrap press not coming up Scrap press part detect sensor not working. Right side linear bushing broken. Scrap shoot divider not making its light when it flips to the right (looking at it) Scrap trim press bad bearings. Scrape conveyor jammed up . See Attached Work Request See attachment for details See attachment for details TP 5/25 See attachment for details. Sensor faulting at okay conveyor. Sensor on extraction Robot hand flickers. Sensor that reads through the trimming press had a cut shorted wire. We have the amplifier in inventory which is a Keyence LV N11N But the LV NH300 sensors are not in inventory. Taka has 3 sets of Shelf design and install for the slag pans. See Kent for details.
Slag Pan that is sitting at holding crucible is not sitting on a secure platform. See attached.
Parts have been ordered 7-20-22 Shorting, not getting correct temp.
Gave to John C. Shot Pressure Alarms Shot Pusher Cylinder, Rod Seals Leaking OIl. Shot going negative Shot is sticking to the tip.
-Fix: Gave operator a new tip. Shot position abnormal faults
Countermeasure: remove and clean shot position sensor. Shot position sensor / broken wire faults
Countermeasure : Replace shot sensor and bushing Shot position sensor/ wiring broke red light. I replaced the shot detect sensor with one that we had on the shelf from one that Drew changed earlier in the week and later found out that it did not fi Shot pressure sensor down alarm
FIX-Replaced injection sensor (PR1) Head sensor Shot sensor
FIX- tightened nut on shot sensor Shot sensor
FIX-Replaced shot sensor Shot sensor broken wire faults Shot sensor bushing worn, has been turned and flipped multiple times. Shot sensor circuit issues. Shot sensor reading -16 Shot sensor wire break alarm Shot sensor wire break alarm. Pulled and cleaned shot sensor and mounting hardware. was oily and debris present. Now OK Shot sensor wire breakage fault, will not reset. Shot sticking to the tip. Shots are getting jammed up in the scrap press.
-Found a few issues:
1.) Holding bars that hold the shot were completely bent down and the shot was going over instead of under
2.) Sensor was adjusted Side door wool need replaced flame coming out on hinged side. Sleeve air blow not enough pressure Sleeve damaged from aluminum "wash out" Sleeve in this machine has water cooling line in it. The water fitting was broke causing water leak. Sleeve is worn has terrible blow back
Replaced Tip & Sleeve along with the plunger shaft spacer Sleeve modification for cooling trial Sleeve turning , aluminum not pouring into the sleeve, plugging the plunger lube line Slide Core Break P2. Slide Core usage. Slide Plate and Liner Replacement by Shibaura Company Slide core P1 and S2 Replaced P1 and S2 slide core Slide core had 30,000 shots
Why: Unknown
C/M: Replaced slide core
Recur: Possibly in time Slide cores will not move out Slow melt running having to shut down for low aluminum Small overflow tabs remain on trim die surface
59B 1RKR Small overflows are remaining on the trim press
Cause: They are not being removed at the overflow remove press
Why: position off from robot crash the day before and also the air line is melted Small scrap conveyor rebuild (scheduled) Sorry this is for die cast 8.Axis alarms Channel 3 since 2nd shift through 3rd shift Spout on crucible broke "12-22-16" Spray Cartriage pump making bubbles Spray Cartridge Diaphram Pump not pumping Spray Cartridge Turn cylinder mount bolt broke Spray Cartridge Unit Leaking Air Spray Cartridge cycle timed out. Spray Cartridge damaged Spray Cartridge mounting bolt broke. Spray Cartridge stopper broke off base Spray Cassette changed out on 3rd shift. it is now running RPY 1RKR cassette #1
When confirming spray points one spray nozzle was broken on cavity 4
Replaced spray nozzle and confirmed spray points. Spray PLC- added x17 to M84. This makes the spray wait until the spray unit is all of the way down in position before it sprays. Request from Craig Randle. Spray cartridge "Air Blow" function does not work. Spray cartridge air blow solenoid not opening. Power to the solenoid. Solenoid not opening. Replace blow solenoid .. Now OK Spray cartridge clean and repair had a broken sprayer and clean and blew out lines. Spray cartridge needs cleaned and inspected. Spray lines needs realigned , Spray nozzles loose. Spray cartridge pedestal internal post sheared off . Removed spray cartridge turn cylinder assy. Removed damaged pedestal shaft and pedestal housing. Removed broken pedestal shaft and bearings. Pede Spray cartridge tank had no pressure from pump, thought the pump had gone bad so I tried a new one but got the same results. Discovered debris in bottom of tank reinstalled old pump. Spray cartridge went down and didn't return to home position. Spray cartridge would not run in automatic cycle. Product detect 1 not seeing part Spray cassette Air blow function not working Spray cassette manifold was missing 2 spray valves. this will not allow for spray cassettes to be interchanged .
countermeasure: removed the blocker plate where the spray valves should be and replac Spray head, fwd and rvs screw assembly had come apart. All the fastners were mising. Operator could not adjust the head position for the change over. Replaced the missing fastners reset spray head cy Spray unit valve Sprue Bushing leaking. 6A0 P F-5
Replace sprue bushing Sprue bushing Sprue bushing leaking 5A2 S F16 at the end of first shift, DCM 4 not running on 2nd shift do to man power, replaced sprue bushing on 2nd shift. JBS Squeeze Master PM Squeeze Master channel 1 keeps bleeding off Squeeze Master was not communicating the axis values to the die cast m/c Squeeze master All channels low
Adjusted all pods. (flow) .Had all parts checked in lab. ok
Note adjust (S) on pods only. Squeeze master Hydraulic Pump was not building pressure Squeeze master PM Squeeze master diaphram pump stopped working. Squeeze master trouble channel 3 Squeeze master will not start Squeeze pin #1 not responding to manual controls, ended up just being a loose selector switch from inside the panel. Squeeze pin bushing broke. Replaced both OT and OB Squeeze pin depth out of spec but readings on control panel and squeeze master both in spec. Stage 2 filters in red zone, replaced with new. Stage 3 "top" filters in red zone. Replaced with new. Stage 3 Hepa filter in the red.
Change stage 3 Hepa filter. Starting 6A0 Die Trials on Die Cast #1 Static break is low on cavity 3 & 4 (RPY 1RKR)
Cause: Trim press pusher block is leaving a sharp edge on the front of the parts tappit side
Countermeasure: round off the sharp edges on the pusher blo Stationary die temps reportedly running high. Steel oiler line on the hydraulic knuckle on the movable die platen. Still had trouble with trim press 3rd shift DH had cavity 3 all cutters loose for adustment. Still having trouble with Squeeze Master Axis channel 3 alarms running high.Also had robot issues. Stopped the machine because of a loud noise when the die opens Sub-runner not being removed after the vibrator
Cause: part slipping in the robot gripper - the locate pin was broken/missing
Replaced the locate pin. Supported production Swing gate for holding crucible didn't have a locking hinge, put a new hinge on TANAKA REQUESTED PARTS TEMPS JUMPING AROUND THERMOCOUPLE THERMOCOUPLE BAD ON MELTING FURNACE THIS CRUCIBLE IS CHARGED OUT ONLY FOR PREPERATION FOR EMERGENCY BREAK DOWN.
IT IS KEPT IN DIE CAST AREA THIS CRUCIBLE STAND SHOULD OF BEEN CHARGED OUT AT THE TIME OF CRUCIBLE CHANGE 6-19-2018 BUT WAS NOT. THIS WORK PERFORMED ON DIECAST 6. EQUIPMENT LOGGED IN WRONG. THREADS BAD THREADS NG TIP BLEW OUT NOT READING RIGHT
CHANGED THERMOCOUPLE TIP BROKE OFF TIP WAS FLASHING AND SQUEALING TOOL LIFE 100,000 TOOL STUCK IN SLEEVE, ALUMINUM BUILD UP ON SLEEVE TRAVIS
OILER LEAKING OIL ON FLOOR, NOT PUTTING LUBE IN DIAPHRAM PUMP TRIAL FOR OVERFLOWS
TRIM DIE #3
GAVE TO CRAIG R. TRIM DAMAGE TRIM DIE #1 59B TENS
BROKE CUTTER, REPLACED TRIM PRESS CUTTER BROKE TRIM PRESS SENSOR SETUP TRIMPRESS UP/DOWN RELAY TRIMPRESS WOULD NOT GO DOWN RELAY BAD REPLACED TURN KNOB ON SELECTOR SWITCH MISSING TURNTABLE BAD BRNG Taka requested program change made changes per sheet as requested will attach sheet. adds additional trim sensor and timer. saved copy of original and changes to engineering plc folder. Tappet depth out of spec, to deep Tappet face cavity 4 marked at trim press Tappet pin broke Cavity P1(Robot side/upper) Tappet pin is going to deep into part. tappet pin was bent. replacing tappet pin and P2 slide core due to crack. Tappit pin depth out of spec, causing ch. 2 and 3 out on squeeze master Tappit pin depth running out of spec RPY 1 RKR, operators are adjusting fixed core on time setting to change pin depth. (Original setting is 1.3 actual is 1.5) This is causing cycle time alarms. Temperature A fix die running too hot 412 deg f Temperature A outer signal temp alarm Temperature alarm high die temp DC 2 and 3 Terminal box on top of robot came un-bolted.
-Fix: Replaced all missing bolts that fell out. The 2 bolts that hold the doghouse came off which caused a gap and is a safety issue from of aluminum leak.
Also, the furnace is getting repaired. The furnace backdoor bottom patch to tall had trouble all of 3rd shift. The open and close lid solenoid on the upper furnace door is bad bleeding off. The trim press hydraulic pump has been slowly failing and leaking from the front pump seal. I replaced the pump and replaced the hydraulic intake filter. There have been frequent P slide cores cracking. We confirmed the die release spray concentration and spray points were adjusted slightly. We found that all eight squeeze pins hoses were hooked up Thermo coupler male plug wires broke during die change.
Soldered in new connections. OK Thermocouple melted in half Thermocoupler NG These are the Ejector Pins that were ground down to make New Drawings "Test" These parts were removed from D.C.#1 to D.C.#2 because of issue with D.C.#1
D.C. #1 OK to run so needed these parts to run machine Thick flashing on biscuit and vacuum. Third stage filter gauge in Red. Third stage filters reading in yellow Tie Bar operation problem ( Tie Bar is moving too slow and will not fully extend)
Cause: adjustments made by Shibaura during MC inspection caused the tie bar to move slowly
Countermeasure: Enter Param Tie bar air cylinder / valve assy. damaged by op side door. Tip and Sleeve change during die change. Tip and sleeve replacement. DH and operator Tip and sleeve worn causing blowback. 18,264 shots
Replaced with new tip and sleeve, cleaned and checked plunger lube tip.
Caused by plunger lube plugged or miss adjusted.
likely will reoccur. Tip and sleeve worn out (55,000 shots)
-parts sticking to plunger tip causing dropped parts
-axis alarms Tip and sleeve- blow back
FIX- Replaced tip. And worked on lube line "replaced tip on WO#8436 Tip change due to Mr Taka tip project Tip changed only,
Worn 55,000 shots on it Took a finger and pawl off of the robot so that I could replace a broken finger on diecast 6. Was not able to locate the finger in inventory or find a drawing. Passed to next shift to either find a dr Took over for 1st shift, finishing up ok conveyor.
1st w/o-7222 Took over from 2nd shift. Airblow system faults. Tool hanger clasp See attachment for details. Top filter on mist collector (606) out of spec. Top gauge out of range Top helper side of die had aluminum blow out behind ejector plate burning up some water lines. Had to pull die and take iut ejector plate and clean up aluminum and replace a couple of water lines. Rem Top level mist collector filter gauge reading In the red. Top slide core Hot return fitting broken. Replace with new fitting. Top slide core cylinder lead switch stopped working, replaced lead switch.
"Used Reed Switch off of another die" Top stage filter gauge reading in the red Top stage filter gauges reading in red. Toscast HMI screen freezes, cannot access screens .
Or does not show correct screen. Tower limit switch was damaged. removed limit arm and reformed. Reinstalled and adjusted for correct position and throw
Tested and OK Training with Toshiba rep. replacing Movable platen shoes, slide plates and wipers. Trial sleeve water line leaking water
FIX- Replaced piping to trial water cooled sleeve Trial sleeve leaking water Trim press alarm Trim #1 cav. Broke cutter on 1st Trim Damage all cavities Trim Damage cavity 3 Trim die # 1
Cause Robot part sit down position NG
Countermeasure: Touch up position P25 and P26 Trim Damage cavity 4 Investigation from trouble call Trim Damage water passage Trim Height Trim Height adjustment .5BA P/S Location problems at Lathe. any measurement exceeeding 0.500 will mislocate at lathe. Parts reading in spec at die cast . Measuring with Calipers ,so very difficult to Trim Height out of spec Trim Height out of spec Cavity 4 (RPY 1RKR) Trim Height out of spec S cavity 2
Trim height OK if shot is placed in trim die by hand but NG using the robot Trim Press Adjustments. Trim Press Cylinder Drifting Down Trim Press PM Trim Press PM Confirmation Trim Press Parts Request. Trim Press cylinder top hydraulic fitting leaking. Able to get one more turn on the fitting and now not leaking. Trim Press faults ,Robot collisions Trim Press not Advancing Down Trim Press not cycling, part presence sensor out of adjustment. Recalibrate and restart. Trim Press would cut parts off correctly, but would not send them to the correct Out going Chute "GOOD OR NG CHUTE" Trim damage Trim damage / dropping shots
Cause: Robot position NG at take out
Countermeasure: re-taught take out position at the die and the set down position in the trim press Trim damage 6A0 Mid cavity 2 F3 die Trim damage Cavity #3 Breather Cover found on the unloading table.
Cause: Part remained in the trim press .
Countermeasure: the part detect sensors were not in the correct position to detect cavity 1 Trim damage cavity #2 Breather Cover
Cause: parts hanging up in the chute , after a couple cycles the part detect sensor would cause an alarm. 1 pcs did come out onto the unload table broken
Counterme Trim damage cavity 1 & 2 on tappit surface trim die #1
Countermeasure : changed trim die to die # 1
Trim Die # 2 leaving flat spots on the rocker surface cavity 1 & 2
Countermeasure ground and polis Trim damage cavity 1 vacuum overflow cutter build up replaced the cutter Trim damage cavity 3 Breather Cover.
Parts jamming up the part chute in the bottom of the trim press. The sensor for cavity 3 and 4 was not set to detect the parts remaining.
Countermeasure : adjust Trim damage cavity 4 6A0 Mid trim die L3 event parts Trim damage on in gate area and right side mounting bolt area when facing the trim press. Trim damage to cavity 1 shaft hole area. Trim die clams wouldnt clamp.
the operator had just filled the tank with fluid.
released some of the fluid. it was far too full.
Re-start. Trim height at max spec 0.500 on tappit vacuum side Cavity 4 Trim height out of spec at the gate Trim issue. Cavity 3 cutter had heavy smeared aluminum on the back cutters. removed aluminum and cleaned cutters now OK parts did not have the previous marks. Trim press
FIX- Replaced air coupler to trim press Trim press #6- added logic to slow down the decent after the bucket dumps. see attached for details Trim press (RPY)
FIX- Replaced cutter and adjusted cutter Trim press Hyd. system, leaking fluid at heat exchanger piping. Trim press air blow not working Trim press air blow staying on. Trim press alarm, will not reset Trim press alarms Trim press block bolts wont screw in. Retap bolt hole and use new bolts. OK Trim press breaking cutters at South East set. We suspect this is due to trim accumulating in the die. Trim press broke a cutter in cavity 3. Replaced cutter with new and made adjustments to air blow lines. Trim press broke back cutter and bolt Trim press causing damage to parts. Trim press cutter broke (RPY)
Fix-Replaced cutter Trim press cylinder came apart, threads pulled out of cylinder have to pull to repair.
Ended up using a rebuilt cylinder and passed to second shift. Trim press cylinder unthreaded from the lifting plate.
Replaced trim cylinder and lifting plate, threads on both too damaged to repair. also replaced two broken guides on cavity 1,2. Trim press die not cutting cleanly, Spec problem. Trim press diverter chute broken Trim press door limit switch damaged Trim press drifts down while M/C is running. Trim press faults due to machine crash. Trim press front seal of cylinder leaking Trim press height N/G on P2 and P1 Cav. Trim press hose from hard pipe to aluminum manifold solid stream leak from the hose. This is a special hose due to the fittings . One side is standard at the manifold and the piping side is metric. Be Trim press hydraulic cylinder is drifting off home position, its also leaking fluid. Replaced hydraulic cylinder with new. Trim press hydraulics not working properly, chattering, loud. Hydraulic tank was empty, Filled with new fluid, Replaced the suction filter, Still no improvement Leaking main pressure hose was what c Trim press is faulting out when cycle start is pressed. Scrap press part presence sensor got bumped and moved somehow, i readjusted it. OK Trim press marking #4 cav Trim press no. 3 diverter not getting return light, intermittent issue Trim press not cutting all trim away. Trim press not cycling in auto.
Trim press product sensor out of adjustment.
adjust sensor position. Trim press part detect sensor. Left bracket loose . tightened bracket and cleaned the trim die. Tested the Part remain sensor and working OK Trim press pump loud . Remove and replace suction filter. now ok Trim press was faulting out when cycle start button was pressed. Replaced scrap press reflector, tested. OK Trim press will not go down Trim press would not go down and cut the parts when the robot placed it into the press.
-Found: Flipper 4 swivel connection had come apart and was not allowing it to get an advance light.
-Fix: Put Trim press wouldn't advance or return Trim press, casting presence sensor bracket loose and out of position.
re-align sensor and re-start Trim-press not blowing extra trim Trimming problems were occuring because the Die clamp pump was out of oil and had unclamped the trim die. Noticed oil running out of the bottom of the clamp pump reservoir after refilling. A piece o Trimpress
Gave to Craig R. Trimpress not cycling down. Tripped the thermal overload for the hyd pump . Trouble shoot losing N2 issue Trouble wih Squeeze Master all night and Spray Unit Trouble with # 3 squeeze pin out of spec. Looked at SQM settings and profile all good. Trouble with pressure hole depth cavity 2 being to deep Troubleshoot M/C fails to send under temp pre-heat parts to NG conv. issue Troubleshoot Tip & Sleeve Air Blow Faults Troubleshoot problem with die, unable to bleed air for squeeze master. Troubleshoot vacuum problem after hose and vacuum block were blown on Operator side. Troubleshoot vacuum system Troubleshoot/Robot Crashing Shot biscuit into Trim press. 2nd shift E/S performed PM prior to this. They rebuilt the robot hand assembly. Troubleshoot/dropping shot at scrap press. Troubleshoot/repair LS switch junction box faulting out Tunnel Cracked
gave to John C. Turn table 2 overload fault. Turn table #2 not turning Turn table #2 motor overload
Fix- put spacers to lift part separator up for new plastic insert disks Turn table #2 stops turning, motor overload indication at trim press control. Turn table fails to turn when loaded with parts. Turntable 2 keeps getting jammed up, took steel table top off and ground out the center to make the circle truly round, then placed back on and centered up and made adjustments to outer retaining wall Turntable 2 not rotating. The bolts that hold the metal top down were broke preventing it from being able to spin.
Removed and replaced bolts, tested. OK Turntable top badly worn, cut through. UPPER CRUCIBLE BROKE ON 1/6-2016 2ND SHIFT
UPPER/LOWER CRUCIBE CHANGED DUE TO PM'S WERE DUE Unload table not turning Unloading Robot chuck mounting assembly fell off, bolts broken. Unsure of tip life operator never started off at 0 at cast change Upgrade ingot loader control to use proximity switch for ingot arrival sensing instead of mechanical limit switch. Upper Furnace over Heating Upper crucible lid Air cylinder mounting bushing bracket broke off at the bottom mounting plate. Remove plate and bracket and reweld. Added an extra metal support piece and welded to add strength to Upper crucible lid unit
FIX- quick connects on air line Upper crucible lid unit modification for easy movement of upper crucible.
FIX- quick disconnects Upper crucible lid wont open Upper crucible lid wont open with switches
FIX- Soldered S11 and Com wires in plug as the solder connections had broke. Upper lid open/close cylinder will not operate.. Cylinder is siezed in position. Replaced cylinder. Tested for closing distance and speed. Now OK Upper limit probe not working on Holding crucible. Repaired damaged wire to probe, installed new wire ring and reinstalled. Now OK Upper squeeze pin assembly cooling water fitting sheared.
disassemble squeeze pin assembly. verify set screw, clean assembly and squeeze pin . install new fitting and reassemble. Upper thermos coupler V CHECK LIGHT NOT WORKING V-check light keeps coming on VACUUM FAILURES
FILTERS SATURATED IN OIL
"NON INVENTORY NP2 VACUUM EXH. FITLER" VACUUM FAILURES, FILTERS CLOGGED VACUUM FAULTS
NON INVENTORY NP2VACUUM UNIT EXHAUST FILTER
OIL FILTER 531.002.00 VACUUM FILTER VACUUM ISSUES VACUUM ISSUES
"NON INVENTORY EXH. FITLER" VACUUM ISSUES
NON INVENTORY NP2 DC VACUUM UNITY EXH FILTER 0532.140.156 VACUUM PROBLEMS VACUUM TROUBLE VACUUM TROUBLE
GAVE TO DH VACUUM TROUBLE "FILTERS WERE AT LIFE"
"NON INVENTORY NP2DIECAST VACUUM EXH FILTER" VACUUM TROUBLE (FILTER CLOGGED) VACUUM TROUBLE (FILTERS SATURATED WITH OIL)
NON INVENTORY VACUUM EXHAUST FILTER VACUUM TROUBLE, FILTERS PAST LIFE
LAST CHANGED 10-10-15
"NON INVENTORY VACUUM EX. FILTER" VACUUM UNIT , MULTIPLE VACUUM FAULTS VALVE LEAKING / NO GOOD VALVE LEAKING/ REPLACED VALVES LEAKING Vaccuum Unit
Reverse Wash Air Blow No2 was staying on Vacuum
FIX- Low speed air pressure was low Vacuum pump Vacuum Failure, when checking filters and screens operator noticed this filter had reached life.
"non inventory Busch vacuum filter" Vacuum Faults Vacuum Machine- Use M480 to cycle stop the DCM machine. M480 is on if operator picks valve 3 on both switches. Also changed logic so operator could not run vacuum on one valve (x15) Vacuum Problems Vacuum Problems. Vacuum Pump Air Bowl Cracked Vacuum Sys. fault "Enticed into 2 clogging up" Vacuum Trouble Vacuum Trouble
Fix: Cleaned strainers and set all set points to match from vac 1 and vac 2 and adjusted air pressure setting to .544 MPA
Tested OK. Vacuum Trouble, filter covered in oil
Gave Filter to DH
"NON INVENTORY, NP2DIECAST VACUUM UNIT EXHAUST FILTER" Vacuum Trouble. Vacuum block failure resulting in blown Vacuum hose operator side Vacuum blocks blowing on operator side Vacuum couplers leaking
FIX-Replaced male and female couplers Vacuum faults Vacuum faults
Cause: die release float sticking causing the tank to overfill the concentration not reading on the chart .948 mostly water, and black hose was leaking on junction block going to the rob Vacuum faults after change over
Change over from RPY 1RKR to 59B 1RKR Vacuum issues due to the tip being worn Vacuum issues running 5BA P/S. Vacuum machine- added output Y2 for the mid die air blow Vacuum problem Vacuum problem
FIX-Die release mixture and vacuum setting N/G. Vacuum problem. Die release filter was dirty would clean filter and would be dirty in 30 mins. So Mike cleaned die release tank and emptied die release bucket and put fresh die release in bucket. Filt Vacuum problems Vacuum problems on the operator side. We replaced all of the air and vacuum lines, checked all of the filters, checked the oil level, filled the accumulator with nitrogen from 6.0 to 6.5 and did a V Vacuum problems,
-many things were changed.
Narrowed to Plunger tip, had excessive wear to scarring.
Replaced Plunger Tip
-Part request, gave to Steve Wagner Vacuum problems, keep blowing robot side vacuum blocks. Switched robot side block to run off of valve V1. Vacuum problems. Checked spray points, spray concentration, filter on the spray, inline filters on the vacuum hose, added nitrogen. The nitrogen was at the minimum of 6.0, I added to get 6.5. V che Vacuum problems. Levi added nitrogen near the end of 3rd shift. We powered everything down and restarted. Found that the water source to the spray tank was turned off when they swapped the units ove Vacuum problems. Replaced the napa gold filter and air filter on the vacuum machine. It was now able to hold pressure. I spoke with JR Otto about the canisters for the Napa golf filter being dinged Vacuum problems. Confirmed all settings on the machine, vacuum and squeeze master. We replaced the vacuum joints on both side and the hydraulic filter was changed, it was running about .4. We found t Vacuum problems. Replaced both air filters on vacuum machine. Vacuum pump coupler not engaged to the motor side... Split the pump and Motor ,removed the damaged coupler. The set screw for the motor side gear was not to be found and the motor gear slid back towa Vacuum pump will not build pressure, checked voltage from contactor OK. Checked voltage at motor, OK, checked voltage for the vacuum valve open solenoid and it was ok as well. passed to Levi Vacuum setting verification Vacuum settings confirmation Vacuum system P.M.
Tracking time required Vacuum system fails to pass reliability check after P.M. Vacuum system leaking off vacuum on Entice #2 Vacuum system leaks Vacuum system not making vacuum. Disassemble motor from vac pump reset motor coupler and lock tighted the set screw. Reassemble and test . Now OK Vacuum tank not building vacuum pressure past -9.2.
Discovered the vacuum tank had a hairline crack at the top horizontally on the seam on both the front and back of the tank, rewelded and reinstalled Vacuum tank pressure ng. Why- ?. CM- I tried to figure it out but had no luck. Had to call in ES. Vacuum trouble Vacuum trouble
Replaced plunger tip (life 17900shots) Vacuum trouble all night. Vacuum trouble motor making noise and smoking Vacuum trouble, Cleaned filter for die release. Replaced stripped cap on filter housing with new one from non inventory. Vacuum trouble, blew operator side block again. Checked entire vacuum system and installed new block, noticed scarring on tip. Replaced tip with new for wear reasons. Vacuum trouble, keeps blowing operator side vacuum block.
-Turned regulator up Vacuum trouble. Vacuum unit not building pressure. Found that coupler was sheared between motor and pump, replaced with non inventory coupler from aisle 4 section 4. Vacuum valve joint filled with aluminum, got the operator another to keep production going and then drilled/cleaned the other one for a spare (in die maint) Varying biscuit thickness, production request inspection of ladle assembly. Verification of Vacuum settings
Changed back to original settings Verification of vacuum settings Verification of vacuum settings per standard settings in Plex
The machine will run with Blown vacuum Blocks and low vacuum pressure in the tank .Running in function 2 with B1 at -50 Mpa the tank press WAHT: MOVE CORE 2 FAULTS
WHY: robot side reed switch bad
C/M: replaced robot side reed switch
REOCCER: unlikely WAHT: blowback
WHY: tip an sleeve worn
C/M: changed tip first still ng / changed tip and sleeve WAHT: blowback
WHY: tip worn
C/M: replaced tip
REOCCER: yes timing WAHT: channel 4 thermocouple fault
why: still investigating
c/m: swapped channel 4 to channel 5 wires WAHT: die release concentration out of spec keeps dropping
WHY: spray unit mixing valve no good
C/M: replaced mixing valve
REOCCER: yes timing WAHT: high speed shot alarms and lots of flashing
WHY: sleeve worn
C/M: replaced tip n sleeve
REOCCER: yes WAHT: shot sensor broken wire
WHY: debris getting in with sensor
C/M: took sensor out cleaned
REOCCER: yes timing WAHT: turntable 2 locking up
WHY: roller bearings (4) locked up and table shaft bent
c/m: replaced 4 bearings and table drive shaft WAHY: vacuum faults
WHY: v1 on vacuum unit had a offset in it could not clear
C/M: moved vacuum hose from V1 to V2 now running ok WAP DIE F 8 FLOW LINES
Flow lines on mounting bolt surface.
Cause: possible temperature difference between the fix die core pin and the moving die core pin.
Countermeasure:I adjusted cooling time on f WAP F 5 DIE
Axis 2 squeeze pin Blistering on the bottom of the hole WAP F5 Casting broken in die
Cause: thought to be a water leak WASHOUT WASHOUT
13,000 SHOTS ON SLEEVE
Replace Sleeve and Plunger Tip
the water lines on the cooling joint was backwards from the previous change WATER POURING ALL THE TIME WHAT : blowback
WHY: tip worn from plunger spray tip lube not hitting tip
C/M: replaced tip and adjusted spray to hit plunger tip WHAT : cavity 2 sticking on top side of trim die
WHY: locate pins had a burr
C/M: cleaned locate pins (2) on cavity 2 WHAT Ladle traveling limit switch malfunction.
WHY faulty cable for xo60
ROOT CAUSE age and no schedule for changing main cable run
COUNTERMEASURE run a temporary cable if there are no more faults ins WHAT PLUNGER STUCK
WHY: debris and a broken spring
C/M: cleaned, greased and replaced spring now ok WHAT Vacuum 3 RB side 1 OP side
WHY ?
COUNTERMEASURE blow out vac hoses, verify all settings, adjust concentration of die release
WILL IT REOCCUR yes WHAT blowing vac blks operator side
WHY unsure
ROOT CAUSE unsure
COUNTERMEASURE went over all hoses lines connectors all seem tight snip ends on black air lines change block and it ran WHAT blowing vacuum blocks
WHY first ones blew because die release pump failed. unsure about subsequent failures
ROOT CAUSE unsure
COUJNTERMEASURES verify die release concentration, OK. change blocks WHAT blowing vacuum blocks operator side
WHY air blow not coming up to pressure black air blow lines worn, loose hose clamps, o-ring worn
ROOT CAUSE need inspection schedule for these items
COUNTERMEA WHAT broken water jacket,
WHY aluminum build up on plunger shaft, plunger shaft warped
ROOT CAUSE
COUNTERMEASURE replace water jacket, and plunger shaft WHAT changeover robot not setting shot in trim press correctly
WHY changeover program not accurate
COUNTERMEASURE touch up points in die and above die
WILL IT REOCCUR it shouldn't
no effect to cycle t WHAT collision detect alarms
WHY: while robot unloading part getting stuck/ robot hitting top of trim die
C/M: re-taught position 64 and had to adjust stroke on trim die top to allow clearance for rob WHAT continuous vacuum block failure
WHY: unknown
C/M: Removed fixed side of die and adjusted thermocouple that was not reading correctly, Moved all settings back to plex settings
Will it reoccur: unk WHAT die lubrication line leaking oil
WHY age
ROOT CAUSE age no set life schedule for replacement
COUNTERMEASURE replace
CYCLE TIME BEFORE 25.0 AFTER 25.0 WHAT die release not pumping
WHY pilot valve bad
ROOT CAUSE pumpthe pilot o-ring is worn out
COUNTERMEASURE replace entire pump as we have no pilot valves WHAT die release pump not pumping
WHY pilot valve is bad
ROOT CAUSE age no replacement schedule
COUNTERMEASURE replace
WILL IT REOCCUR yes WHAT erratic ladle operation
WHY upper chains were twisted going into turnbuckle, lower unit bearings bad
ROOT CAUSE age
COUNTERMEASURE straighten chains, replace lower unit, pass to 1st
WILL IT REOCC WHAT high limit sensor not detecting high aluminum
WHY wires broken
ROOT CAUSE no verification procedure for high aluminum limit wires
COUNTERMEASURE replace cable WHAT holding crucible cold, aluminum solid. temp controller reading 2400 degrees. AL01
WHY holding temp thermocouple broken
ROOT CAUSE unsure
COUNTERMEASURE replace thermocouple
WILL IT REOCCUR yes WHAT ingot loader crash
ROOT CAUSE paddles bent
COUNTERMEASURE clear crash straighten loader paddles
WILL IT REOCCUR no WHAT ladle acting erratic, also electrode faults
ROOT CAUSE ball electrode was loose and flopping off of arm, operator painted electrode ends
COUNTERMEASURE tighten electrode bar, clean ends and instr WHAT ladle getting stuck
WHY lower unit bound up
ROOT CAUSE lower unit binding
COUNTERMEASURE replace lower unit with non- inventory rebuild WHAT mist collector out of spec
C/M replaced stage 3 hepa filters WHAT motor overload at trim press
WHY TURNTABLE 1 sensor sticking on debris on sensor
ROOT CAUSE no procedure to clean and verify status of sensors on turntables
COUNTERMEASURE clean sensor WHAT oil leak at usual spot near fitting with flex hose
ROOT CAUSE pipe integrity compromised
COUNTERMEASURE have die maint weld
WILL IT REOCCUR yes, need new assemble pipe installed WHAT operator selected wrong home program
WHY defective program labeled ng do not use, failure to read
COUNTERMEASURE had to open helper door to allow robot to move home unsure if program can be delet WHAT parts jamming at remelt cutter
WHY cutters worn out
ROOT CAUSE need replacement schedule for cutters
COUNTERMEASURE clean up burrs on cutters new ones are on order WHAT repeatedly blowing operator side vacuum block
WHY screen filter plugged
ROOT CAUSE unsure aluminum sucked into filter
COUNTERMEASURE clean both screen filters check paper filters, and o-rings
CYC WHAT scrap chopper stuck in down position
WHY it was on a bind
ROOT CAUSE cutters worn
COUNTERMEASURE parts are on order WHAT slide core not returning intermittent faults
WHY die not appearing to heat up enough to turn on water (thermocouple)
ROOT CAUSE
COUNTERMEASURE replace thermocouple. temp better but still sticki WHAT trim press air blow fittings broken
WHY age
ROOT CAUSE
COUNTERMEASURE replace
WILL IT REOCCUR yes WHAT trim press hydraulic leak
WHY hose failed age no replacement schedule
COUNTERMEASURE replace hose
WILL IT REOCCUR yes WHAT trim press pulling on robot when pressing causing servo fault
WHY trim not sitting into die correctly
ROOT CAUSE unsure
COUNTERMEASURE touch up positions in die (P24) and just above.
WILL IT REOC WHAT vacuum block failure robot side
WHY possibly low concentration of die release perform multiple countermeasures and it started working
ROOT CAUSE possibly check die release concentration at start WHAT vacuum blocks being blown operator side
WHY
ROOT CAUSE
COUNTERMEASURE WHAT vacuum both sides
WHY unsure
COUNTERMEASURE change vac hoses multiple times on rb side as they were being blown out by hot aluminum. change air blow lines as many occurred during pre heat. check WHAT vacuum both sides 3 on op 2 on robot
WHY possibly broken plunge lube T fitting
COUNTERMEASURE replace vac lines and air blow lines both sides, replace broken plunge lube fitting, clean screens on WHAT vacuum operator side
WHY aluminum blockage in vacuum hose
COUNTERMEASURE have operator replace hoses from vac. unit to pass thru block, pull hose from block to vac block and blow out, replace o-r WHAT yamaguchi die release pump not working
WHY pump lost prime
ROOT CAUSE unsure operator caught it while performing checks
COUNTERMEASURE work with bleeder and flow control to get pump to prime and WHAT: biscuit jumping around
WHY: ladle lower unit bearings locked up
C/M: replaced lower unit (Non-Inventory)
REOCCER: yes timing WHAT: hyd high temp alarms
WHY: heat exchanger plugged up
C/M PULLED HEAT EXCHANGER COVER cleaned tubes
REOCCUR: yes timing WHAT: hydraulic valve stack moving when die open or close
WHY; bracket bolts loose
C/M: tightened bolts added tack welded angle iron to bracket to keep from moving WHAT: leaking spray valve
WHY: debris clogging spray valves
C/M: took manifold back a part and cleaned out debris from main water port WHAT: trim press hydraulic pump making noise
WHY: filter dirty
C/M cleaned filter now ok WHAT: 2 water leaks on start up. slide core leaking. blue water line leaking to moveable die, operator side
WHY: bad orings on cooling joint to slide core cavity 2. blue water line had hole in it up b WHAT: 2000 hr main hydraulic filter change
WHY:
C/M: replaced main hydraulic filter
REOCCER: yes 2000 hrs WHAT: 2nd shift operator called stating his air blow to main trim press is not working and leaving tabs behind in main trim press
WHY: main trim press faulting because of buildup of tabs, causing shot WHAT: ACC filling malfunction
Why: Possible filter screen plugged in PQ valve
C/M: Tore valve apart and replaced o-rings and screen filters WHAT: Broken half pipe
WHY: Noticed lumenex coming loose on half pipe after removing dog house
C/M: Replaced half pipe using soft patch
R/C: Yes time
Cycle time: Unchanged WHAT: CHANGE OVER checked tip and sleeve no good also lots of blow back
WHY: sleeve is very pitted I think from no lube
c/m: replaced tip and sleeve during change over
REOCCUR: yes WHAT: Crucible lid leaking
WHY: Corundum build up on top of crucible causing lid to raise. Thermo coupler was pulled out too far and over heated crucible. Held high temp for too long
C/M: Replaced c WHAT: DH called and requested hydraulic pump filter change
WHY: fitler is at life, 2000 hours
C/M: replace filter and reset filter life WHAT: DH called and said squeeze master wont bleed
WHY: hydraulic lines on squeeze master hooked up incorrectly. were hooked up to manifold for breather cover. it was changed over to water passage on WHAT: DH called and said theyre getting a gouge on tappet area of cavity 1
WHY: build up on cutters in trim press
C/M: cleaned cutters. had parts verified. turned over to production WHAT: DH doing change over asked about condition of sleeve, tip n sleeve worn out
WHY: wash out
C/M: replaced tip n sleeve
REOCCER: yes timing WHAT: DH noticed sleeve wash out during changeover
WHY: unknown
C/M: replaced tip n sleeve
REOCCUR: YES WHAT: DH requested a new ladle
WHY: ladle out on line is cracked and leaking
C/M: gave DH ladle to change out WHAT: DH requested hydraulic filter
WHY: filter at life 2000hrs
C/M: replaced filter and reset filter timer WHAT: DH requested hydraulic filter change
WHY: life up on filter (2000 hours)
C/M: replaced filter and reset life WHAT: DH requested new ladle cup
WHY: ladle cracked and leaking on machine
C/M: replaced ladle WHAT: Die not opening all the way in full or auto cycle (will open in manual)
Root cause: Operator side door switch
Countermeasure: Squeeze master had home light but not home bars were in the green o WHAT: FURNACE side door area damaged getting to the point where alum could leak out
WHY: maybe operator resting jackhammer rod on that area
C/M: built up area at side door with soft patch now ok WHAT: INGOT LOADER charging error
WHY: ingot bottoms have jagged edges which makes sensor read ingot to early, or a build up spot at one corner that lifts ingot too high for sensor to read
C/M: had t WHAT: INGOT loader not loading
WHY: damper door not getting open light
C/M: replaced door open limit switch now ok WHAT: Ingot loader crash
WHY: operator said when loader going up ingot fell off then bent 4 ingot holders. Bent sensor bracket in back for paddles
C/M: Moved sensor to front so it cant get hit again
R WHAT: Injection cylinder hydraulic pipe leaking
WHY: Unknown. Cracked weld
C/M: Drew welded pipe x2
REOCCUR: yes
Cycle time: Unchanged WHAT: Ladle faults
WHY: Lower unit locked up
Counter measure: Replaced lower unit and put insulator on probes. Had to set ladle 90 couldn't let enough aluminum out of ladle to get small enough biscuit WHAT: Loading material lid (bottom mesh) fell off
WHY: Was not right metal
Counter measure: Replaced mesh with right metal
R/C: No
Cycle time: Unchanged WHAT: OK conveyer stopping faulting
WHY: conveyer timing out during cycle (t180) then faulting
C/M: replaced motor
REOCCER: unlikely WHAT: OVERFLOW pieces staying on trim die causing trim damage
WHY: air blows have to be perfect in order to blow off all tabs
c/m: adjusted air blows added a longer air line WHAT: Operator jack hammering back of furnace causing excessive damage. Die cast maintenance in progress to repair back.
WHY: unknown
C/M: patched side door and back door on furnace
REOCCUR: yes timi WHAT: PC MALFUCTION fault H50
WHY: unknown
C/M: unknown - worked with Byron we replaced communication cable from the TC 200 controller to remote I/o no good gets fault operator side door close limit WHAT: PLUNGER LUBE line leaking
WHY: unknown
C/M: installed a t in plunder line
REOCCER: unlikely WHAT: PRESSURE gauge g1 leaking
WHY: gauge broken
C/M: replaced g1 gauge
REOCCUR: yes timing WHAT: Purosity in parts.
R/C: Operator mixed the plunger lube and die release in wrong containers
C/M: Training WHAT: QA called and wanted slide core changed on cavity 1 for cracked slide core
WHY: wear over time
C/M: replaced slide core on cavity 1. had to replace o-rings on cooling joint to slide core. checke WHAT: QA wanted slide core P2 changed for burr on part out of spec
WHY: slide core was chipped out
C/M: replaced slide core P2. verified no leaks and verified operation. turned over to production WHAT: QA wanted slide core S1 changed
WHY: QA said build up in roller groove almost out of spec. slide core chipped
C/M: changed slide core S1. checked for water leaks - ok. printed part confirmation WHAT: Robot fault
WHY: Fixed die came off backing plate maybe loose L brackets? operator side
C/M: Replaced tip, rod and sleeve. replaced die
R/C: Unknown
Cycle time: Unchanged WHAT: Robot faults
WHY: Shot sticking to tip
C/M: Replaced tip an sleeve WHAT: Robot not moving
WHY: Chuck sensor not working broken wire
Counter measure: Replaced sensor
R/C: Yes time
cycle time: Unchanged WHAT: S1 slide core leaking causing porosity
WHY: broken slide core (281 shots)
C/M: replaced slide core
REOCCUR: yes timing WHAT: SHOT STICKING TO TIP
why: TIP AN SLEEVE WORN OUT (WASH OUT)
C/M: replaced tip n sleeve
REOCCUR: yes timing WHAT: SHOT senor fault on plunger rod
WHY: sensor life
c/m: replaced shot detect sensor now ok WHAT: SHOT sensor not going to 0
WHY; dirty
C/M took sensor out cleaned installed works as it should WHAT: Shot not setting in trim press
why: Changeover
C/M: Hooked up plunger line. Replaced spray cartage and set spray points> Adjusted cutters for shot couldn't put in by hand. Then taught robot to p WHAT: Sleeve turning very easy
WHY: Sleeve bushing worn
Counter measure: Replaced bushing for sleeve. (insert hole). Old one -10.01mm new -9.85mm where sleeve face sets
R/C: No
Cycle time: Unchanged WHAT: THERMOCOUPLER broken
WHY: came loose when lid opened broke thermocoupler
C/M: replaced thermocoupler
REOCCER: yes timing WHAT: TIP sized in sleeve
WHY: used sleeve waiting on new
C/M: replaced tip WHAT: TL requested cavity p1 slide core be changed
WHY: slide core broke off in part
C/M: removed slide core, cleaned buildup from slide core blocks and cavity block sits in. replaced slide core. repl WHAT: TPRESS SENSORS NOT ALIGNED
WHY: BRACKET BOLTS CAME LOOSE.
FIX: RE-TIGHTENED AND ALIGNED SNESORS. WHAT: Tip & Sleeve change
Why: Washout Blow back
C/M: Replaced both Tip & Sleeve 63,391 shots
Recur: Possible in time WHAT: Trim damage (59B) one rocker
WHY: Unknown
C/M: Ground on cav #1 tappet cutter for big break. Made it go in tighter.
R/C: Yes
Cycle time: Unchanged WHAT: Trim height. (RPY M)
WHY: still working on cutter design with eng.
C/M: eng. modify cavity 2 block (cutter). Replaced 2 other cutters
REOCCER: yes WHAT: Upper crucible leak
WHY: Either spout, or halfpipe caused leak lots of corundum built up around top of crucible and spout
Counter measure: Replaced upper and lower crucibles and half pipe WHAT: Vacuum faults
WHY: Rebuilt blown block
C/M: Rebuilt blown block. Took all in house parts out and rebuilt with all original parts
R/C: Yes time
Cycle time: Unchanged WHAT: Vacuum faults
WHY: Tip and sleeve
C/M: Replaced tip and sleeve and short piece of rod. Extension piece was out of round. Took new one up and trued at lathe.
R/C: Yes time
Cycle time: Unchanged WHAT: WATER LEAK
WHY: plunger shaft cooling pipe o ring cut leaking because inside of shaft had corrosion built up
C/M: cleaned plunger shaft installed new o ring but still leaking replaced plunger s WHAT: WATERLEAK
WHY: loose connection on fitting for cooling joint water supply
C/M: took piping a part fixed thread tape installed
REOCCER: unlikely WHAT: after trim press stamps shot and comes up, it immediately drifts all the way down and faults robot out for collision detect while robot is trying to pull shot out of press
WHY: unknown. while tr WHAT: air blow not working
WHY: solenoid valve bad
C/M: replaced air blow solenoid valve
REOCCUER: UNLIKELY WHAT: air leak
WHY: air bowl broke
C/M: replaced air bowl on moving side die
RECCER: yes timing WHAT: air leak
WHY: cracked air bowl
C/M: replace air bowl WHAT: air leak
WHY: main air bowl cracked
C/M: replaced main air bowl on robot side of moveable side die WHAT: alo1 faults
WHY: thermocouple bad
C/M: replaced melting furnace thermocouple WHAT: aluminum blow out bottom slide cores
WHY: running a retired die block
C/M: took robot slide core out and cleaned , also cleaned slide core pockets on fixed side
REOCCER: yes WHAT: aluminum metal leak holding crucible
WHY: upper limit probes broken wire metal leak probes not working all the time
C/M: fixed upper limit probe wire and metal leak detect probes we jackhammered WHAT: axis 1 faults on squeeze master
WHY:
c/m: replaced axis 1 fittings on manifold WHAT: axis 1 faults pressure low should b 14.7 reading .5
WHY: hydraulic line (SQUEEZE MASTER) axis 1 line hole in it from rubbing on top of moveable die
C/M: replaced hyd line and used a bungie cord WHAT: axis 3 alarms running on low side of spec 7.0-7.4 adjust then good for awhile then drops out of spec
swapped axis 3 lines with axis 4 still problem
WHY: cavity 3 cylinder going bad
C/M WHAT: back tiebar clamp air leaking
WHY: cylinder solenoid valve gaskets blown out
C/M: replaced cylinder with valve assembly attached now ok WHAT: backdoor not closing at bottom
WHY: id of furnace is smaller so backside of door not fit into furnace opening
C/M: took door off used air hammer to file down inside of door to fit into furnace w WHAT: balz 65 fault / robot battery alarm
WHY: robot back up battery box corroded causing faults
C/M: replaced robot battery box with new /new batteries/ WHAT: biscuit alarms
WHY: ladle lower unit locked up
C/M: replaced ladle lower unit and chain WHAT: biscuit alarms
why: ladle arm upper bearings locked up
C/M: replaced whole arm
REOCEER: yes WHAT: biscuit jumping
WHY: ladle lower unit bearings locked up
C/M: replaced lower unit
REOCCER: yes timing WHAT: biscuit jumping around
WHY: lower ladle bearings locked up
C/M: replaced ladle lower unit
REOCCER: yes timing WHAT: biscuit jumping around
WHY: lower unit bearings locked up
C/M: replaced lower unit with rebuild
REOCCER: yes timing WHAT: biscuit jumping around
WHY: ladle lower unit chain loose
C/M: tightened chain biscuit better now WHAT: biscuit jumping around
WHY: lower ladle unit bearings locked up
C/M: replaced lower unit
REOCCUR: yes timing WHAT: biscuit size jumping around
WHY: lower ladle unit bearings no good
C/M: reolaced ladle lower unit
reoccur: yes timing WHAT: biscuit size jumping around
WHY: lower unit locked up
C/M: replaced lower unit
REOCCER: yes timing WHAT: biscuit thickness alarms
R/C: loose chains due to adjuster jam nuts not tightened
C/M: tightened lower ladle assembly chains
RE-OCCUR: un known WHAT: blew operator side vacuum melted hose caused fire alarm to go off
WHY: unknown but i think there was debris in manifold for operator side
C/M: replaced vacuum block both filters in vac unit an WHAT: blow back
WHY: sleeve worn
C/M: replaced tip n sleeve
REOCCUR: yes timing WHAT: blow back
WHY: tip and sleeve ( Lube line and 45 fitting had hole in)
C/M: replaced tip and sleeve and line and fitting
reoccur: yes timing WHAT: blow back
WHY: tip n sleeve worn tip plugged
C/M: replaced tip n sleeve
REOCCER yes timing WHAT: blow back
WHY: tip worn
C/M: replaced plunger tip
REOCCER: yes timing WHAT: blow back
WHY: tool life 89721 on sleeve
C/M: replaced tip and sleeve
reoccur: yes timing WHAT: blow back
WHY: tip n sleeve worn
C/M: replaced tip n sleeve
REOCCUR: YES TIMING WHAT: blow back causing ladle problems
WHY: tip n sleeve worn
C/M: replaced tip n sleeve
REOCCUR: timing WHAT: blow back/tip worn
why: lube tip broke off bracket mc running no lube
c/m: welded lube tip back on bracket/ gave tip an sleeve to dh WHAT: blow out bottom part of die and robot side
WHY: bottom slide cores filling up with aluminum causing them not to move freely, not allowing die to shut all the way
C/M: clean die an took bottom sl WHAT: blowback
WHY: lube line pinched in 2 spots = no lube
C/M: replaced tip n sleeve
REOCCER4:yes timing WHAT: blowback
WHY: lube pump went bad not always getting lube
C/M: replaced tip n sleeve
REOCCER: yes timing WHAT: blowback
WHY: m/c ran with no water last week
c/m: replaced tip
reoccer: yes timing WHAT: blowback
WHY: operator found spray tip clogged
C/M: replaced tip WHAT: blowback
WHY: plunger lub not in right position
C/M: replaced tip an adjusted plunger lube WHAT: blowback
WHY: sleeve life
C/M: replaced tip n sleeve
REOCCER: yes timing WHAT: blowback
WHY: sleeve washed out (monday we found a hole in plunger lube line fixed replaced tip but still damaged sleeve)
C/M: replaced tip an sleeve WHAT: blowback
WHY: sleeve worn
C/M: replaced tip and sleeve WHAT: blowback
WHY: sleeve worn
C/M: replaced tip n sleeve
REOCCER: yes timing WHAT: blowback
WHY: sleeve worn
C/M: replaced tip n sleeve and bushing. Bushing had wear around where sleeve set
REOCCER: yes WHAT: blowback
WHY: sleeve worn
C/M: replaced tip n sleeve
REOCCER: yes timing WHAT: blowback
WHY: sleeve worn (already tried a tip earlier in shift ng)
C/M: replaced tip n sleeve
REOCCER: YES TIMING WHAT: blowback
WHY: sleeve worn (wash out)
C/M: replaced tip n sleeve
REOCCER: yes timing WHAT: blowback
WHY: sleeve worn very little wash out (tried 2 replace tip only lasted 30min then blowback)
C/M: replaced tip n sleeve
reoccur: yes timing WHAT: blowback
WHY: spray tip out of position causing wear on sleeve
C/M: replaced tip and sleeve WHAT: blowback
WHY: tip and sleeve worn
C/M replaced tip and sleeve WHAT: blowback
WHY: tip and sleeve worn
C/M: replaced tip and sleeve WHAT: blowback
WHY: tip and sleeve worn
C/M: replaced tip and sleeve WHAT: blowback
WHY: tip n sleeve worn
C/M: replaced tip n sleeve
REOCCER: yes timing WHAT: blowback
WHY: tip worn
C/M: replaced plunger tip
tip had 15,638 shots WHAT: blowback
WHY: tip worn
C/M: replaced plunger tip fixed couple water leaks on fixed die
REOCCER: yes timing WHAT: blowback
WHY: tip worn
C/M: replaced tip
REOCCER: yes timing WHAT: blowback
WHY: tip worn
c/m: try 2 change tip to extend sleeve life
REOCCER: yes timing WHAT: blowback
WHY: unknown
C/M: replaced tip
REOCCER; yes timing WHAT: blowback
WHY: unknown
c/m: replaced plunger tip
REOCCER: yes WHAT: blowback
WHY: unknown but plunger was tip plugged
C/M: replaced tip n sleeve
REOCCER: yes timing WHAT: blowback
WHY: wash out
C/M: replaced tip an sleeve
REOCCER: yes timing WHAT: blowback
WHY: wash out , blowback melted plunger lube line the other day, was fixed but to late for sleeve
C/M: replaced tip n sleeve
reoccur : yes timing WHAT: blowback
WHY; tip worn
C/M: replaced tip
REOCCER:yes timing WHAT: blowback
Why: Sleeve bad
counter measure: Replaced sleeve and tip WHAT: blowback
WHY: plunger lube spray tip clogged (0 spray) see attachment.
C/M: replaced tip and sleeve WHAT: blowback
WHY: sleeve worn
C/M: replaced tip n sleeve
REOCCER: yes timing WHAT: blowback
WHY: tip and sleeve worn
C/M: replaced tip an sleeve WHAT: blowback
WHY: tip worn
C/M: replaced plunger tip WHAT: blowback
WHY: tip worn
C/M: replaced tip
REOCCER: yes timing WHAT: blowback and wash out
WHY: sleeve life
C/M: replaced tip n sleeve also noticed a lot of play in plunger coupler so replaced it
REOCCER: yes timing WHAT: blowback clogging lub tip
WHY: think m/c ran with no lube at some point sleeve and tip bad
C/M: replaced tip n sleeve
REOCCER: yes WHAT: blowback thick flashing
WHY: sleeve wash out
C/M: replace tip an sleeve WHAT: blowback, breaking shot
WHY: sleeve worn
C/M: replaced tip n sleeve checked all settings
REOCCER: yes timing WHAT: both bottom slide cores not moving
WHY: debris
C/M: took apart cleaned now moving freely WHAT: bracket that attaches helper side door cylinder to door, broke
WHY: wear
C/M: had bracket rewelded. installed and verified operations and limit switches. turned over to production WHAT: broken half pipe, melting furnace back door leak detect probes broken
WHY: half pipe broke unknown but caused back door probe damage
C/M: fixed back door probes WHAT: broken halfpipe
WHY: See note
C/M: replaced halfpipe
reoccur: Root cause not found WHAT: broken ladle
WHY: cleaning accidently broke
C/M: replaced ladle took a while to get old ladle off installed new pin WHAT: broken ladle
WHY: unknown
C/M: replaced broken ladle WHAT: broken locate pin cavity 2
WHY: build up in the locate pin hole
C/M: removed broken locate pin replaced cleaned locate pin holes all bottom base blocks
REOCCER: YES TIMING WHAT: broken melting crucible
WHY:unknown
c/m: REPLACED melting an holding cruclbles WHAT: broken melting crucible
WHY: unknown/ Possibly loaded empty
C/M: replaced upper n lower crucibles halfpipe welded upper ring
REOCCER: yes WHAT: broken plunger shaft at joint
WHY: unknown
C/M: replaced plunger shaft with spare will build a new spare plunger shaft WHAT: broken safety door latch
WHY: door closed while latch was out snapped end off of it
C/M: replaced latch with new now ok WHAT: broken slide core cavity 2
WHY: unknown
C/M: replaced slide core
RECOUR: yes timing WHAT: broken tappet pin and cracked slide core cavity 2
WHY: unknown
C/M: replaced cavity 2 slide core and replaced cavity 1 slide core was also cracked
REOCCER: yes timing WHAT: burners shutting off
WHY: ceramic block broken allowing probe to hit metal shuts off burner
C/M: made new ceramic block for level detect probes WHAT: carrier not moving
WHY: parts jammed motor very hot
C/M: cleared parts jam motor working will monitor
REOCCER: yes timing WHAT: cast pressure valve not adjusting while in auto cycle
WHY: solenoid valve possibly bad
C/M: replaced DG 33 solenoid valve WHAT: cavity 1 debris in block
WHY: coming from die pins an bushings
C/M: cleaned block out now ok till it builds up again WHAT: cavity 1 getting damage in between tappet area
Why: Build up on cutter
C/M: Replaced Cutter
Recur: Possibly in time WHAT: cavity 1 getting drag mark
WHY: Guides to tight all 4 cavities
C/M: Loosened all guide and replaced cutter shaft hole cav 1
Recur: Possible in time WHAT: cavity 1 had extra material on slide core area on part
WHY: slide core chipped causing problem
C/M: checked squeeze master settings the pressure was 17.2 setting in plex 14.7 adjusted back in sp WHAT: cavity 1 mark on tappet vacuum side
WHY: build up on cutter
C/M: replaced cutter
REOCCER: yes timing WHAT: cavity 1 not pressing part out
WHY: relief hole on block full of debris
C/M: removed bottom blocks cavity 1, 3 also found a guide pin broke off for cavity 1 block
replaced broken guide pin cl WHAT: cavity 1 part stuck top of trim press
WHY: debris left in part from the dies pins and bushings causing to stick to guild pins on top of trim press
C/M: removed bottom blocks cleaned debris all WHAT: cavity 2 an 3 trim damage at tappets
WHY: cutters worn
c/m: replaced cutter at cavity 2 n 3 tappets
REOCCER: yes WHAT: cavity 2 crush part and broken pusher rod
WHY: part stuck on trim press and broke pusher
c/m: replaced all parts for the pusher assembly WHAT: cavity 2 sticking to top of trim press
Why: Die leaving little tabs on part causing jig to fill up which caused pin to break and cavity to stick
C/M: Replaced upper pin and drilled out bottom j WHAT: cavity 2 trim die problems
WHY: part sticking to locate pins WHAT: cavity 2 trim height tappet area
WHY: flashing , and trim press out of alignment
C/M: re- positioned trim press and re- taught robot positions 25,26
REOCCER: yes timing WHAT: cavity 3 squeeze master leaking oil at valve stack base
WHY: o rings life
C/M: cleaned area, stoned base of stack and squeeze master and replaced o rings WHAT: cavity 3 trim at tappet
WHY: robot set down ng and shot tight in trim press
C/M: adjusted trim press so shot fits then re-taught robot positions 25,26 trim looks ok now WHAT: cavity 3/2 sticking to trimpress causing a double stack
WHY: locate pin bent causing part to stick due to the through holes packed with tabs that the locate pin pushes out
C/M: replaced both l WHAT: cavity 4 drag marks
WHY: cutter worn getting build up on it
C/M: replaced cavity 4 cutter
REOCCER: yes timing WHAT: cavity 4 hitting sprue pin
WHY: robot taught to close
C/M: re-taught pr 7,8 to get shot away from pin
reoccer: unlikely WHAT: cavity 4 parts jamming in trimpress
WHY: deflector chute under trimpress bent and broken
C/M: took trimpress apart and removed deflector chute
reoccur: timing WHAT: cavity p2 out of spec (step height)
WHY: slide core not dimensionally correct (Matt Kline)
C/M: replaced p2 slide core now parts ok
REOCCER: YES TIMING WHAT: cavity's 1,2 getting broke (not every cycle)
WHY: robot pick up position ng only 3 points of contact also checked chuck claws out of spec
C/M: replaced chuck claws re-taught pick up position (6 WHAT: check 16 gauge out of spec (die release pressure)
WHY: inside tank of die release pump full of black like wax or grease causing pump pressure low .2 should be .45
C/M: drained tank cleaned insid WHAT: chute from underneath trim press to ng conveyor came apart
WHY: previous tack welds broke apart
C/M: took chute out of machine. cleaned up chute and piece that came apart. welded back together. WHAT: collision detect alarms
WHY: pos 26 needed retaught causing robot to move to much giving a collision fault
C/M: re-taught positions 24,25,26
REOCCER: yes timing WHAT: collision detect alarms
WHY: shot not sitting in press correctly
C/M: re-taught sit down positions 3,4 WHAT: collision detect faults
WHY: robot positions 25.26 off not setting shot in press right
C/M: re-taught positions 25,26 in both pre heat and proudction programs
REOCCER: yes timing WHAT: cooling joint broken
WHY: operator noticed at start of shift that joint laying down in m/c with water shut off instead of getting fixed
C/M: replaced broken cooling joint
reoccur: yes WHAT: cooling joint broken leaking left side
why: unknown
c/m: replaced with a extension pipe only new cooling joint
reoccur: yes WHAT: cooling joint hole in sleeve ng
WHY: old cooling joint broke off in sleeve
C/M: could not remove broken cooling joint , replaced tip and sleeve WHAT: cooling joint leaking
WHY: ladle cracked causing a miss pour
C/M: replaced ladle and cooling joint
reoccur: yes timing WHAT: cooling joint leaking
WHY: new operator hit by accident
C/M: replaced cooling joint
occur: yes WHAT: cooling joint leaking
WHY: ring was on shaft broke joint
C/M: replaced cooling joint
REOCCER: yes timing WHAT: cooling joint leaking broken
WHY: excess flashing hitting
C/M: added an extension piece to cooling joint to get back from tip and flashing
REOCCUR: unknown WHAT: countermeasure for pc malfunction faults H50
c/m: replaced input module TR16DIC
reoccer: will monitor WHAT: countermeasure for plc battery loss (trimpress)
replaced plc battery WHAT: countermeasure for plc program loss (trimpress)
replaced plc battery WHAT: cracked slide core P1
WHY: unknown ,checked all squeeze master settings ok
C/M: replaced slide core P1
reoccur: yes timing WHAT: cracked slide core S1 "shot life 8,000pcs"
WHY: unknown checked all pressures at squeeze master ok
C/M: replaced S1 slide core adjusted spray to hit slide core where it hits part
REOCCUR: yes t WHAT: cycle time alarms
WHY: build up on injection rod and coupler
C/M: took cover off coupler cleaned debris out now injection rod moves free like its supposed to WHAT: cycle time alarms
WHY: helper door not getting return light /broken bracket
C/M: took bracket off welded adjusted advance an return speeds WHAT: die cavity number cavity 2,3
WHY: unknown
C/M: changed out trim press with trim 3
reocccer: YES TIMING WHAT: die change dh noticed sleeve wash out
R/C: sleeve 85000 shots
C/M: replaced tip and sleeve
timing WHAT: die cooling problems
WHY: moving water valve solenoid ng
C/M: replaced moving side cooling water solenoid
REOCCER: yes timing WHAT: die crash off shift cavity 4
WHY: DH noticed that cavity 4 product sensor loose inside housing (new style sensor only had 1 bolt holding)
C/M: took a 4 sensors out drilled another hole in sensor WHAT: die height motor overload
WHY: WHAT: die release concentration out of spec
WHY: spray unit pump bad
C/M; replaced die release spray unit pump WHAT: die release gauge broken
WHY: life of gauge
C/M: replaced die release pressure gauge WHAT: die release gauge broken
WHY: gauge life
C/M: replaced die release pressure gauge WHAT: die release low dilution ratio
WHY: went to replace mixing valve an noticed a pinched air line on valve
C/M: replaced air line (blue fitting on valve) drained and re filled 5 times all times ra WHAT: die release pump bad
WHY: pump life
C/M: replaced pump
reoccur: yes timing WHAT: die release pump not pumping. nothing but air coming from spray cartridge
WHY: bad valve on pump. no replacement pump in inventory
C/M: cleaned and replaced guts of pump with rebuild kit. change WHAT: die release pump not working
WHY: pump bad unknown but die release mixed with plunger lube
C/M: replaced pump and emptied die release bucket filled with new
REOCCUR: yes timing WHAT: die release pump not working
WHY: pump failure
C/M: replaced pump
REOCCUR: yes timing WHAT: die release pump not working
WHY: pump not running
c/m replaced die release pump WHAT: die release pump out of spec ( barely pumping)
WHY: pump bad
C/M: replaced die release pump
REOCCUR: yes timing WHAT: die release spray unit goes down but cylinder not coming out to spray
WHY: found broken wire
C/M: fixed broken wire ok s24a
REOCCER: yes timing WHAT: die release wand not spraying
WHY: die release pump bad not working
C/M: replaced die release pump now ok WHAT: die wont close in auto
WHY: unknown thinking out of cycle
c/m: worked with operator got back in cycle WHAT: dropping cavity 4
WHY: unknown
C/M: replaced tip
REOCCER:yes timing WHAT: dropping parts
WHY: cavity 4 operator side bottom slide core sticking
C/M: clearance cavity 4 slide core
reoccur: yes timing WHAT: dropping parts
WHY: shot sticking to tip
C/M: replaced plunger tip WHAT: dropping parts
WHY: tip n sleeve bad noticed coupler very loose (worn out) and injection rod extension loose
C/M: replaced tip n sleeve ,injection rod coupler tightened rod extension
REOCCUR: y WHAT: dropping parts
WHY: tip sleeve worn 102,621
C/M: replaced tip and sleeve
reoccur: yes WHAT: dropping parts
WHY: squeeze master lines not hooked up correctly due to two different style quick connect fittings
C/M: swapped fixed side hyd fittings on m/c to corresponding cavity with sque WHAT: dropping parts and blow back
WHY: tip n sleeve no good
C/M: replaced tip n sleeve
REOCCER: yes timing WHAT: dropping parts at ok conveyer
WHY: bumpers missing from ok conveyer bucket causing a gap for parts to bounce out
C/M: replaced bumpers WHAT: dropping parts/blow back (sleeve wash out)
WHY: water turn off at cooling joint
C/M: replaced tip n sleeve
REOCCER: yes timing WHAT: dropping shots
WHY: sticking to tip
C/M: replaced plunger tip
REOCCER: yes timing WHAT: electrode bar faults
WHY; electrode ceramic sleeves broke off
C/M: replaced electrode bar assy WHAT: electrode wire break
WHY: wire broken
C/M: replaced ladle electrode cable WHAT: elevator not loading material in melting crucible
WHY: no tower home position light (broken wire in cannon plug)
C/M: re soldered wires
REOCCER: yes timing WHAT: err 0015 on left weight scale, right side digital readout
WHY: SW1-1 was Off
C/M: Found switch on inside of controller turned on was able to get rid of fault but went to calibrate gave fault 007 WHAT: error011
WHY: scale needed re-zeroed / very dirty under scale with overflow pieces
C/M: cleaned under scale zeroed scale confirmed weights 25lbs and 50lbs on scale ok WHAT: excessive wash out
WHY: unknown
C/M: replaced tip n sleeve
REOLCCE: yes WHAT: filter clog fault on squeeze master
WHY: filter life up
C/M: replaced all 3 filters
REOCCER: yes timing WHAT: filter need changed in mist collector
WHY: filter ng (check #35c)
C/M: change filter WHAT: fix side temp alarms
WHY: thermocouple not reading correctly bad spot in cable
REPLACED: thermocouple
reoccur: timing WHAT: fixed side die water flow very slow
WHY: solenoid valve sticking
C/M: took valve a part cleaned now ok WHAT: flapper 3 not getting return light
WHY: part jammed in flapper
C/M: removed part
REOCCUR: yes WHAT: flipper 1 not getting return light
WHY: bolt on flipper 1 linkage jamming on housing found bolt too long
C/M: took linkage apart cut bolt down now linkage has clearance to move full stroke
REOC WHAT: forward limit switch faults
WHY: cable bad for x60 limit switch
C/M: replaced cable x60 from main control panel to ladle terminal box
REOCCUR: timing WHAT: furnace back door not sealing
WHY: WHAT: furnace back door not staying open
WHY: front seal on cylinder blown
C/M; replaced furnace back door cylinder WHAT: furnace control panel main breaker tripped
WHY: found main breaker to furnace control panel wires burnt up under furnace door area, blew 3 fuses in main disconnect
C/M: Replaced wires WHAT: furnace controller could not change temp from 1252 to 1652
WHY: controller buttons broken internally (all functions ng)
C/M: replaced controller with a new one now ok WHAT: furnace leaking in between dog house and furnace
WHY: lower brass nut came loose causing a gap
C/M: took off dog house used soft patch to fix area around dog house half pipe and furnace
reoccu WHAT: furnace melting al01 alarm
WHY: thermocouple bad
C/M: replaced thermocouple for melting
REOCCUR: yes timing WHAT: furnace not jackhammered correctly
WHY: talk to production
C/M: cuts rods and removed the safety fence so operator could jackhammer halfpipe WHAT: furnace repair at side door area
WHY: excessive jackhammering
C/M: patched bottom of furnace at side door area
reoccur: yes timing WHAT: furnace temp staying around 1522 wont read any higher making furnace always run
why; thermocouple bad
c/m; replaced thermocoupler WHAT: gap in metal leak door
C/M: air hammered soft patch out and re-patched it flush with door and furnace to prevent a gap between door and furnace WHAT: getting blowback
WHY: tip worn
C/M: replaced tip
REOCCER: yes timing WHAT: getting vacuum faults
WHY: taka wanted us to replace the plunger tip for the vacuum faults
C/M: replaced plunger tip WHAT: had unburnt gas smell
WHY: after taking readings from roof top exhaust die cast 6 had a very high reading compared to other m/c
C/M adjusted holding gas 14 to 11.6
melting 20.4 to 17.6 WHAT: helper door alarms
WHY: return coil on valve not always working an flow control adjusted bad
C/M: replaced valve ok but still had problems with flow control valve so we took both return an ad WHAT: helper door broke bracket door to cylinder
why: bracket made out of alum too weak
c/m: installed steal bracket but took extra time to make bolts grind new bracket down and re-align WHAT: helper door close limit switch faults
WHY: limit switch 2 bad worked fine one way an other way worked half the time
C/M: replaced limit switch 2 WHAT: helper door faulting
WHY: guide wheel bracket weld broken causing door to lean and jam
C/M: removed helper door re-welded guide wheel bracket
REOCCER; yes timing WHAT: helper door faults
WHY: cylinder bracket joint fell apart causing door to jam once opened
C/M: replaced cylinder joint now ok WHAT: helper door faults while closing
WHY: close limit switch 2 stuck on
C/M: replaced limit switch #2 WHAT: helper door jamming
WHY: helper door moving to fast and door crashing into yellow safety door
C/M: bent bottom of helper door back in and adjusted air to slow down door
REOCCER: yes timing WHAT: helper door limit switch faults
WHY: limit switch 2 out of adjustment
C/M: slowed down cylinder speed for advance an return and adjusted limit switch 2 now ok WHAT: helper door not moving in auto
WHY: safety tape switch bad
C/M: replaced helper door tape switch
REOCCER: yes timing WHAT: helper door not opening
WHY: front seal blown
C/M: replaced cylinder for helper door now ok WHAT: helper side door close limit switch faults
WHY: door frame cracked
C/M: welded door frame
reoccur: yes timing WHAT: high pressure hydraulic pipe for die open die close cylinder
WHY: weld had pin hole
C/M: drew re-welded pipe ok now
REOCCER: yes timing WHAT: high pressure pipe for moving die close leaking
WHY: pipe life up
C/M: rewelded pipe 2 times to fix leak WHAT: high speed shot alarms
WHY: tip worn
C/M: replaced tip
REOCCER: yes timing WHAT: high speed shot alarms
WHY: water off for the sleeve cooling
C/M: replaced tip
REOCCER: yes timing WHAT: high speed shot alarms
why: plunger tip smashed / operator noticed but to late sleeve wash out
c/m replaced tip and sleeve WHAT: high speed shot alarms and blow ack
WHY: tip n sleeve bad
C/M: replaced tip n sleeve
REOCCUR: yes timing WHAT: high speed shots alarms
WHY: sleeve worn
C/M: replaced tip n sleeve
reoccur: yes timing WHAT: hold heater not heating
WHY: contactor bad for heater
C/M: replaced heater contactor WHAT: holding burner misfire
WHY: unknown cleaned rod replaced photo eye swapped flame relays still problem
c/m WHAT: holding crucible filter broke in half
WHY: unknown
C/M: replaced filter
reoccur: yes WHAT: holding crucible temperature jumping around
WHY: thermocouple bad
C/M: replaced thermocouple
REOCCER: yes timing WHAT: holding furnace burning rich
WHY: backside of crucible has to be so close to wall for clearance for ladle travel , not enough space for holding furnace to vent up through doghouse
C/M: removed WHAT: holding furnace metal leak door damaged
WHY: soft patch life so it breaks a part easier
C/M: removed all loose material then re- patched it WHAT: holding metal leak
WHY: overflow
C/M: had to replace leak detect probes clean inside of door also WHAT: hook cylinder air leak
why: gasket blown out
C/M: took gaskets off mc from CANADA Bert is ordering new parts WHAT: hyd high temp alarms
WHY: heat exchanger plugged up
C/M: pulled cover cleaned tubes
REOCCUR: yes timing WHAT: hydraulic leak
WHY: fitting loose
C/M: took fitting off cleaned re-taped an dopped fitting threads now ok WHAT: hydraulic leak
WHY: fixed side hydraulic pipe leaking
C/M: took off welded hole install no leaks
REOCCER: yes timing WHAT: hydraulic leak
WHY: high pressure pipe on die close cylinder had pin hole
C/M: had drew weld x2
REOCCER: yes timing WHAT: hydraulic leak
WHY: injection pipe leaking
Counter measure: Welded pipe WHAT: hydraulic leak
WHY: large leak coming from crack in weld on orange pipe going across top of die to robot side cylinder block
C/M: cleaned all mating surfaces. !st had it re welded and put back o WHAT: hydraulic leak
WHY: bottom fitting on trim press up/down cylinder leaking
C/M: replaced bottom fitting
REOCCER: unlikely but will monitor passed on to 2nd and told 1st shift team leader ther WHAT: hydraulic leak at fixed side valve stack supply pipe
WHY: pipe has been welded couple times one weld cracked causing leak
C/M: had die maint weld pipe replaced o rings ok now WHAT: hydraulic leak on main pipe to valve stack on fixed side for the tappet pins
WHY: been welded a few times
C/M: re-weld pipe
REOCCER: yes timing WHAT: hydraulic leak on move core 2 main line at die
WHY: quick connect fittings worn out
C/M :replaced both male an female fittings ok
REOCCUR: not likely WHAT: hydraulic leak on the injection pipe
Why: Bolts were loose and o-ring hanging out
C/M: pulled off pipe put o-ring back in and tightend bolt down
Recur: possibly WHAT: hydraulic leak trim press
why: loose hydraulic filter bowel and broken O-ring
c/m: replaced filter bowel O-ring and made sure filter bowel was tight.
reoccur: yes timing WHAT: hydraulic leaks fittings on slide core cylinders on the sides
WHY: couple fittings wrong thread and some loose
C/M: took all fittings off replaced wrong fittings and re taped all fittings instal WHAT: hydraulic motor overload
why: robot sitting at back door, pump stays loaded
C/M: recover robot WHAT: hydraulic pump making noise
WHY: suction filter bad
C/M: replaced suction filter now ok WHAT: hydraulic pump overload
WHY: motor starters bad
C/M: replaced both motor starters ml, ol for hydraulic pump
reoccer: unlikely WHAT: hydraulic pump overload after change over x2
WHY: investigating
c/m: monitored 1 hr after second fault did not see amps jump over 61 tag on motor is set at 83
:yes timing WHAT: hydraulic pump very load then quit working
WHY: dirty oil oil hot
C/M: replaced trim press hydraulic pump now ok WHAT: hydraulic temp high
WHy: heat exchanger on dc m/c plugged up
C/M: cleaned heat exchanger WHAT: hydraulic temps running 120
WHY: heat exchanger on dc m/c dirty
C/M: cleaned heat exchanger with drill/ brush WHAT: hydraulic valve stack hanging from moving side backplate
WHY: bolts that hold valve stack came loose fell out \ on remote side had one bolt should be 2
C/M: used crane to get valve stack back up WHAT: ingot lift table not working
WHY: motor bad
C/M: replaced motor and power cord now ok WHAT: ingot loader crash
WHY: bent paddles
C/M: bent about 30 paddles and replaced a lot of bolts nuts an lock washers and replaced 3 paddles WHAT: ingot loader crash
WHY: bottom of ingots have high spots low spots and jagged edges that cause problems because the sensor wont detect the ingot
bent 4 paddles
C/M: replaced bent paddles WHAT: ingot loader crash
WHY: found limit switch 2 the head was loose not allowing switch to work correctly / overtravel switch bracket bent allowing loader to crash
C/M: re-positioned overtravel sw WHAT: ingot loader crash
WHY: ingot fell down under lift and bent 30 paddles due to loader position flipping 1 ingot while lifting them WHAT: ingot loader crash
WHY: pass on but looks like a ingot stuck in bottom then 16 flights hit and bent
C/M: replaced 16 flights WHAT: ingot loader crashing
WHY: bent paddles and inconstant ingot bottoms either sensor sees ingot or it dont
C/M: replaced bent ingot paddles with 10 new ones WHAT: ingot loader ingot paddles damaged
why: FROM LOADER CRASHING
C/M: replaced 17 paddles WHAT: ingot loader making noise going up to load
WHY: to much chain slack
C/M: adjusted loader chain now ok WHAT: ingot loader not loading
WHY: air line for pusher 2 broken
C/M: replaced air line for pusher 2 advance WHAT: ingot loader paddles ng
WHY: previous crashes
C/M; replaced 16 paddles did all work while m/c was running WHAT: ingot loader pusher 2 advance light stuck on
WHY: broken wire
C/M: replaced wires to limit switch
REOCCER: unlikely WHAT: ingot loader safety door fault
WHY: the back door safety switch area is NOT good
C/M: replaced door switch
REOCCER: yes WHAT: ingot loader supply air bowl leaking
WHY: bowl cracked
C/M: replaced air bowl WHAT: injection cylinder rod seal leaking
WHY: rod seal assembly worn
C/M: replaced rod seal assembly
REOCCER: yes timing WHAT: injection pipe leaking
WHY: pin hole in welds
C/M: had drew re-weld pipe
REOCCER: yes timing WHAT: injection pipe leaking
WHY: pipe has been welded multiple times
C/M: removed injection pipe drew welded no leaks
REOCCER" yes timing WHAT: injection rod not moving in manual
WHY: WHAT: injection rod not returning to 0 every shot return number increases
why injection rod worn very bad condition WHAT: injection rod packing leaking out front of plunger shaft
WHY: packing seals worn out
C/M: replaced injection packing seal
REOCCER: yes timing WHAT: injection shaft not returning
Why: Big piece of aluminum stuck in bottom of sleeve
C/M: Replaced Tip and Sleeve (2 SLEEVES WERE REPLACED)
Recur: Possibly in time WHAT: inspected sleeve during changeover noticed it was bad
WHY: wash out
C/M: replaced tip n sleeve
REOCCER: yes timing WHAT: installed a hose reel as a trial for jackhammering furnace per production request
took 3 days to complete job due to working on more important things WHAT: jamming parts in center of conveyer
WHY: conveyer guide center broken weld
C/M: re-welded part guide
REOCCER: unlikely WHAT: ladle arm cup moving a lot while dipping in crucible
WHY: chains loose in arm
C/M: tightened chains in arm
REOCCER: yes timing WHAT: ladle arm stopping
WHY: unknown
C/M: replaced ladle key switch (man off auto)
reoccur: investigating WHAT: ladle bar fault
WHY: bar came loose causing faults
C/M: re-tightened bar WHAT: ladle bar fault
WHY: probes came loose and broke a wire
C/M: tightened probes and replaced cooper end now ok WHAT: ladle bar faults
WHY: blowback due to worn tip
C/M: replaced plunger tip / both water lines (leaking) WHAT: ladle bar malfunction
WHY: bar had broken ceramic insulators still problem found bad spot in ladle wiring
C/M: replaced bar with rebuilt and replaced ladle wire
REOCCER: yes timing WHAT: ladle bar malfunction
WHY: broken wire at ladle bar
C/M: replaced electrode bar and fixed broken wire
REOCCER: yes timing WHAT: ladle bar malfunction
WHY: insulators broken causing fault
C/M: replaced ladle bar with rebuilt
REOCCER: yes timing WHAT: ladle bar malfunction
WHY: ladle bar broken insulator on long probe / and noticed couple bad spots in cable
C/M: replaced ladle cable an ladle bar now ok WHAT: ladle bar malfunction
WHY: the nylon cover we put on fell off
C/M: put new cover nylon cover back on
REOCCER: unlikely WHAT: ladle bar malfunction alum sticking to electrode bar from ladle
WHY: alum sticks to the inside of ladle then when ladle goes to pour the electrode cleans off inside of lade causing bar malfunct WHAT: ladle broken wire
WHY: clamp came loose
C/M: re-crimped new connector ok WHAT: ladle broken wire faults
WHY: wire broken off connector
C/M: re-crimped wire now ok WHAT: ladle cup leaking across crucible ring
WHY: crack in ladle cup
C/M: replace ladle cup WHAT: ladle cup locked up
WHY: bearing life
C/M: replaced ladle lower unit WHAT: ladle dunk in alum
why: ladle bar ?
c/m : made a new ladle bar / ceramic sleeves added also WHAT: ladle dunk in alum causing bearings to lock up
WHY"
c/m: took ladle lower unit off dc 11 to put on dc 9 / replaced ladle WHAT: ladle dunking
WHY: Traveling motor
C/M: Fixed electrode bar and replaced traveling motor
REOCCER: unknown
Cycle time: Unchanged WHAT: ladle electrode bar malfunction
WHY: broken insulator on bulb probe
C/M: replaced electrode bar assembly
REOCCUR: yes timing WHAT: ladle electrode bar malfunctions
WHY: aluminum on probe mounting bracket
C/M: cleaned aluminum from probes and informed operator of areas to check for possible aluminum build up. operator mentio WHAT: ladle electrode break
WHY: broken wire
C/M: had enough wire slack to re connect
REOCCER: yes timing WHAT: ladle electrode faults
WHY: cable had bad spot in it
C/M: replaced ladle electrode cable
REOCCER: yes timing WHAT: ladle electrode faults
WHY: ceramic insulators broke off
C/M; replaced electrode bar with new rebuilt one WHAT: ladle electrode faults
WHY: cover on lower arm was loose and touching probe bracket when ladle traveling towards crucible. one probe wire was exposed and contacting ladle arm when in motion
C/M: WHAT: ladle electrode faults
WHY: broken wire
C/M: replaced ladle wire now ok WHAT: ladle electrode faults
why: no ceramic sleeves
c/m: added ceramic sleeve ladle bar WHAT: ladle electrode malfunction faults
WHY: both ceramics broke on one of the ladle probes allowing probe to teeter and throw the faults. ladle cup was full of aluminum as well
C/M: replaced probe u WHAT: ladle electrode probe bulb fell off
WHY: unknown
C/M: replaced electrode assy
REOCCUR: yes timing WHAT: ladle electrode wire broken faults
WHY: broken wire in cable
C/M: replaced ladle electrode cable WHAT: ladle electrodes loose
WHY: broken insulator
C/M: replaced electrode assembly
reoccur: yes timing WHAT: ladle fault not moving
WHY: lower unit locked up
C/M replaced ladle lower unit
RECCOUR: YES TIMING WHAT: ladle faults
WHY: ladle bar needs re-built and wire broken wire
C/M: replaced lower ladle unit ladle bar and ladle wire WHAT: ladle faults
why: ladle bent from going in to far hitting mc then ladle too close to ladle bar causing fault
c/m: adjusted ladle to not go in as far 145.00 to 144.00 WHAT: ladle faults
WHY broken wire in cable
C/M replaced ladle cable and ladle bar WHAT: ladle forward limit switch sticking on
WHY: unknown
C/M: replaced x60 limit switch sensor
REOCCER: unlikely WHAT: ladle hitting nut clamp cylinder bracket
WHY: lower unit bearings locked up
C/M: replaced ladle lower unit
REOCCER: yes timing WHAT: ladle hitting tie bar lock guard after pour on way out of m/c
WHY: lower unit locked up
C/M: replaced ladle lower unit
REOCCER: yes timing WHAT: ladle inverter fault
WHY: bearings locked up
C/M: replaced lower unit twice one of them would not fit on ladle arm
REOCCUER: yes timing WHAT: ladle invertor overload (pour)
WHY: ladle lower unit bearings locked up
C/M: replaced lower ladle unit
reocur: yes timing WHAT: ladle lower unit locked up, cooling joint leaking
WHY: operator came into from 3rd
C/M replaced ladle lower unit ,cooling joint
REOCCER: yes timing WHAT: ladle moving very slow at slow down before sleeve or at crucible
WHY: found that break relay not energizing (when energized it releases the break) while ladle moving
C/M: replaced relay stil WHAT: ladle not moving
WHY: ladle lower unit bearings locked up
C/M; replaced ladle lower unit an ladle cup due to it was full of alum WHAT: ladle not moving
WHY: lower bearing locked up
C/M replaced lower ladle unit WHAT: ladle not moving
WHY: operator cleaning halfpipe and a bullrush of alum hit side of ladle arm
c/m: replaced lower unit WHAT: ladle not moving
WHY: upper ladle arm bearings locked up
c/m: replaced whole ladle arm WHAT: ladle not starting in auto
WHY: key switch for ladle (man off auto) bad worn out
C/M: replaced key switch with new now ok WHAT: ladle stuck on ladle arm
WHY: ladle cup bracket 1/2 mm to wide causing pin to jam
C/M: 45 min to remove pin then used 90 degree grinder to grind face of bracket till pin fits by hand WHAT: ladle traveling not stopping
WHY: motor bad
C/M: replaced ladle traveling motor now ok WHAT: ladle wire broken
WHY: clamps fell off slack got caught and pulled on wire
C/M: fixed broken wire and clamped to ladle arm
REOCCER: yes timing WHAT: ladle wont move. ladle in by sleeve ready to pour. no faults. ladle cup full of aluminum and cracked
WHY: ladle locking up, possibly bearings going out in lower unit
C/M: manually handled ladle WHAT: line pressure faults
WHY: investigating
c/m: replaced DG13 valve and replaced o rings on accumulator drain valve to fix oil leak WHAT: loader crash
WHY: bent ingot holders
C/M: replaced 8 ingot holders
REOCCER: yes timing WHAT: loader door broken door slide key
why: unknown
c/m: replaced door slide key WHAT: loader faults
WHY: pusher 1 cylinder no good
C/M: replaced pusher 1 cylinder
REOCCER: yes timing WHAT: loading faults at trim press
WHY: part hitting chute in press, put n place pick up position ng
C/M: re-taught robot at put n place , loading position in trim press adjusted chute
REOCCER: yes t WHAT: locate pin missing
WHY: unknown think crashed but reset an ran again
C/M: while replacing locate pin checked all cavity's found pins bent in cavitys 2,3,4 and main locate pin for shot at base WHAT: low reading for the die release
WHY: spray pump unit loosing prime
C/M: replaced spray pump unit now ok WHAT: low speed shot alarms
WHY: tip worn
C/M: replaced tip still problem then replaced tip and sleeve added nitrogen
REOCCUR: timing WHAT: low temp on holding furnace
WHY: bad spot in wire touching housing causing temps to jump around
C/M: cut out bad spot re-terminated ok
REOCCER: yes timing WHAT: lube unit oil empty
WHY: broken lube line on moveable side of die
c/m replaced broken lube line now ok/ replaced leaking hose on water heater WHAT: m/c doing changeover and I noticed that the sleeve was very bad condition
changed tip out and gave sleeve to DH to finish changeover WHAT: m/c getting fault while running
WHY: safety door lock (operator side) coming unlocked during auto cycle
C/M: turned the manual lock to lock on bottom of safety lock now door will stay locked
RE WHAT: m/c making noise when closing
WHY: hydraulic valve stack broke welds and loose bolts
C/M: replaced bolt tightened bolts and welded bracket to moving side of m/c WHAT: m/c moving?
WHY: think anchors moving in floor wallowing out the holes
C/M: re tightened bolts some seem to tighten ok couple others pulling out
REOCCER: yes timing WHAT: machine lost ladle arm axis pos, ladle pour axis pos, move platen pos, back platen pos, shot stroke and eject position
WHY: power outage
C/M: Broken chain buckle on upper ladle, replaced broken WHAT: machine lost ladle arm axis pos, ladle pour axis pos, move platen pos, back platen pos, shot stroke and eject position
WHY: power outage
C/M: set the 90's on ladle arm axis pos and ladle pour ax WHAT: main hydraulic filer clogged
WHY: filter life
C/M: replaced filter
REOCCER: yes 2000hr WHAT: main hydraulic fitting for fixed core leaking
WHY: male fitting bad
C/M: replaced male fitting now ok
REOCCER: YES TIMING WHAT: mark on part
WHY: cutter 4 coating worn causing allum to stick to cutter
C/M: replaced cutter 4 / noticed robot finger broken bolt fixed
REOCCER: yes timing WHAT: marks on back side of parts. cavities 1, 2, 3
WHY:
C/M: WHAT: marks on part
WHY: while loading into trim press part hitting guide
C/M: adjusted robot loading position in trim press was good then came back so i made another adjustment but could not confirm WHAT: melting burner getting misfires
WHY: ignition rod gap ?
C/M: cleaned photo eye still faulting
adjusted blower damper to match dc 6 and moved igniter (spark rod) in couple mm to change spar WHAT: melting burner misfire
WHY: photo eye melted
C/M: replaced photo eye
REOCCER: yes WHAT: melting controller al 01 fault
WHY: cannon plug had broken wire 2p for thermocouple
C/M: repaired cannon plug broken wire
reoccur: unknown WHAT: melting controller not reading temp al 01
WHY: thermocouple bad
C/M: replaced thermocouple
REOCCUR: yes timing WHAT: melting crucible 1900 degrees
why: thermocoupler and wire ng
c/m replaced thermocoupler and wiring WHAT: melting crucible leaking
WHY: broken pedestal causing crucible to drop a little which caused wedges to drop and break seal on half pipe
C/M: replaced melting crucible and pedestal
reoccur: yes WHAT: melting crucible metal leak
WHY: cracked half pipe because of crucible loaded empty
C/M: replaced pedestal , melting crucible , half pipe
reoccur: yes timing WHAT: melting flame outs
WHY: gas valve / ignition rod
C/M: replaced gas valve still had flame out then took ignition assy out cleaned rod and replaced ceramic spacer now ok WHAT: melting furnace exhaust temps jumping around
WHY: thermocouple was loose and moved out of upper lid and bent it
C/M: replaced thermocouple
REOCCER: yes timing WHAT: melting furnace lid damaged very bad
WHY: unknown
C/M: removed repaired bottom of lid WHAT: melting furnace not melting
WHY: wires on upper limit probes ng (bare wires touching)
C/M: pulled slack re-wired probes
REOCCER: yes timing WHAT: melting lid not opening
why: cylinder rod loosened up an came out of bracket
c/: took bracket off put on cylinder put back on lid tightened jam nut now ok WHAT: melting metal leak
Why: cracked around spout
C/M: Replaced crucible and half pipe
Recur: In time WHAT: melting temp jumping
WHY: gas pressure out of spec (reading 19.9 should b 13.9)
C/M: replaced thermocouple and adjusted gas pressure back in spec
REOCCER: YES TIMING WHAT: melting temp jumping around
why" thermocouple broken
c/m: replaced melting thermocouple WHAT: melting temp reading negative
WHY: thermocouple life
C/M: replaced thermocouple now ok WHAT: mesh ok conveyer no good
WHY: overflow stuck in belt broke belt causing jam
C/M: replaced mesh belt
REOCCER: yes timing WHAT: metal leak
WHY: Cracked spout on crucible
C/M: Remove and replace holding crucible and pedestal. Removed doghouse and had to patch the refractory additionally we patched the side door opening t WHAT: metal leak (melting crucible)
WHY: spout broke
c/m- replace crucible half pipe and crucible stand
REOCCER: yes timing WHAT: metal leak at melting crucible
WHY: broken spout
C/M: replace melting crucible WHAT: metal leak melting
WHY:broken halfpipe
C/m= replace crucible
REOCCER: yes WHAT: metal leak melting furnace
WHY: excess alum from previous half pipe break
C/M: fixed metal leak probes again
recur: yes timing WHAT: metal leak not faulting m/c
WHY: wiring e3 , e4 wires burnt up
c/m: replaced wiring ok
reoccer: yes timing WHAT: misfire
WHY: found ignition coil melted wires
C/M: replaced ignition coil for melting burner
REOCCER: yes timing WHAT: mist collector filters out of spec
WHY: filter life
C/M: replaced stage 3 hepa filter WHAT: mist collector not working
WHY: intake cone hitting fan causing fuses to blow
C/M : took apart took 1/8 inch off bottom of cone to make clearance now ok WHAT: mist collector out of spec
C/M: replaced stage 3 hepa filters WHAT: mist collector stage 3 filters in the red
WHY: filter life
C/M: replaced stage 3 filters WHAT: mist collector stage 3 in red
WHY: filter life
C/M: replaced stage 3 hepa filters WHAT: mold heater not working
WHY: contactor for heater aux contacts bad
C/M: replaced heater contactor
REOCCER: yes timing WHAT: mold heater tripping breaker
WHY: heater coil wires on bottom side of coil loose
C/M: put wires back in and tightened up now ok WHAT: move core 2 faults
WHY: reed switch bad (top)
C/M: replaced top cylinder reed switch
REOCCER: yes timing WHAT: moving core 2 hydraulic lines on top of moving side hitting tie bar cylinder
WHY: (changeover crash) on 8/23 tie bar cylinder hit hydraulic lines and bent them
C/M: drained hydraulic fluid out WHAT: moving side (die) supply water line leaking
WHY: hose has hole
C/M: Replaced hose with new
R/C:
Cycle Time: Unchanged WHAT: moving side water line bracket broken
WHY: vibration from loose bolts
C/M: welded old bracket WHAT: moving side water staying on
why: solenoid valve bad
c/m; took apart cleaned but worn very bad an still leaking after clean
0 parts in inventory kevin emailed burt WHAT: negative trim height
WHY: almost every shot coming from die broken cavitys 2,4
C/M: worked with craig we checked all settings to plex still problem tired adjusting die timer but still problem n WHAT: ng conveyer belt not moving
WHY: part inside of mesh belt and jammed on back side ,belt bad shape
C/M: replaced mesh belt and both drive sprockets
REOCCER: yes timing WHAT: ng conveyer mesh belt bad
WHY: belt life
C/M: replaced ng conveyer mesh belt
REOCCER: yes timing WHAT: ng conveyer not moving
why motor bad
c/m: had to replaced motor an gearbox now ok WHAT: ng conveyer not working at trim press
WHY: relay and motor bad
C/M: replaced relay and ng conveyer motor (m6)
reoccur: timing WHAT: no tower home position light
WHY: gap between wool an lid melting limit switch x57
C/M: replaced limit switch and added wool in gap to keep heat off the limit switch
REOCCER: yes WHAT: noticed shot no setting down all the way in trim press
WHY: robot position off
C/M: re-taught positions 25, 26 now ok WHAT: oil leak at main air assy (oilier) for lid cylinder
WHY: adjusted cap broken spraying oil
C/M: replaced oilier unit
REOCCER: unlikely WHAT: ok conveyer
WHY: pass on from 3rd/put new guide rail on
c/m: put ok conveyer back into mc and put all guards back on WHAT: ok conveyer advance sensor stuck on
why: sensor been hit by ok bucket over time
c/m: replaced x16 advance sensor WHAT: ok conveyer faults
WHY: not getting advance light, sensor had broken wire causing sensor to flicker on/off
C/M: replaced advance end sensor WHAT: ok conveyer going to advance position but not returning
WHY: bracket for the sensors to detect broke off
C/M: welded bracket and replaced shoes on bucket worn out
REOCCUR: YES TIMING WHAT: ok conveyer jam on way down
why: chain needed adjusted
C/M: slipped chain one link to make both chains slack the same WHAT: ok conveyer jamming
WHY: chain adjustment
C/M: slipped chain 1 tooth to equal the slack
REOCCER: yes timing WHAT: ok conveyer jamming
WHY: chain on door side not routed right
C/M: re-routed chain
REOCCER: unlikely WHAT: ok conveyer jamming
WHY: chain slack very loose
C/M: adjusted both chains, now slack is same on return end and at advance end
REOCCER: yes timing WHAT: ok conveyer jamming
WHY: chain tension loose on side tight on the other
C/M: adjusted chain slack to make both chains the same
REOCCER: yes timing WHAT: ok conveyer jamming
WHY: key fell out of gearbox
C/M: cleaned gearbox an key re-installed now ok WHAT: ok conveyer jamming
WHY: chain tension tight on 1 side loose on the other
C/M: adjusted chains to even tension on both chains
REOCCER: yes timing WHAT: ok conveyer jamming on way down
WHY: bucket guide shoes worn out causing bucket to move around and jam
C/M: replaced both guide shoes
REOCCER: yes timing WHAT: ok conveyer jamming top
R/C: chain slack different between both chains
C/M: removed chain tightened turnbuckle 1 turn installed new master link
re-occur:Yes WHAT: ok conveyer mesh belt damaged beyond repair
WHY: belt very tight (to short in length)
C/M: temporary chute all parts into one turntable with a divider, Parts on order (installed new mesh belt WHAT: ok conveyer not getting return light
WHY: bolts fell out on ok bucket side fell off
C/M: replaced bolts tightened side back on bucket
REOCCER: unlikely WHAT: ok conveyer not getting return light
WHY: sensor detect bar under conveyer bucket broken causing a jam
C/M: removed welded bar ok WHAT: ok conveyer not moving
WHY: conveyer going to return to far causing a jam
C/M: adjusted bottom sensor
REOCCER: yes timing WHAT: ok conveyer not moving
WHY: gearbox key and output shaft no good
C/M: replaced gearbox now ok WHAT: ok conveyer not moving
WHY: internal break not releasing motor very hot
C/M: replaced ok conveyer drive motor
REOCCER: yes timing WHAT: ok conveyer not moving
WHY: motor very hot internal brake not working (releasing brake) inverter speed settings
C/M: replaced motor
REOCCER: unlikely WHAT: ok conveyer not moving
Why: gearbox keyway stripped out and pillow block shaft no good
C/M: Replaced gearbox and shaft assembly
Recur: Possibly in time. WHAT: ok conveyer stopping
WHY: internal break not releasing sot allowing motor to move
C/M: replaced motor
REOCCER: yes timing WHAT: ok conveyer stopping
WHY: set screw loose allowing the key to fall out so the motor just spinning IN SPROCKET
C/M: took motor n gearbox off and installed the key on motor shaft tightened set scr WHAT: ok conveyer stopping and causing cycle time issues
WHY: gearbox and motor bad
C/M: replaced gearbox and motor
REOCCER: yes timing WHAT: ok conveyer stopping at advance end not returning
WHY: slow down sensor not seeing bucket
C/M: adjusted x16 sensor now ok WHAT: ok conveyer stuck at top
WHY: sensor bar broke off
C/M: re-welded bar ran conveyer up and down checked clearances ok
REOCCER: yes timing WHAT: ok conveyor jammed
WHY: two bolts broken in guide rail
C/M: replaced broken bolts
REOCCER: yes timing WHAT: ok mesh belt parts jamming
WHY: mesh belt tore up
C/M: did not have new belt, found an old belt and made a temporary belt till we get new one
REOCCER:yes WHAT: ok parts flapper broken off linkage rod
WHY: unknown
C/M: welded flapper back together installed in trim press ok
REOCCUER: yes timing WHAT: op side door close limit switch failure
WHY: I/o board no run light found loose wire ov but still problem
R/C: unknown
C/M: replaced I/o board still problem checked both door limit switchs x1 WHAT: operator called and said he has blown 5 vacuum blocks during the shift. all on operator side
WHY: no liquid coming from spray cartridge. a valve was shut off on die release unit. spray point off WHAT: operator called and said hes getting robot faults. when he investigated robot was missing a pawl. running 59B chain tensioners
WHY: unknown, mounting bolt may have backed out
C/M: searched insid WHAT: operator called and said ok conveyor bucket needs fixed
WHY: 2 bolts holding bearing housing on bottom side of bucket broke off
C/M: extracted both broken bolts. tapped bolt holes in bucket. rep WHAT: operator called and said scrap elevator wont dump hopper
WHY: elevator never getting ok to dump. the smelting furnace sensor had previously been moved and set points are not in range
C/M: adjust WHAT: operator called for issues with ok conveyor bucket. bucket gets stuck in multiple spots
WHY: a roller bearing is rusted and locking up, causing bucket to catch before it is all the way up. also WHAT: operator called for robot collision detect faults when sending robot home. not touching anything
WHY: operator says robot faulted out grabbing shot out of die, when trying to return home, it kep WHAT: operator called for robot faulted out at trim press and they cant get robot back home
WHY: robot didnt know where it was
C/M: recovered robot to known point and sent home WHAT: operator door lock not working correctly
WHY: plastic breaking a part
C/M: replaced door lock
REOCCER: yes timing WHAT: operator having multiple issues after die change done on 2nd. die temp low, channel 2 on squeeze master climbing, robot dropping shots coming out of die, casting pressure high
WHY: die temp ridi WHAT: operator noticed mesh tore up jamming
WHY: belt life
C/M: replaced mesh ng conveyer belt WHAT: operator noticed thermocouple broken
WHY: stuck to filter then broke
C/M: replaced holding thermocouple WHAT: operator requested a new ladle
WHY: ladle on line cracked and leaking
C/M: replace ladle WHAT: operator requested new ladle
WHY: cracked and dripping across crucible
C/M: installed new ladle. operator seasoning it WHAT: operator requested new ladle
WHY: cracked and leaking
C/M: replaced ladle WHAT: operator requested new ladle
WHY: ladle cracked and leaking
C/M: replaced ladle WHAT: operator went to start m/c turned switch to full auto then spray cartridge does a 1 cycle
WHY: relay bad (d12)
C/M: took a long time when looking for XA4B that's causing fault but nowhere to b f WHAT: overflow tab staying on part after vibrator
WHY: chuck claw missing and set screw out of adjustment
C/M: fixed air leak,installed new chuck claw, adjusted set screw to keep part from moving
reoo WHAT: p1 slide core cracked
WHY: unknown but last couple slide cores were from d1
C/M: replaced slide core with one not from d1
REOCCUR: yes WHAT: p1 slide core cracked
WHY: tool life 25000 shots
C/M: replaced p1 slide core and tappet pin
reoccur: yes timing WHAT: p1 trim height out of spec
WHY:
C/M: tried to adjust cutters no good, changed the trim press with 1 with all new cutters then was able to get it spec ran 10 min then mc chipped slide core
REO WHAT: parameter error
WHY: power off for weekend plc battery failed
C/M: re-installed a backup program that we just backed up 3 weeks ago WHAT: part getting mark from vibrator
WHY: robot gripper allowing part to move while loading unloading and at vibrator
C/M: WHAT: part sticking on cavity 4
WHY: locate pins bent also caused chutes to get bent
C/M: replaced both pins and re-bent chutes
REOCCER: yes WHAT: parts mixed up on unload table
WHY: ok conveyer not anchored to floor
C/M: anchored ok conveyer to floor with a L bracket
REOCCUR: unlikly WHAT: pass down lube pump not working correctly
WHY: leaking lube out front seal
C/M: replaced plunger lube pump WHAT: passed on diecast 8 is blowing a lot of vacuum blocks
WHY: hardly any liquid coming out of spray cartridge. die release tank was empty. breaker (NFB1) to pump tripped on die release unit. hole i WHAT: passed on from 2nd. post for dog house door crank pulled up out of concrete
WHY: concrete worn out
C/M: anchor holes drilled out on 2nd, filled with concrete epoxy and placed anchors. reinstalle WHAT: passed on nonstop "die lock force change after injection" faults. load % jumping around without adjusting die height
WHY: originally thought probe was ng. after putting new probe on still gettin WHAT: passed on spray cartridge, moving spray cylinder extension, has a bad sensor that needs replaced
WHY: actual problem was a bad spliced wire
C/M: stripped wires back and spliced using a new wire WHAT: passed on that a wire came out of terminal on ladle probes
WHY: wire broke at terminal. cable tie was not securing cable to ladle arm
C/M: stripped wire back and replaced terminal. cleaned ladle WHAT: passed on that operator couldnt get green robot ready light on operation panel
WHY: operator sent robot home using buttons on trim press cage, tobot wasnt making limit switch
C/M: took robot hom WHAT: passed on that robot faults at product detect. robot collision detect alarms at trim press
WHY: product detect was only seeing 2 of the 4 parts. robot set down at trim press is off
C/M: adjust p WHAT: passed on that saftey latch on operator door broke
WHY: unknown. safety latch was missing screws holding it to bracket. bracket for latch was broken
C/M: had to weld bracket back together. repla WHAT: passed on that slide core needs changed
WHY: cavity P1 had large crack in its slide core area, now is chipped
C/M: replaced slide core P1. verified leaks and operation. informed TL of machine ne WHAT: passed on that the ingot loader crashed. flights bent. platform bent. limit switch for conveyor forward ingot positioning bent
WHY: operator and DH from 2nd dont know how it happened. most likel WHAT: passed on that there is a few spots of soldering that needs cleaned up on die
WHY: build up on die over time
C/M: used pencil grinder to clean spots pointed out by QA. let alclean sit for 10 min WHAT: passed on that trim press is having issues. operator said trim press alarms out after every shot thats placed in trim press by robot
WHY: noticed that the trim press sensor readout is at 4592 wi WHAT: passed on the ok conveyor mesh belt falling apart. jamming up motor
WHY: wear over time
C/M: replace mesh belt. tensioned and tracked belt
REOCCUR: in time WHAT: passed on trim is too deep on cavity 1
wHY: trim depth NG
C/M: WHAT: passed on water leak
WHY: aluminum burnt through a water line coming off water tower, robot side, to under fixed die
C/M: replace water line. confirmed no more water leaks
REOCCUR: in time WHAT: passed on water leak from injection area
WHY: all fittings leaking on sleeve cooling joints
C/M: snipped ends of all 4 water lines and replaced all 4 cooling joint fittings. monitored for leaks WHAT: pc battery fault
WHY: battery life
C/M: replaced robot plc battery WHAT: plunger lube bracket broken
WHY: operator hit while cleaning
C/M: took bracket off welded checked plunger shift noticed tip loose re taped and tightened
REOCCUR: yes timing WHAT: plunger lube line leaking
WHY: feral leaking
C/M: cut cooper line replaced feral
REOCCER: yes timing WHAT: plunger lube pump not always spraying
WHY: pump life
C/M: replaced plunger lube pump WHAT: plunger rod making noise
WHY: lube line had big hole in it
C/M: replaced tip and sleeve WHAT: plunger rod making noise
WHY: sleeve wash out
C/M: replaced tip and sleeve WHAT: plunger rod not returning, stopping at 131 mm
why: plunger water valve shut off? aluminum hardened in sleeve so rod could not return
C/M: replaced tip n sleeve also plunger rod coupler very lo WHAT: plunger rod tip stuck in sleeve
WHY: coupler that holds plunger rod loose fell a part injection rod returned but plunger rod stayed in sleeve then ladle poured alum on them
C/M: replaced tip sl WHAT: plunger shaft fitting broke
WHY: aluminum behind tip jam up also lube line hole in it m/c not getting any lube
C/M: replaced tip n sleeve , plunger shaft, fitting, cooling pipe and replaced lube WHAT: plunger shaft joint loose
WHY: unknown
C/M: took apart cleaned re-taped and added lock tight, used the chain vise to tighten
REOCCER: unknown but unlikely WHAT: plunger tip life up 20,000 shots
C/M: replaced plunger tip WHAT: plunger tip stuck in sleeve
WHY: tip an sleeve issues
C/M: honed sleeve adjusted plunger lube spray WHAT: position configuration change G1 at die then faulting
WHY: pr[11] was the problem either taught in wrong u tool or coordinate
C/M: jogged robot a little then touch up pr 11 now ok
REOCCER: unli WHAT: problems melting
WHY: thermocouple wiring was no good and replaced but damage was already done (crucible getting to hot)
took upper lid off and bottom stuck to top of crucible ,
C/M: replaced WHAT: product detect alarms
WHY: cavity 3 sensor ng
C/M; replaced part detect sensor WHAT: product detect alarms
WHY: cavity 4 sensor ng
C/M: replaced cavity 4 sensor x04E
REOCCER: unlikely WHAT: product detect alarms after change over
WHY: robot chuck arm bent, not gripping biscuit bad at die, then noticed when robot leaving product detect hitting bottom left sensor
C/M: changed chuck WHAT: product detect faulting
WHY: p2 cavity sensor ng
C/M: replaced cavity p2 sensor now ok WHAT: product detect faults
WHY: sensor sensitivity out of adjustment not reading part
C/M: re-taught sensor adjusted to hit center of part
REOCCER: yes timing WHAT: product detect faults
WHY: shot sticking to tip plunger lube setting wrong
C/M: adjusted plunger lube from .4 to .8 now ok WHAT: product detect faults
WHY: sensors bad
C/M: replaced both cavity 2,3 now ok WHAT: product detect faults cavity 1
WHY: sensor bad
C/M: replaced cavity 1 product detect sensor WHAT: product detect sensor ng cavity 4
WHY: sensor ng
C/M: replaced sensor
REOCCER :yes timing WHAT: re-melt scrap conveyer turn cylinder for the weight scales sensors bad
WHY: wire broken
C/M: replaced both turn sensors WHAT: removed ladle pour motor
WHY: troubleshooting because diecast 2 ladle issues on pour no spare motor
C/M: OTTO replaced bearings in motor off dc2 installed motor on dc4 to test now working
REOC WHAT: replaced door switch for operator side door that was taken off for dc5 for production needs
now ok WHAT: roBot dropping parts
WHY: both bottom slide cores not moving robot bottom very tight
C/M: removed both slide cores and cleaned now moving freely
REOCCER: yes timing WHAT: robot air supply oilier broke
WHY: oilier adjuster broke stuck wide open
C/M: replaced oilier
REOCCUR: yes timing WHAT: robot chuck fault (ND11 ng chuck)
WHY: chuck close sensor cable broken wire
C/M: replaced chuck sensor cable
REOCCER: yes timing WHAT: robot chuck lock cylinder not getting advance light
why:
c/m: adjusted sensor loosen bolts to housing to get clamp to move a little better but still could be a problem WHAT: robot chuck not opening after it closes
WHY: chuck close air line someone put a chceck valve coupler instead of a normal one
c/m: removed coupler now chuck works WHAT: robot chuck sensor fault
WHY: took quick connect a part had water in it
C/M: took connector apart cleaned sensor working
REOCCER: yes timing WHAT: robot chuck sensor flashing
WHY: sensor quick connect corroded causing a broken wire
C/M: replaced quick connect for robot chuck sensor WHAT: robot collision alarms J6 axis
why: j6 axis servo motor bad
C/M: took motor from dc 2 and installed it in dc 7 now dc7 ok an running WHAT: robot crash at put in place, crash at trim press
WHY: broken shoulder bolts, trim press locate cylinder missing 1 of 2 pushers, overflow chutes bent causing part to hit
c/m: replaced shoulder b WHAT: robot crash at trim press
WHY: loading fault operator tried to recover with new home button robot crashed bent left arm
C/M: re-taught loading and unloading positions at trim press replaced left WHAT: robot crash at trim press chuck bent arm
WHY: robot hit big biscuit at start up
C/M: replaced arm and re-taught at trim press
REOCCER: yes timing WHAT: robot crash into die
WHY: robot lost all pulse encoder positions due to bad battery's
C/M: replaced robot memory back up battery's / had to re-teach all positions (take out , product detect ,tr WHAT: robot crashing at air blow
WHY: robot position very close to air blow assy and noticed air blow assy loose
C/M: re-taught robot at air blow tightened up clamps for air blow assy
REOCCER:yes tim WHAT: robot crashing at trim press
WHY: chuck finger worn not holding shot tight, air blow not working at scrap press, trim damage
C/M: replaced chuck finger,replaced solenoid valve 4 air blow, fixed WHAT: robot crashing at trim press
WHY: put n place position off
C/M: re-taught ROBOT AT put u place pick up position and replaced set screw and adjusted them to hold part better
REOCCER: YES WHAT: robot crashing at trim press
WHY: robot pick up point at die no good allowing shot to drop then crash
C/M: re-taught at die then trim press and scrap press
REOCCER: YES TIMING WHAT: robot crashing at trim press 2
WHY: all 4 chuck fingers worn and only 2 touching biscuit
C/M: replaced all 4 chuck fingers re-taught robot at die and trim press 2
REOCCER: yes timing WHAT: robot crashing in trim press
WHY: Overflow chute out of position causing robot to hit
C/M: Replaced with new chute
Recur: Possibly in time. WHAT: robot crashing loading at trim press
WHY: overflow left in trim press causing to hit chute
C/M: cleaned trim press and checked robot loading positions ok
REOCCER: yes timing WHAT: robot crashing unloading
WHY: positions off at pick up and unloading
C/M: re taught pick up and unloading at trim press
REOCCER: yes timing WHAT: robot dropping parts
WHY: hole in air line
C/M: put a coupler in air line wrapped air line to keep from getting burnt
REOCCER: unknown will investigate more 2 c if we can find where its getting WHAT: robot dropping shot
WHY: chuck fingers worn
C/M: replaced robot chuck fingers,also noticed that the scrap press linear bearings ng so replaced
REOCCER: yes timing WHAT: robot dropping shots at product detect
WHY: plunger lube leaking at nozzle and partially spraying outside of sleeve. tip is worn and needs replaced. shot is sticking to tip causing bent shot in WHAT: robot fault
WHY: ladle not getting ready light, ladle lower unit locked up
C/M: replaced ladle lower unit
REOCCER: yes timing WHAT: robot fault
WHY: scrap press shaft coupler bolt vibrated out of shaft
C/M: took a part cleaned re-tapped shaft hole installed new bolts an lock washers
REOCCER: yes timing WHAT: robot fault
WHY: shot hit scrap press assembly due to cylinder coupler bolt stripped out/ cylinde leaking oil out of front seal
C/M: replaced cylinder but the coupler threads was damaged very ba WHAT: robot fault
WHY: air line bad at coupler
C/M: cut air line back installed into coupler now ok WHAT: robot fault
WHY: chuck open sensor not working due to quick connect bad
C/M: replaced chuck sensor quick connect WHAT: robot fault
WHY: chuck sensor bad
C/M: took spare sensor off spare chuck put on production chuck so they could run
replaced sensor on spare chuck now ok WHAT: robot fault
WHY: sensor wire broken
C/M: replaced sensor
REOCCER: YES TIMING WHAT: robot fault after crash, damaged wiring harness, after replaced harness. j5 and J6 getting srvo-23 and 24 as soon as axis tried to move. Axis 1 2 3 4 all moved ok
WHY: auto home allowed r/b to c WHAT: robot fault at trim press
WHY: bisquik getting stuck in between shot and press causing fault
C/M: took off chute straightened and re-aligned locate cylinders WHAT: robot fault at trim press
WHY: chute bent up catching overflow pieces,also leaving pin tabs in part causing part to stick to top of trim press
C/M: took chute off re-bent chute,called die maint. WHAT: robot fault at trim press
WHY: locate cylinder air line had hole causing cylinder to stay out
C/M: replaced air line to locate cyl
REOCCER: yes timing WHAT: robot fault at trim press
why: chuck up down guide bolts loose an 1 snaped off
c/m: took chuck off up/down cylinder an replaced all bolts for guide/ retaught sit down in trim press/retaught to k WHAT: robot faulting at trim press
WHY: sit down position ng
C/M: re-taught positions 25,26 now ok WHAT: robot faulting out in die
WHY: pendant saying collision detect. noticed spray cartridge not spraying any liquid and shot sticking to die. water valve shut off on die release unit
C/M: opened wat WHAT: robot faults
WHY:
C/M: rebuilt chuck new cylinder shafts bushings left arm and both arm plates to try to reduce robot faults
reoccer: yes timing WHAT: robot faults
WHY: chuck not working due to a broken wire at cannon plug for the end of arm tooling . Wire number 2 in cannon plug (for end of arm tooling)
C/M: temporary fix re-connected broken WHAT: robot faults
WHY: shot sticking 2 tip
C/M: replaced plunger tip
REOCCER yes WHAT: robot faults
WHY: shot sticking to tip
C/M: replaced plunger tip
REOCCER: yes timing WHAT: robot faults
WHY: trimpress leaving pieces behind
C/M: adjusted air blow
reoccur: yes WHAT: robot faults
WHY: model not run for awhile needed all positions re-taught
c/m: started teaching robot pulled away for other call 2nd shift finished WHAT: robot faults
WHY: position 9 off at overflow press
C/M: re-taught set down positions 8 an 9 now ok WHAT: robot faults
WHY: shot sticking to tip tip and sleeve worn (wash out on sleeve)
C/M: replaced tip and sleeve during operator pm WHAT: robot faults
WHY: sticking to tip
C/M: replaced tip and sleeve WHAT: robot faults (cycletime)
WHY: spray cartridge return (up) sensor loosing light due to cylinder failure
C/M: replaced spray cartridge up/down cylinder WHAT: robot faults at put in place
WHY: position 72 at put in place causing robot to hit biscuit moving part
C/M adjusted PR 72
REOCCER: yes timing WHAT: robot faults at scrap press
WHY: guide rod broken then caused damage to cylinder joint coupler
C/M: replaced guide rod replaced cylinder joint had to adjust the down position also WHAT: robot faults at trim press
WHY: air lines for locate cylinder moved out of bracket causing a jam
C/M; put air line back in bracket now ok WHAT: robot faults at trim press
WHY: robot chuck finger bolt fell out not holding part right
C/M: replaced bolt with new ok WHAT: robot faults at trim press
WHY: robot position off
C/M: re-taught positions 3, 4 now ok WHAT: robot faults at trim press
WHY: set down position ng
C/M: re-taught positions for set down ok WHAT: robot faults at trim press
WHY: softfloat time over
C/M: WHAT: robot faults at trim press
WHY: unloading position ng causing part to jam / noticed air blow for trim die not working also
C/M: re-taught unloading positions and replaced air blow solenoid valv WHAT: robot faults at trimpress
WHY: alum stuck in robot chuck /take out positions off sensor bad
C/M: re-taught robot /cleaned alum out of chuck and replaced chuck sensor WHAT: robot faults cavity 2 part sticking on top of trim press causing a double stack
WHY: locating pin bent
C/M: REPLACED LOCATING PINS but still problem ,base block that shot sits on had damage i WHAT: robot faults servo 23,24 fault code WHAT: robot faults unloading at trim press
WHY: part dragging causing robot fault
C/M: re-taught loading and unloading take out positions at trim press WHAT: robot j6 backlash
WHY: motor play (BACKLASH)
C/M: rebuilt j6 reducer and changed motor with used one in inventory that had less blacklash WHAT: robot losing 24v power
WHY: solenoid for air blow at wash tank shorted to ground (wet)
C/M: replaced air blow solenoid for wash tank
REOCCER: unlikely WHAT: robot not going to scrap press
WHY: someone on off shift taking out of program
C/M: re taught robot at scrap press and fixed the exit chute scrap press to scrap conveyer 2
REOCCUER : unknown WHAT: robot not moving
WHY: chuck sensor stuck on
C/M: replaced robot hand chuck sensor now ok WHAT: robot not sitting in trimpress incorrectly
WHY:changeover
C/M: re-taught positions 25,26 (loading positions)
REOCCER: yes timing WHAT: robot soft float fault
WHY: ejector not getting advance light
C/M: replaced relay cry 85 in robot cabinet WHAT: robot stopping at put in place
WHY: broken wire at terminal box causing sensor to flicker on an off
C/M: cut out broken wire in cable then hooked back up
REOCCER: yes timing WHAT: safety door at holding crucible not working
WHY: plug came loose inside of door switch
C/M: took cover off pushed plug back in ok WHAT: safety door not rest at crucible
why: found broken wire inside operator panel
c/m: re-terminated wire now ok WHAT: safety switch broken at loader door
WHT: plastic
C/M: replaced door switch with new WHAT: scrap conveyer 1 jammed
WHY: 1 of the links not hooked up through both holes (hanging down) causing the jam
C/M: removed cotter pin moved rod back far enough to get link back into position re in WHAT: scrap conveyer 1 jammed
why: overflow piece stuck in chain
c/m: took motor off gearbox rotated chain till piece fell out WHAT: scrap conveyer 1 jammed up
WHY: M part stuck in chain, also noticed 4 pins broken , 8 cotter pins , 2 links missing
C/M: replaced and repaired all broken missing parts
REOCCER: yes timing WHAT: scrap conveyer 1 jamming
WHY: too much slack in chain causing it to jam up
C/M: took conveyer out cleaned and tightened belt slack WHAT: scrap conveyer 2 faults jamming
WHY; bent rod couple broken links
C/M: replaced all broken parts WHAT: scrap conveyer 2 jam
WHY: broken cotter keys an missing rollers
C/M: replaced all broken cotter pins an replaced missing rollers WHAT: scrap conveyer 2 jam
WHY: broken cotter pin , rollers an bent rods
Counter measure: Replaced pins and rods WHAT: scrap conveyer 2 jam
WHY: broken rods, roller link an cotter pins
C/M: replaced all broken damaged rods links and pins WHAT: scrap conveyer 2 jam
WHY: cotter pin broke causing link to flip and jam conveyer
C/M: put link back and installed new cotter pin tested ok for now
REOCCER: YES TIMING WHAT: scrap conveyer 2 jam up
WHY: bent rods an missing cotter pins
C/M: replaced 3 rods and 8 cotter pins WHAT: scrap conveyer 2 jammed
WHY: cotter pins missing couple rods bent
C/M: replaced all missing cotter pins / 2 rods WHAT: scrap conveyer 2 jammed giving motor overload
WHY: cotter pins missing, broken roller links , 3 bent rods
C/M: replaced all missing or broken components WHAT: scrap conveyer 2 jammed up
WHY: chain rod bent causing jam
C/M: replaced bent rod
REOCCER: yes timing WHAT: scrap conveyer 2 jamming
WHY: 32 missing links, 1 missing roller, 6 cotter pins
C/M: replaced all missing components WHAT: scrap conveyer 2 jamming
WHY: broken link
C/M: replaced broken link WHAT: scrap conveyer 2 jamming
WHY: links an rods broken
C/M: replaced broken rods, cotter pins, and roller links WHAT: scrap conveyer 2 jamming
WHY: links and cotter pins missing
C/M: replaced all missing parts WHAT: scrap conveyer 2 jamming
WHY: bent rods missing cotter keys
C/M: replaced 2 rods 1 roller and about 15 cotter pins WHAT: scrap conveyer 2 not moving in auto but will work in manual
why: weight scale did not show enough weight 59lbs needs to be 130-180 min and max
c/m liquid tight got cable was under scale enough t WHAT: scrap conveyer guard install WHAT: scrap conveyer jam
WHY: about 10 links damaged
C/M: replaced all damaged links replaced 2 rods also WHAT: scrap conveyer jam
WHY: inner guild rail broke
C/M: took chain a part re-welded guild WHAT: scrap conveyer jamming up
WHY: conveyer needs full rebuild
C/M: took conveyer out from (dc2 due to its down with no touch screen) installed in dc 3 now running WHAT: scrap conveyor 1 jammed up
WHY: piece of overflow stuck in chain
C/M: removed overflow
REOCCER: yes WHAT: scrap conveyor 1 jammed, faulting out for motor overload
WHY: parts of shot jammed in sprocket
C/M: clear jam WHAT: scrap conveyor 2 jammed
WHY: broken cotter keys , one link broken
C/M: replaced about 15 cotter keys and 1 link on trim press side of conveyor
REOCCER: yes timing WHAT: scrap jamming up in conveyer
WHY: guards have a gap in between them causing shots to get caught
C/M: took guard off re drilled an tapped holes to but guard against other guard (try to prevent d WHAT: scrap press
WHY: cutters ,no air blow
C/M: replaced top and bottom cutters and replaced air blow solenoid valve WHAT: scrap press detect sensor bad
WHY: operator broke with hook
C/M: replaced sensor
occur: not likely WHAT: scrap press fell a part
WHY: linear bushings destroyed allowing coupler to come loose
C/M: replaced linear bushings re installed coupler
REOCCER: yes timing WHAT: scrap press leaking oil
WHY: front seal blown causing leak
C/M: replaced scrap press cylinder/ and cylinder joint WHAT: scrap press leaving pieces of casting tree behind causing faults
WHY: air blow 2 not working
C/M: replaced air blow 2 solenoid valve and worked with Byron on air blow timing in the plc
reoccur: WHAT: scrap press linear bushings ng
WHY: life
C/M: replaced linear bushing on press guide rails
REOCCER: yes timing WHAT: sensor error at trim press
WHY: advance end x16 sensor stuck on
C/M: replaced sensor
REOCCER: yes timing WHAT: servo -068 and 069 faults ( pulse coder not returning serial data at the request signal)
Why: Bad cable
Counter measure: Ran temporary wire ran for J4 encoder. (SEE NOTES) WHAT: servo 67 faults
WHY: j5 axiS motor bad
C/M: REPLACED j5 axis motor WHAT: shot breaking
WHY: sticking to tip
C/M: replaced tip
REOCCER: yes timing WHAT: shot breaking
WHY: sticking to tip
C/M: replaced tip
REOCCER: yes timing WHAT: shot breaking
WHY: sticking to tip
C/M: replaced tip
REOCCER: yes timing WHAT: shot breaking in die, faulting robot
WHY: plunger tip worn. shot sticking to tip
C/M: confirmed no water leaks in die, sprue bushing, or injection rod. replaced line to plunger lube that had hol WHAT: shot breaking when die opens
WHY: lube
C/M replaced sprue bushing but still ng noticed when out of pre heat no lube on biscuit talked to oa we adjusted lube setting from .6 to 1.0 now running la WHAT: shot detect sensor
WHY:
C/M: replaced sensor with used one from the Canada machine WHAT: shot detect sensor fault
WHY: sensor bad
c/m: replaced shot detect sensor WHAT: shot getting left in scrap press after being stamped. faulting on every shot
WHY: scrap press cylinder set to low jamming shot into cutters. cutters are uneven
C/M: adjusted scrap press cylinder WHAT: shot life 20,000 on tip
C/M: replaced plunger tip WHAT: shot malfunction alarm
WHY: plunger shaft stuck in sleeve
C/M: replaced tip an sleeve , cooling joint checked plunger lube ok WHAT: shot position sensor fault
WHY: shot sensor bad
C/M: replaced sensor WHAT: shot position sensor/wiring broken faults
WHY: debris on sensor head
C/M: cleaned sensor. had to set origin start. monitored in auto WHAT: shot position sensor/wiring broken faults
WHY: dirty sensor head
C/M: pulled and cleaned sensor. cleaned injection rod and injection coupler WHAT: shot sensor broken wire
WHY: debris
C/M: took a part cleaned sensor WHAT: shot sensor broken wire alarm
WHY: Pack was leaking causing back pressure on rod
C/M: replaced shot sensor. Replaced injection seal pack WHAT: shot sensor broken wire fault
WHY: sensor bad
C/M: replaced shot sensor WHAT: shot sensor broken wire fault (fault would not clear)
WHY: shot sensor bad ( hooked new one up no fault)
C/M: replaced shot sensor
REOCCER: yes timing WHAT: shot sensor fault
WHY: sensor bad
C/M: replaced shot sensor
REOCCER: yes timing WHAT: shot sensor fault
WHY: sensor life
c/m: replaced sensor WHAT: shot sensor faults
WHY: dirty from blowback
C/M: took sensor out cleaned , noticed plunger shaft joint was unthreading so pull shaft out and re-tightened joint ok WHAT: shot sticking
WHY: tip worn
C/M: replaced tip
REoCCER: yes timing WHAT: shot sticking causing dropped parts
WHY: tip n sleeve worn
C/M: replaced tip n sleeve
REOCCER: yes timing WHAT: shot sticking to tip
WHY: tip n sleeve worn out
C/M: replaced tip n sleeve
REOCCUR: yes timing WHAT: shot sticking to tip
WHY: tip worn
C/M: replaced plunger tip WHAT: shot sticking to tip
WHY: tip worn due to lube setting was .4 set to .8 where it should be but the damage already done
C/M: replaced plunger tip WHAT: shot sticking to tip
WHY: unknown
C/M: replaced tip
REOCCUR: yes WHAT: shot sticking to tip
why: tip worn/noticed that cooling lines hooked up wrong causing problems
c/m: replaced tip/hooked plunger tip cooling lines up correctly WHAT: shot sticking to tip
WHY" tip worn
C/M replaced tip and cooling joint
REOCCER: yes timing WHAT: shot sticking to tip, bending shot and faulting out robot
WHY: plunger lube spray weak
C/M: confirmed spray tip clear. cleared debris from lube lines. aligned spray tip to better coat plunger ro WHAT: shots sticking to die ,a lot of blow back
WHY: water lines hooked up backwards on cooling joint
C/M: replaced tip n sleeve
REOCCER: yes timing WHAT: shutdown to confirm trim press to print, 1st E/S was not involved on this machine
WHY: trim problems some component parts different
C/M: made list of parts needed Corey gave to Laura was given o WHAT: sleeve damage
WHY: operator damaged while putting fixed die in m/c
C/M: replaced tip an sleeve
reoccur: not likely
SLEEVE LIFE: 19,836 WHAT: sleeve plugged with allum.
WHY: unknown operator was at lunch
C/M: replaced tip n sleeve
reoccur: YES TIMING WHAT: sleeve wash out
WHY: fast pour speed
C/M:replaced tip n sleeve
REOCCUR: yes timing WHAT: sleeve worn out
WHY: wash out very bad
C/M: REPLACED tip n sleeve
REOCCER: yes WHAT: slide core chipped out
WHY: unknown
C/M: replaced p2 slide core
REOCCER: yes WHAT: slide plates and slide plate shoes worn
WHY: we noticed that the operator side slide shoe damaged from someone left safety bar in m/c (had brock surface grind bottom of side shoe)
C/M: replaced WHAT: sometimes press will drift down
WHY: still investigating
C/M: replaced relay, and solenoid valve adjusted pressure to 13 range is 12-14 running ok now WHAT: spout broke on upper crucible
WHY: unknown
C/M: replaced melting ,holding crucibles halfpipe,installed a rebuilt lid WHAT: sprat unit not going back up
WHY: terminal box very rusty causing spray cartridge cylinder not to get the return light
c/m: replaced terminal box but still problem so i replaced the return senso WHAT: spray cartridge faults
why: loosing sensor lights both top an bottom cylinder is bad think internal magnet broken
c/m: replaced up/down spray cylinder WHAT: spray cartridge leaking
WHY: 3 spray valves no good
C/M: replaced with used valves
REOCCER: yes WHAT: spray cartridge leaking full stream non stop
WHY: spray valve ng "NON INVENTORY"
C/M: replaced bad valve
reoccur: yes WHAT: spray cartridge leaking out top of spray cassette
WHY: 1 spray valve had striped holes and bigger bolts in it m4 to m5
C/M: went to replace the block that all spray valves bolt to ,but is diff WHAT: spray cartridge not spraying
WHY: spray solenoid valve bad
C/M: replaced spray cartridge valve now ok WHAT: spray cartridge not spraying
WHY: secondary cylinder inside spray cartridge not extending all the way out causing no advance light
C/M: replaced cylinder with new WHAT: spray cartridge not spraying
WHY: sensors not working on little spray cylinder that goes into die due to coolant in terminal box on spray unit
C/M: removed cover drained, replaced one screw on WHAT: spray cartridge not spraying (die release)
WHY: solenoid valve no good
C/M: replaced solenoid valve WHAT: spray cartridge not spraying die release
WHY: solenoid valve for spray ng
C/M: replaced spray solenoid valve
REOCCER: yes timing WHAT: spray cartridge not spraying every cycle
WHY: bad solenoid valve
C/M: replaced relay still problem replaced solenoid valve for spray
REROCCER: UNLIKLY WHAT: spray cartridge stuck down
WHY; y7 output stuck on (cylinder down)
c/m: removed wire cylinder moved put wire back on now working WHAT: spray cartridge valve spraying all the time
WHY: valve ng
C/M: replaced with rebuilt valve
REOCCER: yes WHAT: spray lube tip bracket broken/ product detect faults
WHY: stripped hole
C/M: removed bracket welded nut to fix lube spray touched up robot at product detect also WHAT: spray robot air leaks
why: air line hole in it
c/m: replaced 2 complete air line no couplers top of robot to spray head WHAT: spray unit bad lean to in towards moving die
WHY: spray unit flange n spindle broken
C/M: replaced flange n spindle unit for spray unit
REOCCER: yes timing WHAT: spray unit moving around a lot
WHY: pedestal bolts 3 out of 4 broken
C/M: replaced all bolts
REOCCER: yes timing WHAT: spray unit not always spraying
WHY: Base for cx20 to cx23 and cx1 to cr2 bad
C/M: Replaced base
REOCCER: No
Cycle time: Unchanged WHAT: spray unit not spraying all the time
WHY: diaphragm pump bad
C/M: replaced die release pump
REOCCER: yes timing WHAT: spray valve leaking
WHY: valve worn out
C/M: replaced bad valve
REOCCER: yes timing WHAT: spru bushing leaking water (7,862 shots)
WHY: unknown but leaking at the weld where spru bushing put together (same spot they all leak at)
C/M: removed spru bushing from 5BA PS F-8 (out of new o WHAT: sprue bushing leaking
WHY: bushing bad
C/M: replaced sprue bushing
REOCCUR: yes timing WHAT: squeeze master hydraulic pump making noise
WHY: coupler on pump side came loose
C/M : took apart installed new set screws WHAT: squeeze master tripping breaker
WHY: filters clogged
C/M: replaced return and suction filters WHAT: stage 3 hepa filters out of spec
WHY: filter life
C/M: replaced stage 3 hepa filters WHAT: started getting servo 68,69 faults again (J6 only)
WHY (investigating) changed line 170 from fine to cnt to see if it helps WHAT: still having blowback issues
WHY: investigating , noticed that the coupler just started getting loose and able to spin on injection shaft
C/M: taka wanted to replaced tip and sleeve again , als WHAT: supply line to mold heater leaking
WHY: hose bad
C/M: replaced mold heater supply line WHAT: temp reading 1 degree on melting furnace
WHY: thermocouple bad
C/M: replaced melting thermocouple WHAT: temp readings on melting furnace jumping around
WHY: thermocouple broken
C/M: replaced melting thermocouple WHAT: temperature channel 1 thermocouple disconnection DIE F-5
WHY: broken wire in cable unknown
C/M: change out die
reoccur: yes timing WHAT: temps jumping around on holding furnace
WHY: thermocoupler bad
C/M: replaced thermocoupler for holding furnace WHAT: thermocouple broken
why: alum was hard broke thermocouple
c/m: replaced thermocouple now ok WHAT: thermocouple wire pinched in between the die
WHY: cable was run on the outside of vacuum block
C/M: replaced thermocouple
REOCCUR: unlikely WHAT: thermocoupler broken
WHY: unknown
C/M: replaced thermocoupler now ok WHAT: this m/c uses 1 sensor for product detect
we needed a sensor for DC 4 product detect so i took off this m/c since it dont need all of them WHAT: tie bar clamp fault
WHY: inside operators panel, base plate that card mounts to the bolts missing think due to m/c vibration
C/M: cleaned both sensors , re-seated card then added bolts to the b WHAT: tie bar close cylinder broken brackets
WHY: changeover error
C/M: removed brackets from dc 6 to get dc 5 up and running WHAT: tie bar not getting front nut clamp
WHY: front nut clamp cylinder sensors burnt up broken wires x234 an x235
C/M: replaced both clamp an unclamp sensors
REOCCER: un likely WHAT: tip and sleeve worn
why: WASH OUT IN SLEEVE
C/M: replaced tip an sleeve
RECURR: YES TIMING WHAT: tip seized up in sleeve
WHY: unknown
C/M: replaced tip n sleeve and plunger shaft joint
REOCCUR: YES WHAT: tip stuck in sleeve
WHY: lube problems and cooling joint inside tube pinched closed poor water flow
C/M: replaced tip n sleeve and cooling joint
REOCCER: yes timing WHAT: tip worn causing very heavy flashing
WHY: tip worn
C/M: replaced tip with new WHAT: tona 68 oil leak
WHY: lube line broke on moving side die
C/M: replaced lube line WHAT: tonna v68 lube leaking
WHY: the tee on robot side of m/c leaking stripped out
C/M: could not locate same still tee as original, was able 2 make a different tee work
REOCCER: unlikely WHAT: trim at S 2 tappet area
WHY: die change
C/M: removed tappet cutter cleaned and re-shimmed now ok WHAT: trim damage
WHY: all guides to tight not allowing shot to sit down all the way
C/M: loosened all guides and adjusted to shot now shot will seat in press
REOCCER:unknown WHAT: trim damage
WHY: build up on cutter /robot position
C/M: replaced cutter and re-taught position 60 (final sit down position) WHAT: trim damage
WHY: coating worn off cutter 1 allowing build up on cutter causing big mark on part
C/M: replaced cutter 1 cleaned part guide
REOCCER: yes WHAT: trim damage
WHY: cutter 1 had alum build up
C/M: cleaned build up off cutter
REOCCER: yes timing WHAT: trim damage
WHY: cutter 4 worn with build up
C/M: replaced cutter 4 now ok WHAT: trim damage
WHY: cutters out of adjustment
C/M: replaced cutter for s1,p1 tappet area, and loosened all cutters, guides, then adjust to shot (not easy)
REOCCER YES WHAT: trim damage
WHY: cutters set to tight cavity3,4
C/M: adjust 3,4 cutters and adjusted robot position
REOCCER: yes timing WHAT: trim damage
WHY: new style cutters worn out could not adjust in spec
C/M: loosened all guides replaced cutters with old style (otto found some used ones)re aligned guides and cutters to the shot WHAT: trim damage
WHY: overflow stuck on topside of trim press between punch and block 5
C/M: re-taught robot at trim and scrap presses WHAT: trim damage
WHY: part guide pin broke allowing part to move, supply air line for trim press air blows and part locate ripped in half
C/M: replaced part guide pin re-taught positions 59,60 replac WHAT: trim damage
WHY: robot position at put in place ,inside trim press and build up on a guide pin
C/M: cleaned guide pin re-taught robot position at trim press
REOCCER: yes WHAT: trim damage
WHY: die dirty lots of flashing from bottom slide cores causing shot not to fit in trim press
C/M: dm cleaned die , i cleaned a shot (no flashing) re-adjusted trim press to clean s WHAT: trim damage at tappet area (59B One rocker)
WHY: Wrong parts in trim press
C/M: re-taught robot, noticed angle iron deflectors bent,( straightened ) adjusted cavity's 2,4 for inconstant damage
R WHAT: trim damage at tappet area cavity 2,3,4
WHY: Sticking in vacuum blocks. Very sporadic
C/M: adjusted tappet cutters, guides re-taught robot position WHAT: trim damage cavity 1
WHY: guide and both cutters set to tight there is also flashing on shot
C/M: set a good shot and adjusted cavity 1 to set down correctly
REOCCER: yes timing WHAT: trim damage cavity 1
WHY: trim press out of adjustment
C/M: tried a couple adjustments no good so we decided to remove trimpress #2 and installed trimpress # 1 now parts look good and will repa WHAT: trim damage cavity 1 an 4
WHY: cutters worn
C/M: replaced 2 cutters 1 on cavity 1 and 1 on cavity 4
reoccur: yes WHAT: trim damage cavity 1,2 (P part)
WHY:Cutters damaged
C/M: Replaced both shaft hole cutters
Recur: In time WHAT: trim damage cavity 1,4 on tappet
WHY: guides all tight and leaving another mark on part
C/M: adjusted guides and tappet cutters on 1,4
REOCCER: YES TIMING WHAT: trim damage cavity 2
WHY: r/s cutter getting build up damaging part
C/M: replaced r/s cutter adjusted left side guide on cavity 2
REOCCER: yes timing WHAT: trim damage cavity 2
WHY: trim press not set all the way into position
c/m; moved trimpress back against stops re-taught positions 5,6 at die and 24,2 at trim press WHAT: trim damage cavity 2
WHY: overflow adj cutter coating worn causing material build up on cutter
C/M: replaced cavity 2 cutter
reoccer: yes timing WHAT: trim damage cavity 2 (section 1 in between the tappets)
WHY: robot position in press no good and replaced cutter #3
C/M: re-taught robot positions 25,26
reoccur: yes timing WHAT: trim damage cavity 2 on inside of tappet area
WHY: cutter worn
C/M: replaced inlet cutter on cavity 2 touch up robot positions 24,25
REOCCER: yes timing WHAT: trim damage cavity 2,4
WHY: cutter out of adjustment
C/M: adjusted inlet cutter (middle of tappet area)cavity 2,4
REOCCER: yes WHAT: trim damage cavity 4 negative reading (area 1 on check sheet)
WHY: unknowwn
C/M: adjusted shot in trim press now will monitor and let next shift know
REOCCER: yes WHAT: trim damage cavity's 1,4
WHY: UNKNOWN
C/M: removed trimpress #2 and put in trimpress #1 now all 4 cavity's look good
REOCCER: YES TIMING WHAT: trim damage on part
WHY: overflow not getting knocked off by vibrator
C/M: adjusted robot position , clean cutters, replaced cutter #4
REOCCER: yes timing WHAT: trim damage on tappet, cavity 1
WHY: when I arrived there was a lot of tab buildup in trim die
C/M: adjusted air blows so that they blow entire trim die out. adjusted cutter and support block to WHAT: trim damage pass down from 3rd
WHY: overflow left on trim press robot sits shot down on overflow
C/M: adjusted air blow to blow off overflow pieces off trim die WHAT: trim damage tappet area all four cavity's but not every shot
WHY: 3rd did die change said parts going out of spec now for trim damage
C/M: touched robot position (very little adjustment)then adj WHAT: trim damage when breaking shot chunking out part
WHY: uknown
C/M: adjusted cutters and guides till we got parts in spec cavity's 1 n 4 was the worse
REOCCER: yes WHAT: trim height
WHY: 1 cutter taken out laying inside trimpress
C/M: install cutter (p2) adjusted cutters
REOCCER: yes WHAT: trim height
WHY: unknown
C/M: replaced new style cutters with the old style for now trim height is ok
REOCCER: yes WHAT: trim height M PART CAVITY 1
WHY:
c/m: adjusted cutter on cavity 4
REOCCER: YES WHAT: trim height cavity 1,4 (in negative)
WHY: cutter out of adjustment
C/M: removed cutters cleaned base then adjusted cutter
REOCCER: yes WHAT: trim height cavity 2
WHY: cutter worn
C/M: replaced cutter on cavity 2 (cutter 3)
REOCCER: yes timing WHAT: trim height cavity 2
WHY: trim press to tight not allowing shot to sit down all the way
C/M: adjusted trim press to fit shot with no flashing and adjusted robot position also
REOCCER: yes timing WHAT: trim height in cavity 1
WHY: spray cartridge not spraying in that area
C/M: took off spray cassette cleaned 2 nozzles out full of debris now ok WHAT: trim height mostly cavity P 2
WHY: punches worn p2 and s2 also cutter worn
C/M: replaced all 4 punches and p2 s2 cutters cleaned all bottom base components for adjustment
REOCCER: yes WHAT: trim height ng cavity 2
WHY: trim press out of adjustment
C/M: adjusted cavity 2 back in spec
reoccur: yes timing WHAT: trim height on (trim press #2)
WHY: p1 s1 cutters bad also both tappet cutters bad , spring plunger missing and bottom sping plunger support block missing
C/M: replaced s1,p1 cutters tappet cutt WHAT: trim height p1
WHY: cutter design, flashing
C/M: took all cutters and guides out cleaned re-adjusted all cavities to shot
REOCCER: yes WHAT: trim leaing overflow on press
WHY: solenoid valve bad
C/M: replaced air blow solenoid valve now ok WHAT: trim press air blow not working
WHY: solenoid valve no good tripping breaker
C/M: replaced air blow solenoid valve
REOCCER: yes timing WHAT: trim press chute broke off
WHY: chute gets bent then overflow pieces build up and smash the chutes
C/M: removed trim press to get broken chute bolts out and fix all chutes
REOCCER: yes timing WHAT: trim press cylinder leaking
WHY: front seal blown
C/M: replaced trim press cylinder
REOCCER: yes timing WHAT: trim press drifting down losing up light
WHY: front seal blown in cylinder
C/M: replaced trim press cylinder nut and flange
REOCCER: yes timing WHAT: trim press faulting
WHY: cavity 3 part pusher broken
C/M: replaced part pusher
REOCCER: yes timing WHAT: trim press faulting
WHY: return (up) sensor stuck on scrap press
C/M: replaced return sensor
REOCCUR: timing WHAT: trim press faulting
WHY: changeover robot set position off / adjust air blows for overflow pieces left on trim press WHAT: trim press hydraulic leak
why: o rings bad in valve stacks
C/M: replaced o rings in both valve stacks WHAT: trim press hydraulic making noise
why: suction filter clogged
C/M: replaced filter an oil WHAT: trim press hydraulic oil cooler leaking
WHY: oil cooler broke at fitting
C/M: could not locate one so we took a cooler off d9 sub WHAT: trim press hydraulic pump leaking a steady stream of oil out of front seal
WHY: front seal bad maybe from heat oil coolers just cleaned over shutdown but damage already done
C/M: replaced hydra WHAT: trim press hydraulic pump load WHAT: trim press hydraulic pump loud
WHY: filter bad'
C/M: replaced filter WHAT: trim press hydraulic pump making noise
WHY: suction filter clogged
C/M: replaced suction filter WHAT: trim press hydraulic pump noisy
WHY: intake suction filter clogged
C/M: replace intake suction filter WHAT: trim press hydraulic pump very noisy
WHY: hydraulic pump coupler no good SPROCKET and chain worn out
C/M: replaced coupler
REOCCER: yes timing WHAT: trim press hydraulics making noise
why: suction filter clooged
C/M: replaced suction filter WHAT: trim press leaking hydraulic oil
WHY: o ring bad on main line in fitting causing leak
C/M: replaced o ring now no leak WHAT: trim press main lost power
WHY: 2 24v and couple other wires fell out of output card Y080-Y09F ?
C/M: put wires back also tightened them
REOCCER: unlikely WHAT: trim press motor overload
WHY: scrap conveyer 1 jammed up
C/M: removed conveyer and replaced with a rebuilt one
occur: timing WHAT: trim press not moving
WHY: hydraulic pump ng
C/M: replaced hydraulic pump WHAT: trim press red light
WHY: scrap press shot detect sensor cracked no indicator light but ok the reflector was bad
C/M: confirmed sensor working , replaced reflector ok
REOCCER: yes WHAT: trim press sensor fault
WHY: scrap press advance sensor stuck on
C/M: replaced sensor
reoccer: yes timing WHAT: trim press sensor hitting conveyer belt for other model
WHY: mc has never ran this model
c/m moved sensors to new brackets / re-taught robot at all positions WHAT: trim press valve stack still leaking oil
WHY:?
C/M: already replaced all O-rings in valve stack now replaced the valve to hopefully stop oil leaks
REOCCER:? will follow up WHAT: trimpress chunking parts due to die (rpy m) flashing out of spec on parts
why:
C/M: production to pull die change over die maint will fix die on spotting press WHAT: trimpress cylinder loosing up light
Why: Hydraulic manifold cracked
Countermeasure: Replaced manifold
Will problem reoccur: Possibly
Cycle time: No change WHAT: trimpress drifting down causing alarm
WHY: up/ down cylinder ng
C/M: replaced up/down cylinder
REOCCER: yes timing WHAT: trimpress gauge 34 (trimpress clamp) not working
WHY: gauge bad and regulator bad
C/M: replaced regulator and gauge with used one clamp pressure now in spec
reoccur: unlikely WHAT: trimpress hydraulic leak
why: hose had hole in it
C/M: replaced trim press hydraulic hose now ok WHAT: trimpress hydraulic pump making noise
WHY: suction filter clogged
C/M: cleaned suction filter now ok WHAT: turn table 1 not moving
WHY: hit too many times with chip bin
C/M: cut 1/8 inch off the bottom table disc
REOCCER: unlikely WHAT: turn table 1 not moving
WHY: table bolts all snapped off
C/M: removed broken bolts replaced bolts ok
REOCCER: yes timing WHAT: turn table 1 not working
WHY: blown fuse
C/M: replaced fuse / table bearing / cleaned debris under table WHAT: turn table 2 motor overload need to turn table to get it turning
WHY: still investigating
C/M: replaced motor but did not fix start up problem
REOCCUR: still problem WHAT: turn table not moving
why: main shaft broke in half
c/m: replaced turn table main shaft and a roller bearing WHAT: turntable 1 faulting
WHY: wire smashed
C/M: cut back wire to remove bad spot re-terminated now ok WHAT: upper crucible glowing around lid
WHY: corundum built up lifting lid up from crucible causing safety issue
C/M: replaced melting crucible an pedestal
REOCCUR: yes timing WHAT: upper damper lid drifting open
WHY; solenoid valve bad
C/M: replaced damper solenoid valve now ok WHAT: upper limit
WHY: wires melted at crucible
c/m: replaced upper limit wiring WHAT: upper limit liquid detect probes bad
WHY: life
C/M; replaced both holding upper limit probes (detection stick) WHAT: vacuum faults operator side
why: Die release was 1.30 needed to be at 1.70 to run
c/m: Added die release to make 1.70
reoccur: Yes Cant hold mixture
Cycle time: B-24.4 A-24.4 WHAT: vacuum alarms operator side
WHY: slow speed air line disconnected causing vacuum faults
C/M: re connected air line back up to the splitter block
REOCCER : yes WHAT: vacuum fault
WHY: after blowing 2 blocks noticed the second vacuum hose from manifold to pump was full of aluminum
C/M: replaced both vacuum hoses on operator side
reoccer: yes timing WHAT: vacuum fault
WHY: motor to pump coupler broken (motor side) due to pump full of oil
C/M: replaced vacuum pump assembly
REOCCER:YES WHAT: vacuum fault
WHY: operator side top pocket on fixed die full of alum
C/M: cleaned die of all debris WHAT: vacuum fault
WHY: vacuum pump full of oil causing set screw to come out of motor shaft allowing coupler to move
C/M: took apart replaced set screw drained oil
RECCER: yes WHAT: vacuum fault
WHY: pump not building vacuum (broken coupler)
C/M: replaced motor coupler
reoccur: timing WHAT: vacuum faults
WHY:
c/m: replaced die release pump ,cleaned tank ,checked all plex settings for dc m/c and vacuum unit,confirmed plunger lube WHAT: vacuum faults
WHY: VACUUM tank 1 dropping below spec -.50
c/m: REPLACED tip , and vacuum lines (hole in line) on operator side adjusted spray points
REOCCUR: YES WHAT: vacuum faults
WHY: air blow 1 solenoid valve sticking on
C/M: replaced valve for air blow 1
REOCCER: yes timing WHAT: vacuum faults
WHY: casting pressure out of range
C/M: drained nitrogen from 7 to 6 (spec 5.5-6.5)
REOCCER: yes timing WHAT: vacuum faults
WHY: tip worn
C/M: replaced plunger tip WHAT: vacuum faults
WHY: unknown
C/M: changed hoses blocks checked all settings, installed 2 new vacuum blocks tightened vacuum solenoid valve was loose causing vaccum to leak off
REOCCERE: yes WHAT: vacuum faults
WHY vacuum pump bad
c/m: replaced vacuum pump now ok WHAT: vacuum faults
why: robot side manifold clogged an operator side blown
c/m: replaced both vac blocks 1 robot side 3 operator side both vac lines from manifold to die
replaced operator side filt WHAT: vacuum faults
why: sleeve worn wash out
C/M: replaced tip an sleeve WHAT: vacuum faults (DIE F-7) operator side
WHY: still investigating
c/m: REPLACED 3 VACUUM BLOCKS all blew within 50 shots then put new block in m/c has run rest of shift (3.5hrs)(new block was las WHAT: vacuum faults operator side
WHY: maybe because there was a 1.0 shim on operator side and a .05 shim on robot side
C/M: put a .05 mm shin behind chill block on operator side like whats in the ro WHAT: vacuum faults operator side
WHY: unknown
C/M: added a .05 shim behind operator side vacuum block die release to 1.7 switched vacuum lines v2 back to v1 adjusted biscuit size to 16
RECUR: yes WHAT: vacuum faults operator side
WHY: unknown
C/M: adjusted spray point, die release to low adjusted, took out shim behind chill block operator side, checked plunger lube its ok cleaned alum out of v WHAT: vacuum faults operator side
Why: ?
C/M: replace Ejectors , 1.0 mm shim on op chill block and added nitrogen running on low side
Recur: Possibly in time. WHAT: vacuum faults operator side only
why: noticed heavy damage to fixed side of die (operator side), vacuum block stuck in die
C/M: production change over to different model, then we can decide how WHAT: vacuum operator side only
WHY: CHILL block loose causing aluminum to go behind and into bolt hole
C/M: removed block cleaned chill block and area added .05 shim operator side
reoccur: unknown WHAT: vacuum press faults
WHY: pump completely full of oil broke drive shaft/split coupler
C/M: replaced vacuum pump
REOCCER: yes timing WHAT: vacuum press faults
WHY: pump worn out cant make vacuum fast enough
C/M: replaced vacuum pump
REOCCER: yes timing WHAT: vacuum pump making a lot of noise
WHY: coupler broke pump full of oil
C/M: replaced coupler in vacuum pump drained oil
REOCUR: YES TIMING WHAT: vacuum pump motor overload
WHY: pump completely full of oil and motor shaft adapter for the plastic coupler broke
C/M: took motor shaft adapter off old motor and installed on motor on m/c
REOC WHAT: vacuum robot side
WHY: investigating
c/m: replaced vacuum unit exhaust filter checked hoses manifold for debris ok
REOCCER: yes WHAT: vacuum/c faults (setting shortage warning)
WHY: think pump is bad runs preheat shots then m/c switches to run ok parts and pump can not recover
C/M: REPLACED BOTH FILTERS IN VAC PUMP still prob WHAT: vibrator not knocking off overflow
WHY: robot take out positions no good part hitting overflow chute ( moving part)
C/M: re-taught take out positions then while I was there I checked loading and WHAT: walking by and noticed hydraulic line leaking
WHY: squeeze pin 2 hydraulic line, between die manifold and squeeze master manifold up above machine, had hole in it
C/M: replaced hydraulic line, h WHAT: ware plate bolts broken (what the moveable side shoes ride on)
WHY: safety bar left in mc
C/M: removed broken bolts n replaced
REOCCER: yes if safety bar left in while die being closed WHAT: was passed on that cavity 4 had trim that was out of spec on high side and scraping part. QA wanted E/S to look at it
WHY: worn cavity 4 cutter
C/M: replaced cutter. DH had QA verify parts at pr WHAT: water leak
WHY: cooling joint broke
C/M: replaced cooling joint
REOCCUR: yes timing WHAT: water leak
WHY: fitting an hose bad on cooling joint
C/M: replaced 2 fittings and 2 hoses WHAT: water leak
WHY: fitting leaking on plunger rod. fitting broken at threads that thread into plunger rod
C/M: could not extract broken off threading from plunger rod. replaced plunger rod only. br WHAT: water leak
WHY: plunger shaft quick connect worn out
C/M: replaced bad quick connect
REOCCER: YES WHAT: water leak
WHY: fitting on water tower broke causing water leak (had a straight style fitting)
C/M: replaced fitting with a 90 to keep line off tie bar and put new water line on
REOCCER: yes ti WHAT: water leak
WHY: plunger shaft cooling joint leaking
C/M; replaced plunger shaft an shaft extension o ring and cooling joint and tip
REOCCER: unlikely WHAT: water leak at cooling joint
WHY: cooling joint hit while cleaning
C/M: replaced cooling joint
REOCCER: yes timing WHAT: water leak at cooling joint
WHY: flashing built up melted hole in water lines (over the plunger shaft)
C/M replaced cooling joint water lines , tip and added new plunger water line upgrade while WHAT: water leak at cooling joint
WHY: flashing burnt hole in line
C/M: installed hard pipe extensions to prevent burnt lines to keep away from heat
REOCCER: unknown trial for this m/c WHAT: water leak at cooling joint
WHY: hit while cleaning
C/M: replaced cooling joint
REOOCER: yes timing WHAT: water leak at cooling joint
WHY: operator hit while cleaning
C/M: replaced cooling joint
REOCCER: yes timing WHAT: water leak at cooling joint, getting blowback
WHY: cooing joint broken
C/M: replaced the cooling joint, and tip for blowback
REOCCER: yes timing WHAT: water leak at coupler
WHY: o ring bad
C/M: replaced cooling joint , cooling joint o-ring, and plunger tip WHAT: water leak at mold heater
why: life of water line up
c/m: replaced water line WHAT: water leak at plunger shaft
WHY: clamp loose on barb fitting hose off bad leak
C/M: installed new style water lines an fittings (no barbed or coupler fittings)
REOCCER: unlikely WHAT: water leak at plunger shaft
WHY: couplers bad
C/M: replaced with a new style water lines in fittings as countermeasure for all these leak
REOCCEr: unlikely WHAT: water leak at plunger shaft
WHY: water lines wore hole in because bungee strap not put back on them
C/M: trimmed hose back and put bungee strap back on
REOCCUER: yes timing WHAT: water leak at plunger shaft
WHY: worn o-ring
C/M: Found while inspecting parts, coupler, spacer, o-ring replace because of rust and wear,tip replace tip because of blow back
REOCCER: yes WHAT: water leak at plunger shaft (quick connect)
WHY: o ring worn out
C/M: replaced o ring in the quick connect WHAT: water leak coming from slide core P1
WHY: cooling joint was pulled up out of slide core block. bracket that holds cooling joints down was loose and turned to side. o-rings worn on cooling joint
WHAT: water leak from mold heater
WHY: mechanical seal bad
C/M: took motor an pump housing off to rebuild installed new seals now ok
had to let sit over night to allow rtv to dry WHAT: water leak on plunger shaft
WHY: fitting worn out
C/M: replaced both male and female fittings on plunger shaft WHAT: water leak on plunger tip
WHY: hose worn at fitting
C/M: added a new style hose and fitting upgrade to prevent all these water leaks at plunger shaft we wont be using quick connect fittings anym WHAT: water leak plunger shaft
WHY: fittings bad, also covered in blowback
C/M: replaced water fittings and replaced tip to help on blowback
REOCCER: yes timing WHAT: water leak plunger shaft
WHY: o ring bad
C/M: replaced o ring with new WHAT: water leak. 2 red water lines from robot side fixed die (tower to under die). fitting on water manifold to sleeve cooling joint was leaking
WHY: the red water lines had holes in them and fitting WHAT: water line coming from back of mold heater has a hole in it and leaking
WHY: line life up
C/M: replaced water line WHAT: when shot placed in trim press it is faulting out intermittently
WHY: shot needs touched up in trim press. shot is bowing in trim pres
C/M: touch up points 26 and 25 on robot. monitored in auto WHAT: yellow helper door is opening during auto operation, killing hydraulic pump
WHY: on operator side, a bracket is broken that holds moveable die water supply manifold to machine
C/M: WHAT:trim press hydraulic leak at valve stack
WHY: o rings bad
C/M: took valve stack a part cleaned stoned and replaced all o rings
REOCCER: monitoring WHAT; broken ladle
WHY: unknown old ladle pin would not come out,had to use hammer an punch, while getting pin out broken ladle electrode assy
C/M: replaced ladle, pin and electrode assy WHAT; had to remove j6 servo motor for dc7 robot due to production needs
c/m: installed new motor master set an calibrated
2nd shift teach because no die in mc WHAT; high speed shot alarms
WHY: sleave clean 2 was adjusted from 1.5 to 2.5 now blowing all plunger lube out of sleeve
C/M: put sleeve clean 2 back to plex setting 1.5
REOCCER: unlikely WHAT; hydraulic leak
WHY: valve DG33 leaking
C/M: replaced DG33 valve
REOCCER: unlikely WHAT; ladle half pour
WHY: ladle chains very loose
C/M: adjusted ladle chain tension
reoccur: timing WHAT; upper limit probes giving upper limit with low alum
WHY: ceramic block broken allowing probes to touch bracket grounding them out giving high alum
C/M: replaced ceramic block now ok WHAT= Blowing vacuum block r/b side
R/C= ? see notes
C/M= follow step in notes
R/O= yes until we understand R/C
C/T= na WHAT= Countermeasure for PC malfunctions
C/M= replace power supply and set VDC to 23.82 to match other three voltage output WHAT= HMI toscast screen cracked
C/M= replace glass, but screen not reacting to touch. try replacing with old one from D/C 8 before sending out of repair. no luck
will be sending out Monday for repair WHAT= Inclusion, not passing k-mods
R/C= aluminum leaking under filter
C/M= replace filter
R/O= yes, if filter breaks, filter floats
C/T= na WHAT= Melting crucible reading aol
WHY= thermo coupler bad
C/M= replace WHAT= OK conveyor guide rail broke
C/M= replace guide rail WHAT= Toscast screen not responding to touch WHAT= blowing vacuum blocks OP side
R/C= gap between vac block and chill block 5ba p/s parts
C/M= add 100 uh shim behind chill block
R/O= yes many factors for vacuum issues, d/c 7 keep coming back, w WHAT= blue ok conveyor incline bucket cycle time over
WHY= chain has to much slack causing bucket to bind up
C/M= remove 3 links on each chain. reset tension WHAT= cable for dog house door broke
WHY= cable wear
C/M= cut off worn cable and reattach to cable and door WHAT= countermeasure for pc malfunctions
C/M= replace cpu and check connections in j-box per Toshiba WHAT= excessive blow back
R/C= wash out on sleeve
C/M= replace tip/sleeve
R/C= timing wear item WHAT= filter broke
R/C= ?
C/M= Replace filter
R/C= timing WHAT= ingot loader cycle time over
WHY= ?
C/M= raise/lower elevator platform adv. position speed up push cylinder WHAT= mold heater not heating up
WHY= Heater Contactor not pulling in
C/M= Replace Contactor with non inventory WHAT= ok conveyor not operating smoothly
why= break not releasing properly
R/C= no set life expectancy for motor/break assy.
C/M- replace motor/break assy. with new
R/O= yes timing
C/T= no change WHAT= part of tree sticking in scrap die
C/M= raise adv sensor, Otto replace contactors WHAT= requested to remove toscast screen to T/S D/C 8 WHAT= shot sensor faults
WHY= sensor head dirty,
C/M= remove sensor clean put back together, had trouble getting apart a lot of build up WHAT= spray cartridge not moving
WHY= no air
C/M= turn on air WHAT= toscast screen frozen WHAT= trim press air blow not coming on
R/C= program corrupt
C/M= dump old program
R/O= no
CT= na WHAT= trim press faults
WHY= scrap tree getting caught in/on fall away shouts, causing build up
C/M= remove shout on left side of trim die, straight and close up gaps WHAT= vacuum faults
WHY=?
C/M= Work with DH, check spray cartridge spray pattern, concentration, setting, WHAT= vacuum faults r/b side
WHY= ?
R/C= ?
C/M= check all hose/filter change bis size from 25 to 23
R/O= yes, do not know why or R/C
C/T NA WHAT? FENCE OPEN ALARM
WHY? 1811CBL1 door switch does not work properly.
C/M Replace door switch WHAT? Helper side auto door limit switch malfunction
WHY? 2 allen bolts loose on lower horizontal .bar that operates switches
CM TIGHTEN bolts, bend bracket for dogs back in, adjust cushions and air WHAT? Run 120V power to light above conveyor
WHY? For safety
C/M Run conduit for a switch and outlet WHAT? 2 Screws coming thru output conveyor belt
WHY? Backed out
CM Remove screws for now, other screws holding flat plate WHAT? AL02 alarm Melting Crucible Temperature
WHY? Bad probe
CM change probe WHAT? Add new light and power outlet to part conveyor
WHY? Old light is broken
CM Replace with new light and outlet WHAT? Air leak on robot
WHY Broken air line
CM Replace airline WHAT? B-064 Ladle traveling limit switch malfunction
WHY? Unsure
CM Operator was able to recover ladle and fault cleared WHAT? Biscuit size too large varying to 24 and dropping to 9
WHY? unknown
CM Passed to next shift WHAT? Blowing vacuum blocks
WHY? Clogged filters
CM Change L1, L3, and main vacuum filter, moved Vacuum L1 to L2 (filter etc.) WHAT? Broken air pipe at the top of spray cartridge
WHY? Weld broken on manifold piping, water line for movable, helper side has a hole in it
C/M: Welded manifold piping and replaced hose for moveable WHAT? Cable broke for half pipe door
WHY? wore out
CM Change cable WHAT? Can't run in auto, manual only
WHY? 1A fuse blew because TD62787AP chip shorted
Replaced fuse, left chip out WHAT? Carrier out of trim press faulting out
WHY? Poor alignment
CM Align carrier and chuck close stops so part comes out of trim die gently WHAT? Crucible safety lock, faulting on safety and squeeze master issue CH3 (Very little change in stroke
HMI
WHY? Lock manually bypassed, Bad DCV for stroke
CM Unbypass lock and turn off equipment WHAT? DIE cooling rapidly
WHY? Auto water valve passing water
CM Clean out valve WHAT? ESTOP FAULT
WHY? Operator door lock won't lock working
CM Replaced door lock WHAT? Elevator door lower hinge came off
WHY? Tap hole repair wore out
CM Drilled thru and added longer bolt ant nut WHAT? Holding Blower intermittent at the melting panel
WHY? M66 dropping out
CM While tracking down problem Holding Blower started working, continued to monitor but problem did not return. WHAT? Hydraulic leak
WHY? Hole in metal vertical line on DCM near robot
CM Remove, die maintenance weld, install WHAT? Hydraulic leak trim press at pump
WHY? Blown O-ring
CM Replace O-ring WHAT? Hydraulic pump overload will not clear, keeps tripping thermal relay after trying to turn
WHY? Low hydraulic fluid, machine seems to have a lot of fluid underneath and pump staying on too long.
WHAT? Hydraulic pump shuts off can't make it thru preheat
WHY? Yellow door (robot side) moving, causing dog switch to cycle (near door plunger pin)
CM Adjusted bracket for switch to make better contac WHAT? Inaccurate hydraulic pressure gauges G1,G2
WHY? Worn out
CM Change gauges WHAT? Ingot loader will not go all the way down
WHY? Loader not al the way retracted, low air pressure
CM Increased air pressure to 0.45 bar WHAT? Investigating Estop fault
WHY? 1st shift found hydraulic pump contactor confirmation contact had loose wire
CM 1st secured wire WHAT? Investigating no pilot or LOW valve operation
WHY? Temperature slow to come up
CM Checked power at each valve, all approx. 103Vac WHAT? LINE PRESSURE FAULT
WHY? Low pressure
CM Changed URG1 unloading relief valve from scrap machine******** Need to run line pressure setup WHAT? Ladle angle variation causing biscuit size to vary
WHY? Both chains loose in ladle arm
CM Tighten chains WHAT? Ladle bouncing up and down in crucible
WHY? Bulb missing, loose probes, and busted porcelain
CM Change ladle probe unit WHAT? Ladle gets jammed
why: bearings on ladle arm locked up
c/m: replaced ladle arm and all bearings an lower unit WHAT? Level Probes fell into aluminum
WHY? Something must of hit them
CM Install and wire up new probes
CM WHAT? Level probes fell in Aluminum
WHY? Accidental
CM Clean off probes and stone WHAT? Light out above turntables
WHY Bad outlet
CM replace outlet WHAT? Line pressure malfunction
WHY? Low pressure
CM Changed filter WHAT? Lubricant Malfunction after shot
WHY? Pump motor will not run with 100V AC on it
CM? Change lubrication unit WHAT? MOLD heater overheating #4 fault
WHY? Low pressure from chiller 30 PSI
CM Andy changed chiller filter A WHAT? Machine was started and ran with a Holding Furnace Temp = 1130 no fault out, This was after a metal leak alarm
WHY? Engineering found a bad relay
CM Engineering changed relay WHAT? Manual "Vacuum Open" or
Auto
tripping breaker
WHY? Solenoid shorted SOL010
CM Replaced solenoid from a noninventory valve WHAT? Mel-keeper panel +24V power shorted out
WHY? Tower sensor emitter melted because sight glass fell off.
CM Swapped in both parts of sensor from 11 WHAT? Melting Burner Flameout (especially when not running)
WHY? Melting Burner Controller needs reset.and reset fault. Usually have to push several times and hold in.
CM Continue to monitor WHAT? Melting Exhaust temp erratic and spray cartridge getting stuck
WHY? Thermal couple wires in lid touching and touching ground. Spray cartridge turning cylinder bolts missing and loose, missing E WHAT? Melting furnace shutting off too soon, not keeping up with DCM
WHY? Bad lid exhaust gas temp thermocouple, getting to high temp too quickly
CM Change Thermocouple WHAT? Melting won't fire
WHY? Ignition rod touching metal
CM Remove pilot assembly and put rod thru white spacer WHAT? Metal hydraulic line leak behind robot door WHAT? Mold heater display not power up
WHY? ESTOP button came loose and wouldn't operate
CM Tighten up Estop switch and release it WHAT? Motor overload trim press
WHY? X4 in
CM Reset contactor on door in which X4 connects WHAT? No die release pressure
WHY? Bad diaphragm pump
CM Change pump WHAT? No water for spray cartridge
WHY? Bad pump
CM No pumps in stock, Took pump from Diecast 7 WHAT? OK bucket getting stuck
WHY? Missing bearing and bolt sticking out on the robot side
CM Add bearing, eclip and pin (diecast parts area). Drive bolt in WHAT? OK bucket getting stuck half way up
WHY? Chains uneven causing bind
CM? Passed to 3rd they fixed WHAT? OK conveyor bucket will not come back down
Why Dog for sensors missing, broke off
CM Made new dog WHAT? Oil hole robot stuck on part on shuttle
WHY? Unknown
CM? Used joint to move robot and turned air off to get chuck to release part, then origin return WHAT? Ok bucket getting stuck
WHY? Bucket lift moved to far back
CM Pull forward toward turntables WHAT? Ok carrier stopping at advance position
WHY? Timing out
CM Turn speed up on inverter, Also moved table and conveyor for Cavity 4 part jam on good conveyor WHAT? Operator safety door won't latch
WHY? Trim press light curtain and Robot door wasn't latched properly.
CM Line up light curtain and relatch robot door. WHAT? Operator window blew out
WHY? Vacuum blew out
CM Instructed to cover with metal. Turned inner door panel upside down to cover. WHAT? Output bucket not advancing or returning
WHY? Bolts loose on drive base and set screw to shaft loose
CM? Tighten all loose bolts and screws WHAT? Output conveyor does not move
WHY? Motor/Gear box jammed
CM Take off motor and gearbox and retighten WHAT? Over Pressure Die Release Spray
WHY? Adjustment needed
CM Setup on HMI near cage door, Spray pressure setting screen, adjust upper limit to from .800 to .900, clear fault, adjust black pressure WHAT? PLC LINK EROR
WHY? Cable came out of comm. connector at squeeze master
CM Put cable and connector back together WHAT? PLC shutdown in error mode, cannot communicate to
WHY? Bad PLC??
CM PLC was changed on another shift to fix WHAT? ROBOT WON'T HOME, starts to and goes back to ready to pick from die WHAT? Remelt hopper not going up all the way to empty
WHY? Sensor going off too soon
CM Adjust top sensor for a more complete dump WHAT? Remelt hopper safety door will not latch and hopper not going on forks
WHY? Misaligned from hopper getting stuck on door
CM Align latch and move hopper switch up WHAT? Replace Metering pump
WHY? worn out
CM Change metering pump
CM WHAT? Robot Malfunction (not going in to get part out of die
WHY? unchuck sensor not lit
CM Adjust sensor WHAT? Robot door slow
WHY? Aluminum grit on tracks
CM Blow off WHAT? Robot pulling out of trim press too early
WHY? Sensors dirty
CM Cleaned sensors in and around trim press WHAT? Robot stopped do to high holding furnace temp
WHY? Low temp X031 made
CM change Events EV1,2,3 see below WHAT? Robot will not HOME
WHY? Stuck in program
CM Function, Abort All, GO HOME prog. line 170, enter, SHIFT+FWD WHAT? SCRAP CONVEYOR 1 JAMMED
WHY? Scrap jammed in conveyor
CM Use large pipe wrench to unjam WHAT? SPRAY PRESSURE TOO HIGH
WHY?Reducing Valve bad
CM Mehar turned off all flow and pressure limits for spray. WHAT? Safety door lock will not latch
WHY? Bad lock
CM Replace lock WHAT? Scrap conveyor getting jammed
Why? Metal guard rail has been bent up
CM Replace with sheet metal piece per DH request, until a heavier metal guard rail can be made WHAT? Scrap conveyor not moving
WHY? Worn out
CM Replace with new conveyor WHAT? Small NG conveyor under trim press not turning
WHY? Belt bad
CM Change belt WHAT? Spray cartridge L bracket bolt holes stripped
WHY? Worn out over tightened
CM PASSED TO 3RD SHIFT and they used hellicoil to fix WHAT? Spray cartridge leaking
WHY? Bad Valve
CM Change valve WHAT? Squeeze master CC-Link fault and intermittent power
WHY? Broken coax connector for PC-LINK and bad 24V power supply AP24
CM Resolder tip to coax cable and change power supply WHAT? Swap water reducing valve GD-24 to diecast 9 from diecast 11 per John's request
WHY Too high of spray pressure even after adjusting
CM Swap WHAT? TRIM press does not always go up
WHY? X412 Decel. sensor for press cylinder too far back from dog to always make
CM Move sensor even with X411 Cylinder Advance WHAT? Tie bar issue will not move, cant remove die
WHY? First shift found broken wire on switch
CM They repaired disconnected wire WHAT? Transport out of trim press erratically handles battery hold down parts
WHY? air needs adjusted on up/down cylinder
CM adjust air WHAT? Trim press mist lube won't hold oil
WHY? Holes melted in reservoir
CM Used JB Water weld to patch holes WHAT? Trim press not taking section off
WHY? Bolts fell out of blade
CM? Rebolt blade and added oil to outer trim WHAT? Trim press scrap conveyor jammed
WHY? Aluminum stuck inside
CM? Reverse 2 leads on middle contactor, run backwards WHAT? Trim press will not HOME
WHY? Press Lock cylinder not going in by controls or manual buttons on valve
CM Removed airlines from cylinder and worked back and forth WHAT? Trim press, press not coming down
WHY? Sensor for part present not going below threshold 87.5
CM Adjust sensor WHAT? Turn on melting blower immediate flame out alarm
WHY? E1 P2 False Flame alarm from melting burner controller
CM Press reset button on melting burner controller to clear alarm WHAT? Unload Robot Faulted
WHY? Part got jammed into trim press
CM HOME robot, menu, system, variables, OPWORK, uot disable, 0 to 1 to clear fault. WHAT? Unload chuck not getting light in trim press
WHY? Unloader crooked
CM Loosen 4 allen bolts to the right of chuck and move chuck to where it gets its lights WHAT? Unload table alarming out trim press
WHY? Chips building up under mat not allowing it to slip under load
CM Blow out under mat WHAT? Unloading carrier crashed into frame extrusion and broke sensor mount
WHY? Operator fault recovery error intially caused by excessive flashing
CM Cycle CP21 breaker to clear fault on Servo 21 (I WHAT? VACUUM ALARM
WHY? XA28 made
C/M Daryll and Monica found vacuum leak in mechanical part of die press WHAT? Vacuum issues B-306 53728 Alarm
WHY? Vacuum blocks in die blowing out flashing robot side
CM Operator installed new vacuum block and chill block WHAT? Vacuum keeps blowing out
WHY? Unknown
CM Changed V1 and V3 vacuum filters WHAT? Vacuum problems
WHY? Air leaks and clogged filters
CM change main vacuum and L1 filters , replaced thin green air line to vacuum block on operator side, and large air line on back of DCM (was wh WHAT? Vestil Lift will not charge, charges ok but lift drops slowly
WHY? Hydraulic Valve sticking open
C/M Swapped hydraulic valve with other of same type WHAT? Water Leak bottom of metal pipe for spray
cartridge
WHY? Wear and tear
CM Cut bad spot out and rethread WHAT? Water leak below operator door lock, there is a block that has 2 hoses for wand, back metal pipe
WHY? Broken pipe
CM Replace nipple WHAT? Water leak spray cartridge robot
WHY? Hole in water line near spray side of distribution box
CM? Cut out 1.5 inch of water line near distribution end fitting WHAT? Will not run
WHY? Pins sticking out causing squeeze master numbers to be erratic
CM Rebled squeeze master WHAT? Wire came off of holding crucible level probe
WHY? wore out
CM reterminate WHAT? Won't do V check, Yellow V Check light will not go solid
WHY? 1st shift found out that injection rod is bad, up to 30mm off at times.
CM passed to next shift WHAT? large Hydraulic hose leaking behind robot door going up to die
WHY? worn out
CM Removed passed to 3rd WHAT? safety latch to aluminum lift door fell off
WHY? Cant use
CM Reattached safety latch to aluminum lift door frame WHAT?LEXAN SENSOR BRACKET BROKEN TRIM PRESS
WHY? Old
CM Make new bracket WHAT?LINE PRESSURE FAULTS
why: root cause unknown
c/m: performed pressure setting procedure from book several times, changed the PVC card, no change put original card back on. WHAT?Metal Leak Probe wire broke
WHY? Worn out
CM Reterminate WIRE BROKE NG READING WONT RUN WORN WORN AND CRACKED WORN CHUCK CLAWS WORN DOWN/ONE LONGER THAN THE OTHER
CHANGED DETECTION STICKS WORN, GAVE TO OPERATOR Wat: Dropping parts/ Chunking cavity 2
Why: Fitting on cavity S2 hydraulic hose bad male end pulled off oil pouring out
C/M: Replaced the fitting and bled the SQM really good Water Leak from broken fitting. Dremeled a relief area to allow fitting to move more freely . Replaced broken fitting Water Leak- sprue bushing. RPY 1 RKR F-14 Water Passage Spray casset crashed due to not being returned Operator said the swing was turned to OFF position on the selector switch Water Passage had marks and dents on the parts affecting machined areas after machining. Also the vibrator for the Sub Runner was shut off so the operator was using the table as a removal tool. Water Passage lathe for check SPEC
jig1 : 3pcs
jig2 : 3pcs Water controller temp running high Water flow for mold heater is low compared to die cast 6
Die cast 6 flow rate to mold heater 66L/min 14.5 psi
Die cast 5 flow rate to mold heater 40L/min 14.5 psi Water leak on Cracked upper slide core of 3D4 F-1. Bypass cooling Joints S20 Cleaning and Testing of the Die. F-3 running now and Periodic adjustments and testing while running. Drew and I both work Water leak on moveable side of die.. removing ejector plate to fix water leak. fixed water leak and cleaned die. Water leaking underneath operator panel Water leaks on 1 inch hose on moving side die
Also changed the plunger shaft cooling outlet fitting and hose size to POKE-YOKE it to prevent mistakes with cooling water direction. Water line broke in top slide core Water passage Die F8
What: Soldering. Die needs cleaned.
Why: Build up.
Countermeasure: Cleaned Die. Water passage die F-2 Replaced the F1 pin in the fixed side of the pin. Water passage die. Water leak on the top slide core. Replaced the broken fitting. Soaking the squeeze pin and bushing in al clean. John is going to reassemble the die and water test the die so tha Water,Passage lathe for spec check.
jig1 parts 3pcs
jig2 parts 3pcs Way lube tank emptying within a couple hours. Found several fittings loose and one 500 mm flex hose line that was cracked and leaking badly. Replaced flex line and tested for leaks . Now ok We were told this morning that an RPY P,S had trim height well Travis and I investigated it and found that it was ran awhile ago so we do know it was RPY F10 so craig was to let jr know to look at tha Wear Part replacement while machine is out for refractory rebuild. Wear, 80,000 on T/L should reach 100,000. Weld repair needed for helper door cylinder bracket. What
What: Trim damage
Why: Overflows getting flipped up on press
C/M: Took old bent bracket off and made a heavier duty bracket and 3/8" taller
Recur: Possibly in time
Recur: Possible in time What - Sprue bushing leaking water.
Why - Wear
Countermeasure - Installed new sprue bushing.
Reoccur - Yes, time. What - broken fixed fin on the robot side slide core.
Why - Unknown. Possibly built up on the pin.
c/m - Replaced pins S33 and S34
Reoccur - Yes What : Air leak
Why: Air bowl split at back helper door
Counter measure: Replaced bowl
R/C: No
Cycle time: Unchanged What : Axis #2 over 14.5
Why: Water leak
Counter measure: Fixed water leak
R/C: Yes time
Cycle time: Unchanged What : Biscuit alarms and trim damage at tappet area cavity 4
Why 90 degree was off on the ladle pour, robot sitting shot down on top of cavity 4 cutter
C/M: Set the 90 and retaught the robot to set i What : Having trouble with Temperature jumping around
Why: Low aluminum
C/M: Shut down let aluminum level rise now ok
Recur: In time What : Water leak at cooling joint
Why: Hose had hole in it
C/M: Cut hose back and replaced broke hose fitting
Recur: Possibly in time What :Air leak
Why: Bad air fitting
Counter measure: Replaced fitting What :pipes come loose again
Counter measure: Reattached What = part standing on die biscuit size at max 23
WHY= adjust power cycled you must log in
CM= take video and email What Bottom helper slide core cracked and leaking water.
Why: Cracked around the slide core base. No appearent impact.
Countermeasure: Replace bottom helper slide core What Bowl heater over heat
Why: In line filter plugged up
Counter measure: Cleaned inlet filter. (Chilled water supply line. Back of heater) What Chipped slide core P-2 Die 5A2 P/M 32
Why: Coating chipped
Counter measure: Replaced slide core
R/C; No
Cycle time: unchanged What Exhaust temp Thermocouple failed.
Why:Tip of Probe Failure
Countermeasure: Replace Thermocouple and set distance
Reoccur: Yes What Furnace hood limit switch no good
Why: excessive heat/ wool not placed correctly
C/M: Replaced limit switch
Recur: Possibly in time What High speed shot Alarms
Why:Tip and sleeve both damaged due to spray lube bracket damaged and no lube. This issue with the spray lube bracket was repaired on 6-23. Tried to get more life out of What Ladle broke What Operator door close limit switch fault
Why: DDCLS2 X236 not going true, should flip flop with X141.
C/M: re-seat connector to Remote I/O bd. in operator control panel.
Will it Re-occur: Timing, Y What Safety door would not show closed . Why Seal tight and wiring in seal tight burnt on safety door by crucible . C/M Cut seal tight back till got past the burnt wiring and installed safety switch b What Sodering in roller groove cavities P1 and P2. Why- Wear on roller grooves. C/M- Replaced cavities P1 and P2 roller grooves and cavity P1 slide core pin. Reoccur- Maybe in time. What The safety system had the machine locked out . R/C The safety system thought the squeeze masters safety was on . C/M cycled power to the safety system . Will it reoccur NO . What Tower ingot lift chain
Why: Chain Buckle broke
Counter measure: Welded bolt on it
R/C: No
Cycle time: Unchanged What Trim damage cavity 2
Why: Trim die not set to shot. Too tight
Counter measure: Adjusted die and robot set down What Vacuum
Why: Tank pressure limit wrong
Counter measure: Set to plex
R/C: No
Cycle time: Unchanged What Vacuum No1 faults . Why ? C/M Fixed vacuum leaks in filters and unions , changed vacuum filters , operator changed vacuum hose to No1 - replaced air line to operators side vacuum block and Craig What When machine was switched from hi - slow speed shot the air never went off to the vacuum block locking it closed . Why Settings changed in the Toscast screen without everyone being informed of th What broken ladle . R/C Build up in crucible C/M Handed out a new ladle to operator . Will it reoccur timing . What cav 2 squeeze pin depth ng. Why- Squeeze master is messed up. C/M- 1st shift had swapped cav 1 and 2 axis lines.. Had operator switch back cav 1 and 2 lines and bleed squeeze master. I had to ta What ladler will not move . Why Burnt up wires in the level detect . C/m Replaced the ladle level detect wires . What vacuum trouble.
Why: unknown
C/M: Drained vac tank
Recur: Possibly in time What" Blue ok conveyor issue
Why: Stuck at top
Counter measure: Skipped chain and tightened chain What)- spec issues
(why)-slide core cracked
(counter measure)- changed p2 slide core
(re-occurrence)- yes in time What- Aluminum part of robot arm bent
Why- Operator started machine with too large of a biscuit
C/M- Replaced arm, replaced a finger on the chuck that got bent, and touched up line 80 P6 for the robo What- Axis problems
Root cause- Air in line
Counter measure- Bled lines and adjusted calibration pods in squeeze master
Will problem reoccur- Happens after model changes What- Cav P1 and S1 burr by roller groove NG. Why- Cav P1 and S1 slide cores cracked. C/M- Replaced P1 and S1 slide cores. Slide core S1 trial slide core for different coating. What- High die temp moveable side. Why- Thermocouple pinched and is NG. C/M- Replaced moveable side thermocouple. What- Ladle arm overload
Why- Ladle arm too far down into the aluminum due to low aluminum
C/M- Manually raised the ladle arm and reset the overload. Informed operator of low aluminum level What- Ladle inverter fault
Why- Low aluminum
C/M- Reset ladle inverter, let operator know to let aluminum level come up before running What- Shot not sitting in trim press right. Why- Heavy flashing around cav 3 bottom slide core area. C/M- Cav 3 and 4 bottom slide cores not moving freely. Took apart bottom slide cores And cleaned o What- Water leak at sprue bushing. Why- Sprue bushing cracked. C/M- Replaced sprue bushing with non inventory sprue bushing. Reoccur- Yes in time What- 1 axis running high
Why- Had hydraulic lines swapped going into the manifold, also had hydraulic leak on top of die.
C/M- Swapped hydraulic lines, tightened hydraulic fittings and rebled squeeze What- 2 axis jumping around
Why- Cause unknown
C/M- Put new hydraulic lines from manifold to die for squeeze channel 2, line bled channel 2 and rebled squeezemaster
Reoccur, possible What- 4 axis alarms from squeezemaster
Why- Squeeze master valves on top of die felt loose
C/M- Powered squeeze master down and rebled What- 5A2 P1 slide core crack over 10 mm. Why- Slide core failure. C/M- Replaced P1 slide core. Reoccur- Yes in time. What- 5BA S1 slide core cracked
Why- ?
C/M- Changed slide core
Reoccur, timing What- A piece of the water passage broke off and was stuck to the die.
Why- Machine not recovered correctly after shot got stuck in die.
C/M- Production pulled die. What- AL blowout on the robot side of the die.
Why- Damage to the chill block allowing the AL to escape the cavity.
C/M- Cleaned everything, replaced the damaged chill block
Reoccur- With time What- Air leak
Why- Cracked air bowl on back of robot panel
C/M- Replaced air bowl What- Air leak
Why- Bad air bowl
C/M- Replaced bowl What- Air leak
Why- Broken air bowl for help side door
C/M- Replaced air bowl
Reoccur, timing What- Air leak Root cause- Melted air bowl Countermeasure- Replaced air bowl Reoccur- not until melts again What- Air leak from spray cartridge
Why- Hard air line snapped in half. Air line was snapped because bolts were broke in air manifold causing it to rock during operations
C/M- Removed broken bolts and What- Air leak from trim press area.
Why- Cracked air bowl.
C/M- Replaced air bowl. What- Air leak from vacuum pump
Why- Bolts loose on one of the valves, allowed the gasket to blow out
C/M- Reseated gasket and tightened bolts on valve What- Air leak on robot side of DCM
Why- Cracked air bowl
C/M- Turned off air, replaced air bowl and turned air back on What- Air leak.
Why- Air bowl on back of robot panel cracked.
C/M- Replaced air bowl. What- Air line blew on spray cartridge
Why- Wear
C/M- Air line was stretched out so it couldn't fit in the air valve, replaced line
Reoccur, timing What- All 4 lot marks stuck Why- 2nd shift didn't take out while die was hot on Friday night shut down. C/M- tried heating die up and still didn't work. Had them pull die to see if I could get out bac What- Aluminum blow out around robot side chill block/vacuum block area. Why- worn chill block. C/M- Got a new chill block and also put a shim behind chill block. Reoccur- Possibly in time. What- Aluminum blow out from operator side of die
Why- Bad chill block
C/M- Changed chill block on operator side, noticed an oil leak coming from squeeze pins, had to change die for that
Reoccur, poss What- Aluminum blow outs on the operator side.
Why- ?
C/M- Tried a new spray cartridge, verified plunger lube, die release pump, chill blocks were shimmed, tried taking them out. Couldn't run five sho What- Aluminum blow outs, operator side
Why- Bad chill block
C/M- Replaced two water lines that got burnt from the blow outs, installed new chill block and 100 micron shim behind chill block.
Reoccur, What- Aluminum blow outs, operator side. They were having blow outs earlier so they changed the die, still having them.
Why- Worn chill block
C/M- Changed chill block and vacuum block, checked shim fo What- Aluminum blowout in die
Why- Unsure, operator stated that he stopped his machine for break and noticed it looked blown out
C/M- Thoroughly cleaned and removed aluminum from die, changed both chi What- Aluminum blowout in the die
Why- Ladle was going to the sleeve and dumping a little bit of aluminum in before the main pour, while the lube air was still blowing. It blew that aluminum into the What- Aluminum blowout on operator side of die.
Why- Ongoing issue on this machine. Has blown out on multiple dies and multiple different models.
C/M- Cleaned die, had operator change operator side v What- Aluminum blowout on robot side. Why- Chill blocks had some damage. C/M- Replaced chill blocks. Reoccur- maybe in time. What- Aluminum blowouts and flashing operator side vaccum b and chill block area and cav 4 bottom slide core. Why- Cav 4 bottom slide core not moving freely. C/M- Took out cav 4 bottom slide core to c What- Aluminum build up in cav S1 roller groove. Why- Deterioration on S1 slide core. C/M- Replaced S1 slide core. What- Aluminum in robot top slide core pocket. Why- Aluminum blowout. C/M- Took slide core 1 that was in die F-2 and put it back in die F-1. What- Aluminum leaking form ladle
Why- Cracked ladle
C/M- Replace ladle
Reoccur, timing What- Angular pin on operator side on fixed die broke. Why- Bottom operator slide core bolts came loose not letting slide core line up with angular pin. C?M- Replaced fixed side operator side angular What- Axis 1 alarms. Why- ?. C/M- Powered down squeeze master and M/C then bled squeeze master. Running but axis 1 in on the high end of the spec. For some reason you can't adjust axis in by using the What- Axis 1 alarms. Why- squeeze pin dirty and moving slow. C/M- Cleaned squeeze pin with alclean jell and bled squeeze master. What- Axis 1 faults low. Why- ?. C/M- Set flow back to 68(was at 9) and re bled squeeze master and it came back in spec. What- Axis 1 running low
Why- Leaky hydraulic fitting
C/M- Replaced fitting and rebled squeezemaster What- Axis 3 alarms. Why- Channel 3 line not closed down all the way. C/M- Took all quick connects off to make sure nothing was in them to cause them not to seat properly. Then when went to bleed out What- Axis alarms and bisquit breaking from shot. Why- Plunger lube not spraying in sleeve correctly. C/M- Operator Adjusted plunger lube line to spray into sleeve .
What- Axis alarms are high for all four parts after changeover to breather baffle.
Why- Reoccurring issue after changeovers between 1RKRs and baffles. Pressure for squeeze is way too high, around 5 or What- Axis problems #2 and #4
Root cause- #2 had Aluminum flashing in the coupler. #4 had air in line on unused side.
Counter measure- #2 cleaned coupler. #4 hooked unused hydraulic lines together an What- Axis problems started on 2 and 3
Why- Hydraulic lines were hooked up wrong
C/M- Swapped channel 1 and 2 lines, and swapped channel 3 and 4 lines, bled sq mst.
Reoccur, unlikely What- Bad Parts. Why- M3 pin is bent. What- Bad blowback and flashing from tip
Why- Bad tip
C/M- Change tip, verify plunger lube. Snapped threads off joint connecting plunger rod and tip while putting tip on so had to replace that and coo What- Bad thermocouple. Why- DH didn't wrap thermocouple correctly, so when die closed it broke. CM- Replaced thermocouple. What- Bare wire on thermocoupler on upper lid
Why- Coating came undone, wire rubs every time the lid opens and closes. Wire was rubbing because there was no fitting attaching the conduit to the thermo What- Bare wiring for exhaust thermocoupler
Why- Heat and wear
C/M- Trimmed and reterminated wiring
Reoccur, timing What- Big end piece fell off of ladle electrode
Why- Cause unknown
C/M- Replaced large end probe
Reoccur, not likely What- Big scrap conveyor jamming up
Why- Cotter pins missing, links flipped up
C/M- Replaced cotter pins and put links back where they're supposed to be
Reoccur, timing What- Big scratch mark in cav 2 roller groove. Why- Sodering on cav 2 roller groove slide core. C/M- Replaced cav 2 roller groove slide core. What- Biscuit jumping around from high to low
Why- Lower ladle bearings locking up, ladle not moving smoothly.
C/M- Replaced lower ladle unit (Non-Inventory)
Reoccur, timing What- Biscuit jumping around, also noticed smoke coming out of ladle arm. It was coming from the lower unit.
Why- Lower unit locked up
C/M- Replaced lower unit, adjusted chain for upper arm. Adjusted What- Biscuit thickness issues
Why- After changing over to 1RKR, a cooling joint was never added to the sleeve. 1RKRs have to have a sleeve cooling joint and it's not a part of the change over matrix. What- Block 5 broke off of trim die. (RPY 1RKR)
Why-?
C/M- Replaced Block
Reoccur, timing What- Block 5 missing from trim press
Why- Bolts keep snapping
C/M- Ran trim press down, made sure blocks weren't coming into contact with anything on the bottom of the press. Replaced block 5. Tried What- Blow back at plunger tip and sleeve. Why- wear on tip and sleeve (64,609 shots). C/M- changed tip and sleeve. Reoccur- Yes in time. What- Blow back, shot injection is rough
Why- Tip needs changed
C/M- Change tip and checked plunger lube spray. Tip life 75,000
Reoccur, timing What- Blowback
Why- Tip was worn, plunger lube position was off
C/M- Changed tip and adjusted plunger lube spray
Will it happen again- Yes, timing What- Blowback from tip
Why- Worn tip
C/M- Replaced tip, and plunger shaft extension
recur- timing What- Blowback from tip and ladle over pouring
why: warn out tip
c/m: replaced plunger tip
reoccur: yes in time What- Blowback from tip putting holes in water lines
Why- Tip worn out Shot life- 45,000
C/M- Changed tip, replaced leaking water lines
Will it happen again? yes timing What- Blowback on and in plunger shaft area
Why- Bad tip, Shot life 16,500
C/M- Replaced tip and checked plunger lube spray
Reoccur, timing What- Blowout on operator side and die temp issues. Why- Aluminum build up around cav slide core and bad thermocouple. C/M- Cleaned up aluminum around cav 4 slide core and replaced the thermocouple. What- Blue Ok conveyor won't go up. Why- The chains didn't have even tension. C/M- Adjusted chains to have even tension. Reoccur- Maybe in time. What- Blue conveyor motor and gear box bad.
Why: Gearbox gear teeth tore up and motor shaft tapered
C/M: Replaced both gearbox and motor
Recur: No What- Bolts in bracket securing main water line to MC sheared off
Why- Unknown cause
C/M- Removed broken bolts and replaced What- Bottom half of holding crucible filter came out on 3rd shift.
Why- Patching material for filter may have been no good, filter could have been knocked out.
C/M- Replaced holding pedestal, crucibl What- Broke all 4 slide cores. Why- M/C had a move core 2 malfunction and broke all 4 slide core in the process.. C/M- Replaced all 4 roller groove slide cores. Also replaced main cable to junction bo What- Broken S1 & S4 slide cores. Why- M/C was having move core 2 malfunctions and it was the cause of the slide cores breaking. C/M- Replaced S1 & S4 slide cores and fixed the move core 2 malfunction What- Broken air line for pusher 2 for the return.
Why- Pipe split at the fitting, worn over time.
C/M- Replaced pipe. What- Broken crucible
Why- ? Op was scraping sludge and spout broke off
C/M- Replaced crucible
Reoccur, timing What- Broken ladle
Why- Build up on crucible ring
C/M- Replaced ladle and cleaned build up
Reoccur, timing What- Broken link on scrap conveyor
Why- Piece of scrap got lodged in the side of conveyor
C/M- Replaced link + three cotter pins
Will it happen again- Yes timing What- Broken links on big scrap conveyor, scrap conveyor sagging and getting in the way of the scrap detect sensor causing it to alarm.
Why- Normal wear and tear from daily operation.
C/M- Replaced br What- Broken slide core. Why- Slide core not moving freely. C/M- Replaced M4 bottom slide core and tried to fix so it would slide freely. Couldn't get slide core to go back in. So had them pull die so What- Broken tapet pin, RPY S cavity 1. Slide core also had excessive buildup on the model number.
Why- Potentially worn coating
C/M- Replaced tapet pin and slide core on cavity 1. Operator ran test p What- Broken tappet pin P1 cavity
why: tappet stuck in part broke while returning slidecores
c/M: Replaced tappet pin and reinstalled. slide core confirmation paperwork lineside and DH notified for co What- Broken thermocouple on fixed side of die. Why- Operator broke thermocouple doing tip and sleeve change. C/M- Replaced thermocuple. What- Broken thermocouple. Why- Thermocouple cord not routed properly during die change so when operator closed the die the cord ripped out of box. C/M- Replace thermocouple. Reoccur- Yes if not wrapp What- Burr Cav S1. Why- Cav S1 chunked out. C/M- Replaced cav S1 slide core. What- Burr P1 roller groove. Why- Cav P1 slide core chipped out. C/M- Replaced Cav P1 slide core. What- Burr S1 roller groove area. Why- Cav- S1 slide core chipped out. C/M- Replaced cav S1 slide core. What- Burr S1 roller groove area. Why- S1 slide core is chipped out. C/M- Replaced S1 slide core. What- Burr S2 roller groove. Why- Cracked slide core. C/M- Replaced S2 slide core. What- Burr around P4 slide core. Why- Damaged slide core. C/M- Replaced P4 slide core(20000 shot life). Reoccur- In time What- Burr cav 4 roller groove are. Why- Cav 4 slide core chipped. C/M- Replaced cav 4 slide core. What- Burr cav P1 and S1 near roller groove. Why- Cav P1 and S1 slide cores chipped out. C/M- Replaced cav P1 and S1 slide cores. What- Burr cav P1 and S1 roller groove. Why- P1 and S1 slide cores chipped out. C/M- Replaced cav P1 and S1 slide cores. What- Burr cav S2 roller groove. Why- Cracked slide core. C/M- Replaced cav S2 slide core. What- Burr in Cav P1 roller groove. Why- P1 slide core chipped out. C/M- Replaced P1 slide core. What- Burr in Cav S4 roller groove area NG. Why- S4 slide core chipped out. C/M- Replaced S4 slide core. Reoccur- Maybe in time. What- Burr in P1 and S1 roller groove is out of spec. Why- Crack in slide core. C/M- Replaced P1 and S1 slide cores. Reoccur- Yes What- Burr in P1 roller groove is NG. Why- P1 slide core coating has some wear on it. C/M- Replaced P1 slide core. Reoccur- Yes in time. What- Burr in P1 roller groove. Why- P1 Slide core cracked. C/M- Replaced P1 Slide core. Reoccur- Yes in time. What- Burr in P2 roller groove is out of spec. Why- P2 slide core cracked. C/M- Replaced P2 slide core. Reoccur- Yes in time. What- Burr in P2 roller groove. Why- P2 slide core cracked. C/M- Replaced P2 slide core. What- Burr in S1 roller groove out of spec. Why- S1 Slide core cracked. C/M- Replace S1 Slide core. What- Burr in S2 roller groove is out of spec. Why- S2 slide core chipped out. C/M- Replaced S2 slide core. Reoccur- Yes in time What- Burr in S2 roller groove out of spec. Why- S2 slide core chipped out. C/m- Replaced S2 slide core. Reoccur- Yes in time. What- Burr in S4 roller groove. Why- S4 slide core has a big chip out of corner. C/M- Replace S4 slide core. Reoccur- Maybe in time. What- Burr in cav P1 roller groove. Why- P1 slide core chipped out. C/M- Replaced cav P1 slide core. What- Burr in cav P4 roller groove. Why- Cav P4 slide core. wear. C/M- Replaced cav P4 slide core and pin. What- Burr in cavity S2 roller groove. Why- S2 slide core chipped out. C/M- Replaced S2 slide core. Reoccur- In time. What- Burr in roller groove. Why- Cracked slide core. C/M- Replaced slide core. Reoccur- Yes in time What- Burr in roller groove. Why- P2 slide chipped out. C/M- Replaces P2 slide core. Reoccur- Yes in time. What- Burr ng cav P1 and S2. Why- Cracked slide cores cav P1 and S2. C/M- Replaced cav P1 and S2. What- Burr on P1 roller groove. Why- Cav P1 slide core chipped out. C?M- Replaced P1 slide core. What- Burr on cav P2 slide core area. Why-Damaged slide core. C/M- Replaced P2 slide core. What- Burr on cav S4 roller groove ng. Why- Cav S4 slide core is chunked out. C/M- Replaced cav S4 slide core. What- Burr on chamfer of mounting hole. Why- Moveable die pin C chipped out. C/M- Replaced moveable side die pins A,B.C. What- Bypass conveyor jammed
Why- Piece of aluminum got under conveyor and jammed into sprocket
C/M- Ran backwards with a pipe wrench and removed aluminum
Reoccur, unlikely What- Cable that lifts the dog house door snapped.
Why- Cable worn over time.
C/M- Replaced with new cable. What- Can't read the 5BA stamping on cav S1. Why- 5BA stamping is chipping out. C/M- Replaced cav S1 slide core. Reoccur- Maybe in time. What- Can't see in the 5BA stamping in cavity S1. Why- Aluminum filled in the 5BA stamping in Cavity S1. Reoccur- Maybe in time. What- Carrier for ingot elevator got bent, broke the welds
Why- It appears and ingot fell out during loader and got wedged, caught the ingot carrier while it was on the way up
C/M- Leveled loader and What- Cav M4 slide core guide pin broke. Why- Slide core stuck up when operator was checking slide cores and didn't line up with pin when they closed die. C/M- Replaced cav M4 slide core guide pin. What- Cav 1 and 4 slide core won't plug gauge. Why- Had M. Kline trial slide cores. C/M- replaced cav 1 1nd 4 M Kline slide cores will TEG slide core. What- Cav 1 chunking out around 20 ID. Why- Bad hyd cylinder. C/M- Replaced cav squeeze pin and hydraulic cylinder. Reoccur- Maybe. What- Cav 2 & 4 side slide cores broke. Why- operator side slide core unit sticking. C/M- replaced cav 2 & 4 side slide cores and had operator clean die release filter. Reoccur- In time. What- Cav 2 and 3 trim damage on end of part near tappet pin. Why- Damage to cav 2 and 3 trim die block. C/M- Replaced cav 2 and 3 trim die blocks. What- Cav 2 part sticking to squeeze pin. Why- Squeeze master axis 2 not bleeding properly. C/M- Found a fitting leaking to axis 2. Had to replace fitting to fix hydraulic leak. Reoccur- Maybe in time What- Cav 2 squeeze pin spec NG. Why- Cav 2 squeeze pin cylinder is bad. C/M- Replaced cav 2 squeeze pin cylinder. What- Cav 3 RG slide core water leak. Why- Cracked slide core. C/M- Replaced cav 3 RG slide core. What- Cav 3 mark on part by squeeze pin. Why- Cav 3 squeeze pin not returning all the why and scrapes part when parts in ejected from die. C/M- DH replaced die release pump. I checked squeeze master What- Cav 3 slide spec ng. Why- Cotter not pushing slide core in all the way. C/M- Put .200mm shim behind cav 3 cotter. What- Cav 4 RG not plug gauging. Why- A lot of build up on slide core. C/M- Replaced cav 4 RG slide core. What- Cav 4 burr back side slide core is out of spec. Why- Slide core is damaged. C/M- Replaced cav 4 back side slide core. What- Cav 4 tappet pin out of spec. Why- Cav 4 slide core pin bent. C/M- Replaced Cav 4 slide core pin. What- Cav P1 Chunking out. Why- Bad o-ring in hydraulic fitting on hose behind hydraulic manifold. C/M- Put new O-ring in hydraulic fitting on hydraulic fitting behind hydraulic manifold. What- Cav P1 and P2 roller groove burr NG. Why- P1 and P2 slide cores cracked. C/M- Replaced Cav P1 and P2 slide cores. What- Cav P1 and S1 roller groove burr ng. Why- Cav S1 and P1 cracked and wear. C/M- Replaced Cav P1 and S1 slide cores. What- Cav P1 and S1 roller groove burrs NG. Why- Cav P1 and S1 side cores cracked. C/M- Replaced cav P1 and S1 slide cores. What- Cav P1 and S1 roller groove burrs NG. Why- Cav P1 and S1 slide cores cracked. C/M- Replaced Cav P1 and S1 slide cores. Ran into issue with slide not wanting to go into holder cap. Holding cap wa What- Cav P1 build up in roller groove. Why- Cracked slide core. C?M- Replaced P1 slide core. What- Cav P1 burr in roller groove. Why- P1 Slide core cracked. C/M- Replaced cav P1 slide core. What- Cav P1 burr in roller groove. Why- P1 slide core has a chunk out of it. C/M- Replaced P1 slide core. Reoccur- Yes in time. What- Cav P1 chunking out in squeeze pin chamfer. Why- Bad cav P1 squeeze pin hydraulic cylinder. C/M- Replaced cav P1 squeeze pin hydraulic cylinder. What- Cav P1 tappet pin broke. Why- Cav P1 tappet pin broke off of slide core holing block. C/M- Replaced cav. P1 tappet pin. What- Cav P1 tappet pin broke. Why- Wear. C/M- Replaced cav P1 tappet pin. What- Cav P1/P2 have burrs in roller groove area. Why- Slide cores are chipped out. Replaced cav P1/P2 slide cores. Reoccur- Maybe in time. What- Cav P2 slide core crack over 10 mm. Why- Ongoing problem. C/M- Replaced P2 slide core and slide core pin. Also slide core didn't want to fit back in holder. Had to rework holder cap to get slide What- Cav P4 soldering NG. Why- Cav P4 slide core coating NG. C/M- Replaced cav P4 slide core. What- Cav S1 and P2 tappet pin depth NG. Why- Cav S1 and P2 tappet pins too a hit. C/M- Replaced Cav S1 and P2 tappet pins. Also Cav P1 and S2 tappet pin got replaced because I changed the wrong cavit What- Cav S1 burr NG. Why- Cracked out S1 slide core. C/M- Replaced S1 slide core. What- Cav S1 burr in roller groove NG. Why- Cav S1 Slide core chipped out. C/M- Replaced cav S1 Slide core. What- Cav S1 burr in roller groove. Why- Chip in S1 slide core. C/M- Replaced S1 slide core. What- Cav S1 has a burr in roller groove. Why- Cav S1 has a chunk out of it. C/M- Replaced Cav S1slide core. Reoccur- Yes in time What- Cav S1 roller groove burr ng. Why- Cav S1 slide core chipped out. C/M- Replaced cav S1 slide core. Also had water leak behind ejector plate when i turned the water on. I Was able to fix that wi What- Cav S1 tappet pin NG. Why- Broken tappet pin. C/M- Replaced cav S1 tappet pin. What- Cav S3 roller groove burr NG. Why- Cav S3 slide core chipped out. C/M- Replaced cav S3 slide core. What- Cav S4 big burr by roller groove. Why- Cav S4 chipped out. C/M- Replaced Cav S4 slide core. What- Cav. S1 tappet pin not moving. Why- Tappet pin is seized up bushing. C/M- Can't fix in machine so die will need pulled to be fixed. What- Cav. S2 adj. tappet pin hole spec ng. Why- Cav. S2 adj. tappet pin smashed. C/M- Replaced Cav. S2 adj. tappet pin. What- Cavity 1 and 4 squeeze pin depth going below offset value. Adjusting flow wasn't helping.
Why- Adjusting flow for cavity 1 wasn't helping because hydraulic lines for cavity 1 and 2 were backward What- Cavity 1 and 4 trim damage
Why- Blocks on top of trim die fell off, bolts broke
C/M- Drilled broken bolts out of blocks and reinstalled. Adjusted cutters
Reoccur, possible What- Cavity 1 trim damage
Why- Build up on cutters
C/M- Cleaned and adjusted cutters What- Cavity 2 trim damage
Why- Checked chuck fingers on robot, one was crooked and another one was loose
C/M- Straightened and tightened chuck fingers
Reoccur, possibly What- Cavity 3 dropping parts. Why- Cavity 3 bottom M slide core not sliding freely. C/M- Took slide core out and cleaned up. Still not moving great but have to wait till die comes out to get better. What- Cavity 3 parts falling out of OK carrier
Why- Carrier slightly crooked, not going far enough back
C/M- Adjusted carrier and moved sensor back
Reoccur, possibly What- Cavity S1 slide core pin broke. Why- Worn. C/M- Replaced S1 slide core pin. Reoccur- In time. What- Channel 1 thermocoupler ng
Why- Bad wiring
C/M- Changed thermocoupler What- Channel 2 squeeze pin stuck out, would not return
Why- Hydraulic fitting for channel 2 pin was loose
C/M- Tightened fitting, bled squeeze master. Pin returned into die What- Chip in Cavity S1 of roller groove. Why- Sodering build upon edge of roller groove. C/M- Replaced S1 slide core and had operator clean out die release filter. Filter was dirty. Reoccur- Yes in t What- Chip in Operator side slide core. Why- Over shot life. C/M- Replaced Operator side slide core and slide pins S21 & S22. Reoccur- In time What- Chuck open limit switch NG on robot
Why- Broken chuck sensor wire
C/M- Reterminated existing sensor wire
Reoccur, timing What- Chunk missing on moveable side of die. Why- Sodering buildup. C/M- Polished aluminium from die' What- Clamping safety device limit switch malfunctions
Why- Bad sensor
c/m- changed safety hook out sensor x205
reoccur- yes in time
c/t- unchanged What- Collision detect coming out of trim press Root cause- Robot position off Countermeasure- Touch up position 443 at trim press Reoccur- No What- Continuous operator side vacuum failures
why: possible hole in black hose
c/m: replaced op side black hose and trimmed end off rb side hose What- Conveyor chain for ingot loader came off the sprocket on one side
Why- Ingot stuck under conveyor, operator tried to move conveyor
C/M- Loosened tension to get chain back on sprocket, replaced f What- Cooling joint on sleeve broke.
Why- Aluminum getting pulled back with plunger tip after injection and breaking the cooling joint. Tip and sleeve severely worn.
C/M- Change tip, sleeve and cool What- Crack in P2 roller groove out of spec. Why- P2 slide core cracked. C/M- Replaced P2 slide core. Reoccur- Yes. What- Crack in S1 slide core over 10mm. Why- Ongoing problem. C/M- Replaced S1 slide core. Reoccur- Yes What- Crack in S2 slide core(3311 shots) Over 10mm. Why- Not sure its a on going problem. C/M- Replaced S2 slide core. Reoccur- Yes in time What- Crack/Buildup on P2 cavity slide core causing soldering.
Why- Wear, tried cleaning slide core, quality said parts were still bad
C/M- Replaced slide core
Reoccur, timing What- Cracked P1 and S1 slide core
Why- General wear
C/M- Changed both slide cores
Reoccur, timing What- Cracked S2 cavity slide core
Why- Wear
C/M- Replaced slide core What- Cracked S2 slide core , 2,600 shots
Why-Squeeze maser settings were incorrect.
On time - .5 should be .6
Off time - 4.should be 4.6
Pressure - 12.5 should be 14.7
Flow - 70.5 should be 50.0
C/M- What- Cracked ladle
Why- ?
C/M- Replaced ladle
Reoccur, timing What- Cracked ladle
Why- Ladle caught on fire and cracked. Seemed to have excessive plunger lube.
C/M- Replaced ladle, checked plunger lube setting and adjusted spray tip.
Reoccur, timing What- Cracked ladle
Why- Wear
C/M- Replaced ladle with new
Reoccur, yes timing What- Cracked ladle leaking aluminum.
Why- Wear
C/M- Replaced ladle
Reoccur, timing What- Cracked slide core
Why- ?
C/M- Replaced S1 slide core
Reoccur, timing What- Cracked slide core P1,P2 and S2 5BA P/S F-9
why - All slide cores have 24,000 shots
C/M - Replaced the 3 slide cores
reoccur - yes What- Cracked slide core S1 cavity
Why- Wear
C/M- Changed slide core
Reoccur, timing What- Cracked slide core, P1 cavity
Why- Wear
C/M- Changed slide core
Reoccur, timing What- Cracked slide core, S2 cavity, 5BA P/S die #9
Why- ?
C/M- Replaced slide core
Reoccur, timing What- Cracked sprue bushing, leaking water in full auto
Why- Die was run at incorrect temperature on 3rd shift
C/M- Change sprue bushing
Reoccur, timing What- Cycle time over, robot going to helper side door and not entering die, causing cycle time over.
Why- Plug for robot chuck sensor bad, also had product detect problems
C/M- Changed plug out for c What- DH found air leak coming from spray cartridge unit
Why- Blown front rod seal on up/down cylinder
C/M- Replaced cylinder, had to cut rod off of old cylinder due to it being seized up in the base What- DH put a new die in, sprue bushing leaked when he turned the water on What- DH requested new chart recording paper What- Damaged operator side reed switch. Why- While putting die in operator smashed reed switch between die. C/M- Replaced operator side reed switch. Reoccur- No What- Die dropping parts
Why- ?
C/M- Changed settings in optional shot, point 7 from 3.30 to 3.40, point 9 from 3.30 to 3.40, and changed fmlend from .71 to .80. Polished cavity 4.
Reoccur, What- Die leaking from one of the lines on top of the die
Why- Bad fitting
C/M- Replaced fitting What- Die not closing right after change over.
Why- Die height number on die matrix not correct.
C/M- Worked with Mahara and Aston to set die height apon getting it to correct die height closed positi What- Die not wanting to close. Why- Cavity M4 angular pin bent not aligning up with slide core not allowing die to close. C/M- Replaced operator bottom angular pin. What- Die release pump not working. Why- Pump went bad. C/M- Replaced die release pump. Reoccur- In time What- Die temp A was reading low. Why- Bad thermocouple. C/M- Replaced thermocouple. Reoccur- In time. What- Die temp issues still a issue. Why- Found thermocouple hole was full of debris. C/M- Cleaned debris from thermocouple hole and replaced thermocouple. What- Die temp on moveable side of die NG. Why- Moveable side thermocouple NG. C/M- Replaced moveable side thremocoulpe. What- Die temp problems fixed side of die. Why- Bad thermocouple and debris in thermocouple hole not letting it seat properly. C/M-Replaced thermocouple and tried to clean thermocouple hole of debris. What- Die temp problems moveable side of die. Why- Bad thermocouple. C/M- Pulled die and replaced Moveable side thermocouple. What- Die temp problems moveable side of die. Why- Bad thermocouple. C/M- Replaced thermocuple moveable side of die. What- Die temp running high.
Why- Setting for when the water turned on were off.
C/M- Adjusted water temp settings for die. What- Die was stuck closed, would not open
Why- Squeeze pins would not return home, keeping the die from opening
C/M- Powered down DCM and squeeze master to get the squeeze pins home and open the die. What- Diet and oil sludge around top squeeze pin hole. Why- While putting die in the day before DH had a bad fitting and when they took hydraulic line off to replace fitting hydraulic oil drained down What- Drag mark being left in fixed side insert A area. Why- Bolt on top side of trim press hitting part leaving drag mark. C/M- Bolts are bent. Have no new bolts so had to grind down on head of bolt What- Draw bar broke in back of die during change over.
Why- Wear
C/M- Removed broken piece of draw bar from die and replaced. What- Draw bar nut lost during die change. Gave DH new draw bar nut. What- Dropping cav 1. Why- ?. C/M- Checked die concentration and filter, checked spray points, checked pl;unger lube line, replaced robot side vacuum valve, and polished moveable cavity pins cav 1. What- Dropping cav 2 and some flashing around cav 2. Why- Aluminum build up around op side vacum and chill block. C/M- Took out op side chill block and vacum block to clean up pockets and make sure th What- Dropping cav 3. Why- ? C/M- Cleaned die and squeeze pins. What- Dropping cav 4 part. Why- ?. C/M- Cleaned die, polished cavity, Had operator check die release and filter. What- Dropping cav 4. Why- ?. C?M- Matt Fossen and Japan support worked on all day. Mainly they put new fittings and hoses for axis 4 from die to steel hydraulic lines. All i did was polish cav 4and t What- Dropping parts off of the die
Why- Water to die release tank was left off after diaphragm pump replacement earlier in day
C/M- Turned water back on
Reoccur, no What- Dropping parts, Water leak at sleeve, and fixed die getting high temps. Why- Dropping parts because 2nd shift changed ladle and didn't adjust biscuit size. water leak was fitting to sleeve. Fixe What- Ejector pin height too high on cavity 3.
Why- Either has the wrong length ejector pin in die or the pin has been ground on.
C/M- Production will have to pull die. What- Excessive blowback from injection
Why- Tip and sleeve NG
C/M- Changed tip and sleeve, checked plunger lube spray What- Excessive blowback from injection
Why- Tip and sleeve ng
C/M- Replaced tip and sleeve What- Excessive blowback from tip/sleeve.
Why- Worn tip
C/M- Changed tip and confirmed plunger lube. What- Excessive flashing/blowback from tip and sleeve, also continuous high shot speed alarms.
Why- High life on sleeve
C/M- Changed tip and sleeve, verified plunger lube What- Excessive trim depth on cavity 1, area 1
Why- Cutter too tight on the part
C/M- Adjusted cutter on trim press What- Fixed core 1 malfunction, not reading "in" position
Why- Read switch went bad
C/M- Changed read switch, ok now
Will it happen again- Yes, timing What- Fixed core 1 malfunction. Why- Bad cable. C/M- Replaced hydraulic cable connector. Reoccur- No What- Fixed side die temp issues. Why- Bad thermocouple. CM- Replaced fixed side thermocouple. What- Fixed side die temp not coming up tp temp. Why- Bad thermocouple. C/M- Replaced fixed side thermocouple. What- Fixed side of die temp not coming up. Why- Bad thermocouple. C/M- Replaced fixed side thermocouple. What- Fixed side thermocouple broke. Why- DH broke when taking out die so ES could do tip and sleeve change. C/M- Replaced thermocouple. Reoccur- Possible in time. What- Fixed side thermocouple not reading. Why- Plug in for thermocouple NG. C/M- Switched thermocouple from input 1 to imput 2. What- Flame coming out from under tower for upper crucible
Why- Wool fell out and left a gap
C/M- Shoved some wool in the gap
Reoccur, no What- Flashing
Why- The chill blocks are damaged
C/m- Replaced the chill blocks
Reoccur- Yes What- Flashing around Cav 3/4 bottom slide cores. Why- Bottom slide cores not sliding properly. C/M- Took both slide cores out and cleaned up. Reoccur- Yes can't clean very well with die in m/c. John What- Flashing around vacuum block area. Why- Aluminum build up on vacuum blocks. C/M- Replaced both vacuum blocks and installed .050mm shims behind chill blocks. Also spotted die in m/c and it looked What- Flashing being pulled through the back of the sleeve after injection
Why- Worn tip
C/M- Replaced tip, checked plunger shaft for wobble What- Flashing build up around Cav 4 roller groove Cooling joint. Why- Had a aluminum blow out. C/M- Removed Cav 4 roller groove cooling joint and removed aluminum build up from around cooling. Also c What- Flashing cavity 4. Had a blowout and aluminum got be hind cooling joint. C/M - Took apart cav 4 slide core to clean aluminum from cooling joint area. Also replaced cav 4 slide core and pin and t What- Flashing real heavy around Cavity 4. Why- Aluminum blowout around Cavity 4 slide core. C/M- Took apart Cavity 4 bottom slide core and cleaned aluminum from pocket. Also cleaned aluminum from fac What- Flipper 1 not working
Why- Bolts that held bushing in for flipper snapped off
C/M- Had to remove flipper unit and drill bolts out, replace bushing
Will it happen again, timing What- Gap in holding crucible leak door, allowing molten aluminum from metal leaks to come out while door is closed
why: door not closing properly
c/m: repatched door and confirmed metal leak probed What- Getting high die temp alarms. Why- Bad thermocouple. C/M- Replaced thermocouple. What- Getting high shot speed alarms. Why- Bracket to plunger lube line broke not allowing plunger lube into sleeve. C/M- had to take bracket off and weld bracket. Put back on and adjusted plunger lub What- Gouge mark in rocker shaft hole
Why- Squeeze pins not working properly
C/M- Put all clean and wax on squeeze pins, checked spray points and die release , added die release What- Had multiple issues 1- Axis alarms 2- Trim Press. Why- For axis alarms bad hydraulic line. For trim damage robot needed retaught. C/M- Axis alarms cav 4 replaced bad hydraulic line. Trim damage What- Head damper closing extremely slow/not closing at all.
Why- Open/close solenoid NG.
C/M- Replaced solenoid. What- Heavy flashing and blow back. Why- Tip and sleeve worn. C/M- Replaced tip and sleeve. Reoccur- In time. What- Heavy flashing around Cav 3/4 bottom slide cores. Why- Cav 3/4 bottom slide cores not moving freely. C/M- Took apart Cav 3/4 bottom slide cores and cleaned up and got them to move more freely. R What- Heavy flashing around Cav 3/4 bottom slide cores. Why- Cav 3/4 bottom slide cores not moving freely. C/M- took apart Cav 3/4 bottom slide cores and cleaned up so they would move freely. Reoccur- What- Heavy flashing around Cavities 3 and 4 bottom slide cores. Cav 4 bottom slide core broke. Why- Because bottom slide not moving freely. C/M- Took apart cavities 3 and 4 to replace both bottom sli What- Heavy flashing around bottom 2 slide cores. Why- Bottom 2 slide cores not moving freely. C/M- Took bottom 2 slide cores out and clean up and got the slide cores moving freely. Reoccur- Yes if de What- Heavy flashing around bottom of die. Why- Cav 3 and 4 slid cores weren't sliding smoothly. C/M- Took Cav 3 & 4 out and cleaned up so they would move freely. Reoccur- Yes in time What- Heavy flashing around bottom slide cores. Why- Cav 3 and 4 bottom slide cores not moving properly. C/M- Took out cav 3 and 4 bottom slide cores and cleaned up to free them up so the would move f What- Heavy flashing around cav 3 and 4 bottom slide cores. Why- Cav 3 and 4 bottom slide cores seized up. C/M- Removed cav 3 and 4 bottom slide cores and cleaned up pockets to make them move freely. What- Heavy flashing around cav 3/4 bottom slide cores. Why- Cav 3/4 bottom slide cores not moving freely. C/M- Took apart and cleaned cav 3/4 slide core holders and pockets. Had to do a little extra What- Heavy flashing around cav 4 causing trim damage. Why- Slide cores approaching shot life. C/M- Replaced cav 4 roller groove and back slide cores. Reoccur- Maybe in time. What- Heavy flashing causing problems at trim press. Why- Cav 3 and 4 bottom slide cores were locked up. C/M- Took apart cav 3 and 4 slide cores to clean slide cores and pocket to get slide cores to What- Heavy flashing, blow back
Why- Worn plunger tip
C/M- Replaced tip
Reoccur, timing What- Heavy flashing. Why- Bottom slide cores not moving freely. C/M- Took bottom 2 slide cores out and cleaned up to get them to move freely. Reoccur- Yes What- Heavy flashing. Why- Had aluminum blowout. C/M- Tried taking out bottom slide cores and cleaning behind them. Tried taking out shims behind cotters for bottom slide cores and put new ones in. I What- Helper door close limit switch malfunctions.
Why- Both close limit switches staying on/not working properly.
C/M- Tried new switches on both, no change. Put old back on. What- Helper door limit switch error
Why- Sensor bracket on inside of helper door was loose due to door opening and closing hard
C/M- Tightened sensor bracket and slowed door down. What- Helper side door slamming shut. Why- Cylinder seals bad. C/M- Replaced SMC519 cylinder. Reoccur- No What- Helper side door won't open or close. Why- Bad valve. C/M- replaced SMC114 valve. Reoccur- no What- High aluminum alarm. Why- operator dropped aluminum on probe C/M- Cleaned aluminum off probe. Reoccur- Yes if operators aren't careful when slagging off crucible. What- High die temp. Why- What- High shot speed alarms
Why- Checked plunger lube and m/c settings, tip had 100,000 shots on it
C/M- Replaced tip
Reoccur, timing What- High shot speed alarms and dropping parts out of the die
Why- Believe plunger lube and die release are getting mixed up
C/M- Had operator dump plunger lube and die release buckets and fill both What- High shot speed alarms. Why- Not getting good plunger lube. C/M- Tighened plunger lube bracket and tip and adjusted plunger lube line. Reoccur- Yes in time What- High shot speed, low shot speed, and blow back from plunger shaft
Why- Wear, high life on tip
C/M- Tried adjusted plunger lube nozzle, replaced plunger tip.
Reoccur, timing What- High trim height on S1 cavity
Why- Buildup on cutter
C/M- Cleaned build up off of cutter, reinstalled. Checked parts by manually pressing shots out and with the machine running, operator verifie What- High trim on area 1 cavity 3
Why- Needed adjustment
C/M- Adjusted cutting block What- Holding burner misfiring What- Hole in OK parts conveyor
Why- General wear
C/M- Replacing mesh conveyor belt and gears
Will it happen again- Possibly with time What- Hood for upper crucible stuck, will not go back over crucible
Why- Flange on top of hood wasn't level with pipe on top
C/M- Put nuts in between where flange and pipe connect to level it out, put What- Hydraulic filter change
Why- Machine check #36 was out of spec. Reading 0.45, should be between 0.05 and 0.35
C/M- Changed filter
Reoccur, yes timing What- Hydraulic leak behind fixed side of die. Why- Hydraulic fitting was loose. C/M- Tightened loose hydraulic fitting. What- Hydraulic leak operator side slide core unit. Why- Bad fitting. C/M- Replaced fitting. Reoccur- In time. What- Hydraulic leak operator side squeeze pin unit. Why- Hydraulic line popped out of feral and fitting. C/M- Replaced hyd. line with one from another die. Reoccur- No. What- Hydraulic leak, robot side steel line to squeeze pins. Why- Bad ferrel and fitting. C/M- Replaced steel line with one from another die. Reoccur- No What- Hydraulic leak.
Why- Hose for mvcore 2 had a hole in it.
C/M- Replaced hose. What- Hydraulic leak. Why- Bad hydraulic line. C/M- Replaced hydraulic line to top side squeeze pin. What- Hydraulic leak. Why- Bad seal s between fitting and steel line. C/M- Replaced steel line and fitting with flex steel braided hydraulic line. Reoccur- Until we get enough steel braided hyd line a What- Hydraulic leak. Why- Fitting on manifold loose. C/M- Tightened fitting. Reoccur- No What- Hydraulic leak. Why- Hydraulic hose got a hole in it. C/M- Replaced hydraulic hose. Reoccur- no What- Hydraulic leak. Why- Hydraulic hose to tappet pin got a hole in it. C/M- Replaced hydraulic hose. Reoccur- Maybe in time. What- Hydraulic leak. Why- Loose fitting on back side of die. C/M- Removed fixed side of die and tightened hydraulic fittings and hydraulic tested ok. Reoccur- Possibly in time. What- Hydraulic leak. Why- Steel line and fitting popped out of feral. C/M- Took steel line off spare die and put on die in M/C. Reoccur- Yes in time. What- Hydraulic leak. Why-Bad hydraulic line from back side of hyd manifold to die axis 3. C/M- Replaced hyd line axis 3 from back side of hyd manifold to die. What- Hydraulic manifold bracket snapped manifold fell into helper side door.
why: wear
c/m: removed bracket and welded on new steel, reinstalled bracket and attached hydraulic manifold back to machin What- Hydraulic oil leak from pipe on back of machine near plunger lube line area
Why- Ferule went bad
C/M- Cut new pipe, replaced ferule and nuts.
Reoccur, possible What- Hydraulic pump would not stay on after die change, would turn off when helper door opened/closed.
Why- Welds broke on yellow safety door causing it to not make the limit switch.
C/M- Rewelded in What- Hydraulic temp high. Why- Hydraulic inter cooler clogged. C/M- Drilled out hydraulic inter cooler. Reoccur- In time. What- Incorrect length of the ejector pin on cavity 4.
Why- I found that the E2 and E10 ejector pin were swapped during installation
C/M- swapped the pin location
Reoccur- No What- Ingot loader conveyor crashed. Why- Conveyor forward limit switch bracket broke. C/M- Welded bracket to limit
switch. Reoccur- no What- Ingot loader crashed
Why- Ingots fell out during loading possibly due to ingot support platform being bent
C/M- Bent platform back so that it was straight, straightened out paddles for loader What- Ingot loader crashed. Why- Ingot loader conveyer over traveled and loader came down on ingots bending ingot loader. C/M- Bent loader back and checked conveyer sensor everything seemed ok. Reoccu What- Ingot loader crashed. Why- Operator said while dumping ingots one didn't fall out completely and when loader started to go back down it jammed up and lifted top crucible hood up and dropped back What- Ink ribbon not working
Why- Life
C/M- Replaced ink ribbon What- Keep getting blow outs on robot side Why- vacuum block and chill block not fitting tight. C/M- Put .100 shim behind chill block. Reoccur- Yes if no shim behind chill block. Forgot to clock in to What- Key for operator door safety switch broke
Why- Wear
C/M- Replaced key
Reoccur, timing What- Ladle broke
Why- Worn/old ladle
C/M- Replaced ladle What- Ladle broke. Why- Wear. C/M- Gave operator new ladle. Reoccur- Yes in time What- Ladle electrode break
Why- Two of the wires broke off of the ladle electrodes.
C/M- Pulled some slack through on the wiring and re terminated What- Ladle electrode break fault.
Why- Ladle electrode wiring pulled out from the copper tubing on the ladle arm. Long term exposure to heat causes wiring to become brittle.
C/M- Replaced ladle elect What- Ladle electrode malfunctions
Why- Both ceramic insulators on one of the ladle bars were broken
C/M- Replaced both ceramic insulators
Reoccur, timing What- Ladle electrode malfunctions
Why- Ceramic sleeve on ladle electrode was busted
C/M- Replaced ceramic sleeve
Reoccur, timing What- Ladle hitting crucible filter
Why- Holding crucible looks like it's too close to the operator panel
C/M: Began Crucible replacement passed onto next shift for completion. What- Ladle malfunction alarm. Why- Aluminum on sensor. C/M-Cleaned off sensor. Reoccur- Yes in time. What- Ladle malfunctions. Why- Ladle travel sensor not working properly. C/M- Levi adjusted ladle travel sensor. Reoccur- In time What- Ladle not moving, stuck in one position. Got it to move but it locked up again
Why- Lower unit bearings locked up
C/M- Replace lower unit
Reoccur, timing What- Ladle not moving.
Why- Out of cycle.
C/M- Had to manually move ladle away from sleeve area. What- Ladle start button not working
Why- Cause unknown
C/M- Checked wiring on button, started ladle several times with no issue What- Ladle switch wasn't working
Why- Broken wire inside operator panel
C/M- Reterminated wire What- Ladle travelling limit switch malfunctions
Why- Bare wire on limit switch
C/M- replaced limit switch What- Ladle wouldn't move. Why- Safety door bolts had come loose from floor, causing it to not make sensor. C/M- tightened floor bolts. Reoccur- no What- Large amounts of blowback from plunger tip.
Why- Tip extremely worn, not getting enough plunger lube.
C/M- Changed plunger tip. Removed plunger lube spray nozzle and removed blockage, confirme What- Large water hose leaking behind operator side door
Why- Age of hose, wear
C/M- Replaced hose What- Leaking oil behind plunger shaft
Why- Injection rod seal went bad
C/M- Replacing injection rod seal assembly
Will it happen again- yes, timing What- Low 2 axis alarms
Why- Sq master needed bled
C/M- Cycled power for sq master and rebled What- Low biscuit alarms.
Why- New style 1.0KG ladle does not have enough volume to produce a big enough shot, shot weight setting is maxed out and fine spill is already at 0.0 so there is no room for What- Low fixed side die temp
Why- Fixed side solenoid for die water not kicking on. FixDieTemp 1 low temp setting was too low after a die change.
C/M- Changed FixDieTemp 1 low setting from 325 to 365 What- Low fixed side die temp.
Why- Occurred after die change, suspect thermocoupler.
C/M- Replaced fixed side thermocoupler. What- Lower ladle unit locked up
Why- Bad bearings
C/M- Confirmed upper bearings ok, replaced lower ladle unit & broken ladle What- Lower ladle unit locked up
Why- Ladle probes had build up and caused the ladle to dunk too deep in aluminum
C/M- Cleaned probes off and changed lower unit
Reoccur, timing What- M/C getting cycle times alarms. Why- E/S traced problem to top squeeze pin sticking. C/M- Replaced top squeeze pin and bushing. What- Machine stopping, getting mold heater abnormal light. Mold heater is over heating and getting a #4 fault.
Why- Unknown
C/M- Started investigating to find root cause of why it was overheating, cl What- Main water line to moveable side of die bubbling up, potentially about to pop.
Why- Old hose.
C/M- Replaced hose. What- Mark on cav 4. Why- Burr on top guide that pushes part down through trim press. C/M- Polished burr on guide that pushed part down through trim press. Reoccur- Maybe in time. What- Marks on cavity 3 and 4 from trim press
Why- Damaged top punches
C/M- Tried new punches, parts looked worse. Put old punches back in and stoned them What- Marks on parts coming from die, all cavities.
Why- Buildup on die.
C/M- Cleaned die with alclean. What- Melting burner misfires
Why- Dirty photo eye
C/M- Cleaned photo eye What- Melting burner randomly shutting off with no fault or apparent reason.
Why- One of the holding crucible leak detect probe wires broke
C/M- Reterminated wire What- Melting burning not getting hot enough, topping out at about 1350 degrees, set at 1652
Why- Solenoid on gas valve sticking
C/M- Replaced solenoid and confirmed temperature increase
Reoccur, timi What- Melting furnace temperature jumping around
Why- Terminations for thermocoupler wire NG from wear and excessive heat
C/M- Reterminated wires What- Melting pot temp not reading right. Why- Thermocouple bad. C/M- replaced thermocouple to melting pot. Reoccur- No What- Melting temperature not getting high enough, exhaust temp reaching upper limit too fast, kicking off melting burner.
Why- Thermocoupler went bad
C/M- Replaced thermocoupler
Will it happen again What- Missing a paddle on the ingot loading conveyor
Why- Appears to have fallen off
C/M- Replaced missing paddle What- Mold heater keeps going into stand-by while machine is in auto, stopping machine.
Why- Broken/Melted wire in heater. After reterminating wire, the jumper attached to the initial wire turned cher What- Mold heater kicking off causing MC to Cycle stop. Why- Not positive but noticed when both fixed and moving side would kick on that pressure into MC would spike down causing mold heater to shutdo What- Mold heater would not reach temp setpoint
Why- Water flow issues, AVT butterfly valve connection to the motor shaft was loose.
C/M- Tightened set screw on valve What- Motor overloads at trim press panel
Why- Small scrap conveyor won't go forward/ jammed
c/m: removed over flow tab from chain What- Motor overloads on scrap conveyor
Why- One of the rods backed out and one of the links was dragging on the track
C/M- Knocked rod back through the links and replaced missing cotter key. Found an What- Motor overloads on trim press
Why- Scrap press jammed, found several broken links and missing cotter pins due to wear and pieces of shot getting stuck in conveyor.
C/M- Cleaned scrap out of conv What- Move 2 core malfunctions. Why- Not sure this was a new die. C/M- Replaced Operator side and robot side reed switches. Reoccur- No What- Move core 2 malfunction. Why- Water in junction box to slide cores. C/M- Replaced junction box. What- Move core 2 malfunctions. Why- Bad lead switch on operator side slide core hydraulic unit. C/M- Tried changing Hyd. Cyl. cable and extension cable for lead switch but that didn't work so had to What- Move core 2 malfunctions. Why- Couldn't find the problem. C/M- Replaced extension cable to operator side slide core reed switch. Replaced grey cable from slide core unit to machine. Couldn't pin What- Move core 2 malfunctions. Why- Operator lead switch NG. C/M- Replaced operator side lead switch. Reoccur- In time. What- Moveable core 2 limit switch malfunctions.
Why- Top lead switch for slide cores ng.
C/M- Replaced lead switch. What- Moveable core 2 malfunctions
Why- Tested each reed switch for moveable cores, found a bad switch. Also found crossover reed switch from operator side to robot side was shorted out.
C/M- Replaced What- Moveable side die temp keeps jumping high. Why- Bad thermocouple. C/M- Replaced thermocouple. Reoccur- Maybe in time. What- Moveable side die temp problem. Die temp low. Why-Constant water flow to moveable side of die even when it shouldn't be on. C/M- Didn't really do anything was troubleshooting problem when i noti What- Moveable side die temperature reading over 1000 degrees
Why- Bad thermocoupler. Appeared to have been pinched
C/M- Replaced thermocoupler
Reoccur, possible What- Moveable side of die no die temp reading. Why- Bad thermocouple. C/M- Replaced thermocouple. What- Moveable side thermocouple got smashed. Why- When last thermocouple was installed operator didn't run it correctly and it got smashed. C/M- Replaced moveable side thermocouple again. What- Needs new fitting for hydraulic hose
Why- Won't attach to male fitting
C/M- Replaced fitting
Reoccur, timing What- No die temp reading for fixed side of die. Why- Bad thermocouple. C/M- Replaced thermocouple on fixed side of die. What- Not sitting shot in trim press correctly every time. Why- Shot not coming out of die the same every time. C/M- Bill B. came back and said they have re-taught rotot but still every once in a whil What- OK carrier is not moving
Why- Motor NG from normal operating circumstances.
C/M- Checked key and keyway from gear box to conveyor shaft, checked chain. Could get carrier to go sometimes but not What- OK carrier not moving
why: rails and sprockets wore along with chain
c/m: replaced all wore parts, verified tracking of bucket
reoccur: no What- OK carrier stopping about halfway to the tables.
Why- Chain was extremely loose.
C/M- Tightened chain. What- OK conveyor belt got damaged
Why- Part got jammed up
C/M- Replaced belt, had to reweld part divider
Reoccur, timing What- OK conveyor chain damaged, not turning on sprockets
Why- Set screws came loose and sprockets were walking on rod causing belt to go off track
C/M- Tightened sprockets down and replaced belt
Reoc What- OK part carrier wouldn't move
Why- Part stuck between carrier and chute from trim press
C/M- Removed part What- OK part conveyor not going all the way up. Why- Tension on blue bucket is out of alignment. C/M- Travis adjusted tension on chains to ok conveyor so blue bucket would go up and down better. What- OK parts carrier getting stuck at the top
Why- Shoes worn causing the bar that the advance sensors read to hit a rod at the top of the track
C/M- Changed shoes
Reoccur, timing What- OK parts carrier not advancing
Why- Keyway on gearbox shaft worn out, motor turning but conveyor not going
C/M- Replaced gearbox
Reoccur, timing What- OK parts conveyor getting jammed up
Why- Chain tension, chain on one side of conveyor jumped a link
C/M- Adjusted tension and walked the chain back one link
Reoccur, possibly What- OK parts conveyor getting stuck on the way up
Why- Roller on conveyor was hitting the home sensor bracket on the way up. This was caused by the wings in the track being extremely worn. Wear appe What- OK parts conveyor not getting return light
Why- Return sensor dirty, not able to see OK conveyor
C/M- Cleaned return sensor What- Oil leak
Why- Hose for moveable core 2 had a pin hole. Cloth sleeve was not long enough.
C/M- Replaced hose and hose sleeve What- Oil leak
Why- Plastic lube box for open/close casting die press cracked
C/M- Replaced box with non inventory lube box What- Oil leak
Why- Hydraulic line for tapet pins worn
C/M- Replaced line
Reoccur, timing What- Oil leak from line on squeeze master.
Why- Wear
C/M- Replaced hose What- Oil leak from operator side slide core hydraulic fitting
Why- Worn fitting
C/M- Replaced female fitting, replaced male end with a spare from the die change cart What- Oil leaking from robot side top squeeze pin cylinder
Why- Three bolts holding cylinder in place were loose and one was broke. Two bolts holding front plate onto cylinder were broke, seals inside What- Ok conveyor not going up. Why- Chain jumped a tooth causing it to bind up. C/M- Loosened up sprocket to adjust chain. Reoccur- in time. What- Ok parts turn table not turning. Why- $ bolts to turn table broke. C/M- Darrell and i had to remove broken bolts and put new install new bolts. What- One of the shaft and roller assemblys for the ok carrier disappeared.
Why- Snap ring must have come off and the shaft backed out, could not locate.
C/M- Replaced with used shaft assembly from di What- Operator could not get squeezemaster to bleed after changeover.
Why- Operator side movable core 2 limit switch wire was broken.
C/M- Replaced limit switch cable extension What- Operator noticed mist coming from mist collector
Why- Inspected filters, one of them was falling apart
C/M- Replaced filter. Gauge 35c on mist collector wasn't reading due to lack of filter. It What- Operator noticed white milky substance in his way lube tank
Why- Appeared to be plunger lube, must have gotten mixed into wrong container
C/M- Emptied and cleaned tank, replaced with correct oil What- Operator requested new ladle.
Why- Old one fell apart.
C/M- Gave operator new ladle to install. What- Operator requested new ladle.
Why- Old one fell apart.
C/M- Gave operator new ladle. What- Operator requested new vacuum filter What- Operator side bottom slide core fell out of m/c, broke water fitting
Why- Loose bolts
C/M- Replaced bolts and changed water fitting, put slide core back in die
Reoccur, unlikely What- Operator side bottom slide core would not move freely.
Why- Flashing in slide core cavity.
C/M- Removed slide core and cleaned out the cavity and the block. Die blew out again and filled a cavit What- Operator side door wouldn't close
Why- Safety lock was stuck
C/M- Tried to manually unlock safety switch, still wouldn't work. Replaced lock
Reoccur, timing What- Operator states slide cores not returning
why: squeeze pins not getting return position to allow slide cores to return and robot to unload
c/m: Rebled squeeze master, stroked squeeze master veri What- Operators unable to put sleeve all the way into the sleeve bushing during changeover
Why- Inner edge on the back of the sleeve bushing appears to be damaged, possible dropped
C/M- Replaced sleev What- Over pour on sleeve
Why- Ladle forward limit
Counter measure- Adjusted ladle forward limit from 146.8 to 147.0
R/C- Yes, time
Cycle time- unchanged What- P parts getting stuck in trim press, unable to pull trim press due to parts stuck
Why- Chutes missing in bottom of trim press
C/M- Had to disconnect trim press from cylinder and disconnect clamp What- P1 and S1 won't plug gauge. Why- Slide cores coating worn. C/M- Replaced cav S1 and P1 slide cores. What- P1 broken slide core((9150 shot life). Why- Don't really know broke during start up while doing pre heat shots. C/M- replace P1 slide core. Reoccur- no What- P1 slide core broke(16,500 shot life). Also sprue bushing water leak(56,000 shot life). Why- Not really sure. Sprue bushing problem ongoing problem. C/M- Replaced P1 slide core and both cooling What- P1 slide core broke. Why- ?. C/M- Replace P1 slide core. What- P1 slide core crack over 10mm. Why- ?. C/M- Replaced P1 slide core. Reoccur- Yes What- P1 slide core crack over 10mm. Why- On going problem. C/M- Replaced P1 slide core with non-inventory Matt Kline slide core. Reoccur- Yes What- P1 slide core pin broke. Why- Wear. C/M- Replaced P1 slide core pin. Reoccur- Yes in time. What- P1 slide core(2500 shots) crack over 10mm. Why- On going problem. C/M- Replaced P1 slide core. Reoccur- Yes in time. What- P1 tappet pin depth ng. Why- Cav p1 tappet pin broke. C/M- Replaced P1 tappet pin. What- P2 Broken tappet pin. Why- ?. C/M- Replaced P2 tappet pin. Reoccur- Maybe in time. What- P2 burr in roller groove out of spec. Why- P2 slide core cracked(34,000 shot life). C/M- Replaced P2 slide core. Reoccur- Yes. What- P2 ok parts falling into ng conveyor. Why- Flipper 4 not working properly. C/M- Put washer and retainer clip where flipper 4 unit does 90 degree turn back to p2 cavity. Reoccur- maybe in time. What- P2 roller groove burr ng. Why- P2 slide core cracked. C/M- Replaced P2 slide core. What- P2 slide core NG plug gauge. Why- Wear on coating. C/M- Replaced P2 slide core. Reoccur- Yes in time What- P2 slide core broke. Why- Slide core stuck in part and broke tip off. C/M- Replaced P2 slide core and both cooling joints. Reoccur- In time. What- P2 slide core crack over 10mm. Why- ? C/M- Replaced P2 slide core. Reoccur- Yes What- P2 slide core crack over 10mm. Why- Ongoing problem. C/M- Replaced P2 slide core. Reoccur- Yes. What- P2 slide core pin broke. Also found sprue bushing was leaking when we turned the water back on. Why- Wear. C/M- Replaced P2 slide core pin. Also replaced sprue bushing. What- P2 sodering. Why- Aluminum buildup on slide core. C/M- Tried to polish slide core but didn't help. Had to replaced P2 slide core. Reoccur- Yes in time.
"NON INVENTORY 5A2DM0060" What- P2 tappet pin out of spec Why- Thought slide core pin was broke but it wasn't. So really don't know what problem was. C/M- Replaced P2 slide core pin(40,126 shot life) and it fixed the problem. What- PC malfunction- Broken ejector pin. Why- Still investigating. C/M- Stared to teardown die to replaced parts and production decided to put other die in mc. Reoccur- Yes What- Part stuck in die, slide cores would not return home to eject the part.
Why- Occurred under normal operating conditions in full auto.
C/M- Turned mold heater to 70, torched die until cores retur What- Part stuck in the die
Why- Operator side movecore 2 did not come out of part
C/M- Operators followed stuck part standard, I heated the die with the torch for about an hour and was unsuccessful i What- Part stuck on die due to slow channel 2 squeeze pin.
Why- Leaky fitting, needs bled.
C/M- Removed broken part from die, replaced leaking hydraulic fitting, cleaned squeeze pin. Rebled sq master. What- Parts falling off of the shot in the die
Why- Molten aluminum was too hot. Aluminum was glowing but the thermocoupler was making contact with the level probes so the reading was low, causing the What- Perosity in all cavities. Why- Sprue bushing cracked on inside. C/M-Replaced sprue bushing. Reoccur- Maybe in time. What- Pin for bottom side operator slide core snapped off
Why- Slide core possibly locked up
C/M- Tried to get pin out to replace with new, was not successful. Production pulled die
Reoccur, not likel What- Plunger lube bracket snapped off + soldering on cavity 3
Why- Operator broke bracket while cleaning material off of sleeve
C/M- Welded bracket back together and adjusted plunger lube tip, cleane What- Plunger lube leak
Why- Ferule for copper plunger lube line smashed
C/M- Cut end of copper line off and replaced ferule What- Plunger lube leaking from lubricant pump
Why- Loose fitting on copper line
C/M- Tightened fitting, verified lube no longer leaking What- Plunger lube line problem. Why- Plunger lube line bracket broke. C/M- Took bracket off and welded where it broke. Reoccur- No. What- Plunger lube tip clogged up. Why- Sucked up aluminum. C/M- Replaced plunger lube tip. Reoccur- Yes in time. What- Plunger tip making noise, got stuck in sleeve.
Why- Not getting any plunger lube, nozzle was out of position.
C/M- Adjusted and tightened plunger lube bracket. What- Plunger tip plugged. Why- Aluminum poured on tip. C/M- Replaced plunger tip and steel plunger lube line that goes to plunger tip. Aluminum was sucked all the way through both tip and line not le What- Plunger tip seized up in sprue bushing. Why- Passed on for second shift that mc double poured aluminum. C/M- Replaced sprue bushing. What- Porosity S2 cavity
Why- Leaking spray point + blown vacuum blocks, also had a spray point going directly into the sprue bushing
C/M- Replaced spray valve, redirected spray point and op changed b What- Porosity in P1/S1 cavities. Why- Maybe squeeze master flow settings too low. We have this problem on RPY P/S dies quite often. C/M- First I checked for water leaks and found none, then checked s What- Porosity in S cavities. Why- water leak somewhere- C/M- checked spray point and air blow. Replaced sprue bushing. What- Porosity in all 4 cavities. Why- leaking sprue bushing. C/M- Replaced sprue bushing(76,000 shots). Reoccur- In time What- Porosity in cavity 2. Why- Spray cartridge valve Not spraying to well in that cavity. C/M- Replaced spray cartridge valve. Reoccur- In time. What- Porosity in part. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. Reoccur- Maybe in time. What- Porosity in parts. Biscuit was also jumping all over the place, causing vacuum faults when it got too high.
Why- Spray cartridge was on backwards, cooling joint sleeve was left on after changeo What- Porosity in parts. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. What- Porosity in parts. Why- Sprue bushing leaking. C/M- Replaced sprue bushing. Reoccur- In time What- Product detect sensors not being made
Why- Robot position is off
C/M- Adjusted robot position to make all sensors
Will it happen again, yes timing What- Production PM Air filters need replaced What- Production pulled die for a cracked slide core, new die was leaking oil from the tapets on cavities 1 and 3
Why- ?
C/M- Replaced cylinders for cavity 1 and 3, I broke the tapet pins on the opera What- Production was unable to locate female air fitting for large clear vacuum hose on the robot side of the die. I was unable to locate the correct fitting in the shop and die cast maintenance area. What- Ps slide core cracked over 10mm (6000 shots). Why- ? C/M- Replaced P2 slide core. Reoccur- Yes in time What- Quality didn't like sodering on P1/P2 roller grooves. Why- Aluminum build up on slide cores. C/M- Replaced P1/P2 slide cores. Reoccur- in time. What- Quality said cav 1 ng. Why- Crack in roller groove. C/M- Replaced cav 1 roller groove.(Had none in inventory but Bert had a non inventory roller groove that we used, What- Quality said cav P2 and S2 had burr on parting line around slide cores were NG. Why- Slide core wear. C/M- Replaced P2 and S2 slide cores. Reoccur- Mabe in time. What- Quality said raised area in roller groove in all 4 cavities. Why- All 4 slide cores have wear. C/M- Replaced all 4 slide cores. What- Reed switch broke operator side. Why- Not really sure. looks like reed switch got bumped into and cut switch in half. C/M- Replaced reed switch. What- Repeated ladle electrode bar malfunctions
Why- Loose nuts on the ladle bars
C/M- Tightened electrodes, verified ladle movement What- Robot collision detect at trim press after changeover to Water Passage.
Why- Shot not getting set down correctly.
C/M- Checked robot claw, checked sit down at jig before trim press. Part rubbing What- Robot continuously faulting out at trim press for collision detect
Why- Potentially caused by small biscuit on shot. Lower ladle unit had been recently changed, shot weight not dialed in yet.
c What- Robot crashing at dunk tank air blow unit
Why- Checked robot fingers, ok. Air blow bracket was loose and sitting lower than usual
C/M- Set air blow unit at proper height and retightened. What- Robot crashing in die after grabbing shot
Why- Biscuit is being pulled off of die by the tip before robot grabs it
C/M- Confirm plunger lube, change tip.
Reoccur, timing What- Robot dropping parts. Why- Robot chuck finger broke. C/M- Replaced chuck finger. Reoccur- No What- Robot dropping shots
Why- Bare spot in cable of robot hand sensor
C/M- Replacing sensor+cable and running cable through an air line to eliminate bare spots
Will it happen again- No What- Robot dropping shots
Why- Shot sticking to tip causing the robot to not grab the shot properly
C/M- Verified plunger lube, changed tip
Reoccur, timing What- Robot entering die and grabbing shot, but leaving shot in die and returning to home position
Why- Possibly bad chuck sensor
C/M- Replaced chuck sensor
Will it happen again, no What- Robot faulted inside of the die
Why- One of the robot fingers and pawls snapped off
C/M- Was unable to locate the fingers in inventory, took a finger and pawl off of Diecast #4(machine choice pe What- Robot faulting at trim press What- Robot faulting at trim press. Robot drifts up with trim press after it presses the shot and faults out.
Why- Cavity 1 cutter was too tight causing the shot to sit on top of the cavity instead of What- Robot faulting out at scrap press due to scrap pieces being left behind
Why- Scrap press had wrong size cutters installed
C/M- Put correct cutters in scrap press
Reoccur, no What- Robot faulting out in die. Why- Unknown. C/M- Levi touched up robot in die and seemed to take care of problem. Reoccur- In time. What- Robot faulting out while trying to pull part out of trim press
Why- Cylinder that holds part steady is getting wedged and not coming off of the part. Robot PR 60 going into the trim press wasn't What- Robot faults
Why- Product detect sensors not lined up right
C/M- Adjusted product detect sensors
Reoccur, no What- Robot faults at Trim press
Why: Vibrator not knocking overflow off
C/M: Retaught Vibrator positions In
Recur: Possibly in time What- Robot faults at trim press. Why- Needs touched up. C/M- Touched up position P25. Reoccur- In time. What- Robot faults from product detect sensors
Why- Shot moving during takeout, all four fingers not touching biscuit
C/M- Adjusted spray point on spru pin and touched up robot chuck position at takeo What- Robot faults, followed by cycle time over
Why- Product detect, I noticed that when the product detects occurred that the shot was broken coming off of the die. Squeeze pins could be slow causing What- Robot faults. Why- Shots sticking to tip Pulling shot away from sprue pin so robot doesn't grab part correctly. Happening about every 45 mins to an hour. Talked with team leader and he said they What- Robot getting collision detect alarms at scrap press
Why- The shot was running into the paddles on the scrap press
C/M- Touched up line 316 P[56] to level out the robot arm and avoid hitting the What- Robot leaving shot in trim press
Why- Twice clamp switch on trim press control panel got turned off
C/M- Turned twice clamp switch back on What- Robot leaving shots in die
Why- Robot was not taking the shot due to vacuum issues. Several blown vacuum blocks on the operator side.
C/M- Had operator change both blocks, still blew the blocks. What- Robot not gripping shot correctly
Why- Chuck hand cylinder was loose
C/M- Tightened chuck cylinder and operator verified parts What- Robot not gripping shots correctly
Why- Robot arm bent from being crashed
C/M- Replace robot arm. Retaught robot in die and at trim press
Will it happen again, no What- Robot not returning to home
Why- Robot crashed into trim press
C/M- Returned robot with pendant What- Robot problems at trim press. Why- Tabs from shot falling down wrong chute And builds up all the way from NG conveyor up to the trim press not letting part sit in trim press correctly.. NG conve What- Robot product detect alarms.
Why- Parts being dropped from shot while it is being ejected out of the die. Part of this was being caused by the squeeze pin hydraulic hoses going to the wrong sque What- Robot side slide core pin broke. Why- Wear. C/M- Replaced S31-S35 slide core pins. Reoccur- In time. What- Robot side vacuum valve stuck in die. Why- Holding block near vacuum valve took a hit. C/M- Had to pry the old vacuum valve out and then polish up where vacuum valve goes to get it to go in and What- Robot was leaving trim press before shot pressed, trim press came down while robot was leaving and crushing the shot.
Why- Dirty trim press sensors
C/M- Cleaned trim press sensors
Reoccur, no What- Robot would not return home
Why- Operator did not use the correct home program
C/M- Used trim_hp instead of go_home program, returned robot to home position What- Robot wouldn't pick up shot off of die
Why- Buildup in air chuck air line
C/M- Bled air line to robot chucks, air fitting to plunger lube line had also come apart, replaced fitting What- S1 slide core bad. Why- Chunk out of slide core. C/M- Replaced S1 slide core. Reoccur- In time
"NON INVENTORY SLIDE CORE, TRIAL SLIDE CORE FROM MATT" What- S1 slide core broke. Why- Cause unknown. C/M- Replaced S1 slide core. Reoccur- In time What- S1 slide core change
Why- 5BA inscription on slide core no longer legible
C/M- Replaced slide core cavity S1
Reoccur, timing What- S1 slide core crack over 10mm. Why- On going problem. C/M- Replaced S1 slide core. Reoccur- yes What- S1 slide core crack over 10mm. Why- Ongoing problem. C/M- Replaced S1 slide core. Reoccur- Yes in time. What- S1 slide core cracked, out of spec.
Why- Worn.
C/M- Replaced S1 cavity slide core, 5BA P/S die #14. What- S1 slide core replacement
Why- Buildup on slide core model stamp
C/M- Replaced S1 slide core What- S1 slide core spec problem. Why- S1 slide core NG. C/M- Replaced S1 slide core. Before I replaced S1 slide core I had taken slide core unit apart and cleaned up thinking some aluminum got in beh What- S1/S2 burr in roller groove is out of spec. Why- S1/S2 slide cores cracked. C/M- Replaced S1/S2 slide cores. Reoccur- In time. What- S1/S2 slide core specs NG. Why- Bad Matt K. slide cores. C/M- Replaced S1 slides core with TEG slide core and S2 slide core with Matt K. Slide core that was confirmed by Quality. Reoccur- Maybe What- S1/S2 slide core specs NG. Why- Slide cores made at FTP radius spec NG. C/M- Replaced S1/S2 slide cores. C/M- Possibly. A lot of problems with slide core made in house. What- S1/S2 slide cores crack over 10mm. Why- Wear(20,000 shots) C/M- Replaced S1/S2 slide cores. Reoccur- Yes in time.
RPY PS F-1 DIE What- S2 Slide core sodering NG. Why- Coating on slide core gone. C/M- Replaced S2 slide core. Reoccur- In time What- S2 burr in roller groove out of spec. Why- S2 slide core cracked. C/M- Replaced S2 slide core. Reoccur- Yes What- S2 part getting broken.
Why- Right side tree getting left behind in the trim press sometimes.
C/M- Adjusted air blow. What- S2 slide core broke (? shots). Why- shot life and wear. C/M- Replaced S2 slide core and pin, also replaced both cooling joints and 4 water lines. Reoccur- In time. What- S2 slide core crack depth out of spec. Why- above 10 mm. C/M- Replaced S2 slide core and pin. Reoccur- Yes in time. What- S2 slide core crack over 10mm. Why- ? C/M- Replaced S2 slide core and pin. Reoccur- Yes What- S2 slide core cracked causing burr on part. Why- Was a used slide core when I put it in last week. C/M- Replaced S2 slide core with another used one. Reoccur- Yes in time. What- S2 slide core height NG. Why- Build up behind slide core block and face of slide core cap dented up. C/M- Took out slide core and cleaned up behind slide core and took apart slide core and clean What- S2 sodering NG. Why- Coating worn off and aluminum builds up. C/M- Replaced S2 slide core. Reoccur- Yes in time. What- S2 tappet hole ng. Why- S2 tappet pin broke. C/M- Replaced S2 tappet pin. What- S2 tappet pin hole spec ng. Why- S2 tappet pin broke. C/M- Replaced S2 tappet pin. What- Safety circuit not resetting on ingot loader
Why- Light curtain blocked by die release test kit
C/M- Closed die release test kit, informed operator why the fault occurred. What- Safety latch for crucible not mounted to anything.
Why- Bolts came loose over time.
C/M- Remounted safety lock. What- Safety lock for operator door broke
Why- Unknown
C/M- Replaced safety lock.
Reoccur, timing What- Safety relief valve on mold heater was leaking in October, did not have a new valve at the time so had to close the valve.
C/M- Part came in, replaced safety relief valve, turned water on and co What- Scrap conveyor alarming out. Why- Conveyor sagging setting out senor. C/M- Put link back on with new cotter pin. Reoccur- Yes What- Scrap getting left behind in trim press after pressing shot
Why- Air lines not hitting the right spot
C/M- Adjusted trim press air lines What- Scrap on cavity 2 from the die
Why- Small amount of buildup in the cavity
C/M- Cleaned area with dremel What- Scrap piled up on scrap conveyor
Why- Side guarding on conveyor came off and was sitting over the conveyor causing the scrap to just pile up in one spot
C/M- Installed new bolts in guarding What- Scrap press guides, coupling, and press joint broke
Why- What- Scrap press laser sensor was stuck on
Why- Hose clamp holding sensor was too tight
C/M- Loosened hose clamp and sensor started working.
Reoccur, possible, sensor is questionable but there aren' What- Scrap press not always breaking shots causing robot to fault out.
Why- Down sensor making too soon not allowing the cylinder to cut the shot
C/M- Adjusted down sensor for scrap press What- Scrap press not cutting shot after robot sets it down.
Why- Robot position was off. Down sensor for press was set too high.
C/M- Retaught robot positions for line 515 and 516 RPY 1RKR robot pro What- Scrape conveyor jammed up. Why- Missing cotter pins and chain link. C/M- Replaced some cotter pins and 1 chain link. What- Secondary pressure hole depth out of spec. Why- Pin came loose from cylinder cause depth to be to deep. C/M- Tighten pin to cylinder. Reoccur- Yes in time until we can take die apart and get wre What- Sensor abnormal faults at trim press
Why- First advance sensor for ok carrier(X017) was stuck on due to wear
C/M- Replaced sensor What- Shot breaking off when die opens sticking in sprue bushing. Why- Yesterday had same problem and E/S replaced tip. Started happening again today and Craig R. requested we replace the sprue bushin What- Shot ejection faults. Why- Sensor dirty. C/M- Took shot sensor out and cleaned up and put back together. Reoccur- In time. What- Shot sensor problem. Why- Sensor not returning to zero. C/M- Tried taking sensor out and cleaning it twice and didn't help so I replaced shot sensor. Reoccur- yes in time. What- Shot sticking in die causing the robot to fault out + aluminum blowout on operator side
Why- Buildup on die
C/M- Cleaned die with alclean and scotch brite, replaced operator side vacuum block an What- Shot sticking to plunger tip
WHY: no plunger lube
C/M: replaced pump adjusted lube bracket and tip
reoccur: yes timing What- Shot sticking to tip. Why- Tip is worn. C/M- Gave tip to DH to replace. Reoccur- Yes in time. What- Shots getting bent, not going into trim press correctly
Why-Shots sticking to tip
C/M- Changing tip
Will it happen again, yes timing What- Shots getting set in trim press wrong but it's inconsistent
Why- Noticed gap between biscuit and spru
C/M- Tip change What- Shots sticking to tip, bending shot
Why- 3rd shift ran tip with no water
C/M- Changed tip
Will it happen again- Yes, timing
Shot life- 832 What- Sleeve keeps turning. Why- E/S says sprue bushing is worn. C/M- Replaced sprue bushing. Reoccur- Maybe in time.
OA showed me measurement on sprue bushing. Old was 12.040 new was 12.010 only alou What- Sleeve plugged full of solid aluminum
Why/How- Op said he was covering another operators break, had a robot fault and when he recovered the machine the sleeve was plugged. It's likely that since What- Slide core A on fixed side of die broke. Why- ?. C/M- Replaced slide core A and cooling joint to that slide core. Reoccur- In time. What- Slide core S1 water leak. Why- Bad O-rings. C/M- Replaced O-rings What- Smashed thermocouple. Why- When doing die change operator smashed thermocouple between die and back plate. C/M- Replaced thermocouple. Reoccur- no What- Sodering P2 slide core. Why- Wear on slide core. C/M- Replaced P2 slide core(NON INVENTORY) Reoccur- yes in time. What- Sodering cav 1 and 4 ng. Why- Wear on slide cores cav 1 and 4. C/M- Replaced cav 1 and 4 slide cores. What- Sodering cav P4 roller groove. Why- Aluminum build up on P4 slide core. C/M- Replaced P4 slide core. Reoccur- Yes in time. What- Sodering cavity 4 NG. Why- Coating worn off allowing aluminum to build up. C/M- Replaced P4 slide core and had operator clean die release filter. Filter was very dirty. Reoccur- Yes in time. What- Sodering in P1 roller groove. Why- Sodering on tip of P1 slide. When looking at slide I noticed P2 also looked bad. C/M- Replaced P1 and P2 slide cores and pins. They had around 23,000 shots on What- Sodering on P1/P2 slide cores. Why- Die release filter dirty and concentration low. C/M- Replaced P1/P2 slide cores and cleaned die release filter and added some die release. Adjusted spray poin What- Sodering on S2 slide core. Why- Slide core is cracked and it was building up around crack. C/M- Replaced S2 slide core(4558 shots) with a used slide core(non inventory) Reoccur- yes in time What- Soldering
Why- Aluminum build up
C/M- Cleaned die What- Soldering
Why- Aluminum build up
C/M- Cleaned die with alclean What- Soldering cavities 1,2, and 4
Why- Build up on die
C/M- Cleaned die with alclean and stone, confirmed spray points and operator checked die release filter What- Soldering cavity 1
Why- Recurring issue
C/M- Cleaned die, checked spray points and die lube
Reoccur, timing What- Soldering cavity 3
Why- Aluminum build up on die.
C/M- Cleaned with drimmel and alclean. What- Soldering cavity 3
Why- Build up over time, die potentially worn
C/M- Cleaned die What- Soldering on S1 slide core, won't come off with all clean. Appears to have been ground on at some point.
Why- Wear
C/M- Changed slide core
Reoccur, timing What- Soldering on all four slide cores.
Why- Worn coating on slide cores. Had operator check die release concentration which was okay. Checked spray points.
C/M- Cleaned slide cores, operator is goi What- Soldering on both sides of die
Why- Aluminum build up
C/M- Cleaned die with alclean gel and stone. Operator checked die release concentration which was in spec but on the low end, added some die What- Soldering on cavities 2, 3 and 4
Why- Build up on die
C/M- Cleaned roller grooves What- Soldering on cavity 2 roller groove
Why- Excessive build up, potentially worn roller groove inserts
C/M- Cleaned roller groove with alclean and polished with dremel. Build up showed up as soon a What- Soldering on cavity 3 slide core
Why- Material build up over time.
C/M- Cleaned slide cores with alclean. Also had to remove two stuck lot marks. What- Soldering on cavity 3 squeeze pin
Why- Aluminum build up
C/M- Cleaned squeeze pin with alclean, checked die release and spray points What- Soldering on die
Why- Aluminum build up, checked spray points and die release concentration.
C/M- Cleaned soldering with all clean What- Soldering on every cavity
Why- Aluminum build up
C/M- Cleaned die with alclean and stone, operator checked spray cartridge and die release filter What- Soldering on parts
Why- Aluminum build up on die
C/M- Cleaned die with alclean gel and stone What- Soldering on parts
Why- Build up on die
C/M- Cleaned buildup with alclean and drimmel What- Soldering on parts
Why- Excessive aluminum buildup in die
C/M- Cleaned die, checked spray cartridge and die release What- Solenoid valve plug and air line in trim press got broken during changeover.
Why- Valve placed in a bad spot.
C/M- Replaced plug on solenoid valve, replaced air lines and fittings. Ran wires and What- Spray cartridge leaking
Why- Bad spray valve
C/M- Replaced spray valve What- Spray cartridge leaking
Why- Bad valve
C/M- Replaced spray valve
Reoccur, timing What- Spray cartridge leaking
Why- Spray valve ng
C/M- Replaced spray valve on spray manifold What- Spray cartridge leaking
Why- Spray valve went bad under normal conditions
C/M- Replace spray unit valve What- Spray cartridge leaking
Why- Two bad valves on spray unit
C/M- Replaced valves What- Spray cartridge leaking from about ten valves
Why- 1st shift changed about ten valves, still leaking. Possibly bad spray cartridge
C/M- Changed spray cartridge, only one unit was still leaking. What- Spray cartridge leaking.
Why- Bad spray valve.
C/M- Replaced valve. What- Spray cartridge leaking.
Why- Multiple bad spray valves.
C/M- Replaced valves. What- Spray cartridge water leaks.
Why- NG spray valves.
C/M- Replaced seven spray valves. What- Spray valves leaking. Why- Bad valves. C/M- Gave operator 3 new spray unit valves to replace. Reoccur- In time. What- Sprue bushing leaking
Why- Cracked
C/M- Replaced sprue bushing
Reoccur, timing What- Sprue bushing leaking water. Why- Sprue bushing cracked. C/M- Replaced sprue bushing. Reoccur- Yes in time. What- Squeeze master hydraulic pump won't start. Why- Circuit breaker tripped. C/M- Opened up side panel and reset breaker. Reoccur- No What- Squeeze pins running too deep
Why- Water leak from squeeze pin cylinder.
C/M- Production pulling die
Reoccur, possible What- Squeeze pins taking chunks out of r/s hole.
Why- Unsure
C/M- Changed squeeze master settings back to plex settings, cleaned squeeze pins and bled sq master. Problem came back but the parts are s What- Steel hydraulic line to injection rod leaking hydraulic oil. Why- Old weld cracked. C/M- took hydraulic line out and welded it again. Reoccur- Yes What- Stuck lot mark cav P2 fixed side of die. Tried to get out and couldn't get lot mark out. Was going to have to tear down die to get out. Production decided to do change over. What- Temp C alarms. Moveable side of die too hot.
Why- Thermocoupler wire kinked.
C/M- Reran thermocoupler wire, started m/c. What- Thermocoupler needs replaced.
Why- Wiring got yanked out of plug during die change.
C/M- Replaced thermocoupler
Reoccur, timing What- Threads for spray valve unit stripped, die was dropping cavity 2 part, product detect was still seeing part
Why- Wear. Robot position needs touched up
C/M- Tried to clean up threads for spray va What- Threads stripped out on draw bar for moveable side of die
Why- Wear
C/M- Replaced draw bar What- Three out of four bolts holding spray cartridge unit to the base snapped
Why- Spray cartridge is cranked too close to the moveable side of the die, hitting the die and putting stress on the bolt What- Tie bar nut would not close
Why- Seal for close solenoid on tie bar nut was leaking air
C/M- Repositioned the seal for the solenoid What- Tip is bad causing biscuit and axis alarms. Why- Think die release was mixed in with plunger lube. C/M- Replaced tip and emptied plunger lube bucket and made sure to put plunger lube in bucket. What- Top right product detect sensor for shots coming out of die not working.
Why- Beam weak, no adjustment.
C/M- Replaced and adjusted sensor. What- Top slide core not returning. Why- Bad cylinder. C/M- Replaced top cylinder. What- Top slide core squeeze pin leaking water.
Why- Water fitting worked loose.
Countermeasure- Replaced fitting on squeeze pin.
R/C- No
Cycle time- unchanged. What- Top squeeze pin cylinder hydraulic leak. Why- Loose bolts on hydraulic cylinder. C/M- Tightened bolts to cylinder. What- Trim damage
Why- Part locate cylinder on trim press wasn't hitting part correctly, robot was not putting the part all the way down on the pins in the trim press.
C/M- Checked shoulder bolts on r What- Trim damage S1 cavity
Why- Buildup on cutter
C/M- Removed cutter, cleaned buildup off with wire wheel, reinstalled. Operator verified parts What- Trim damage all four cavities
Why-
c/m: Removed all 4 rear cutters and replaced with original short cutters. These cutters were installed due to amount of downtime involved
will it reoccur; timi What- Trim damage cav 3. Why- Robot not sitting shot in trim die correctly. C/M- touched up P25 and P26 positions. Reoccur- In time. What- Trim damage cavities 1 and 4
Why- Overflow block broke on cavity 4, buildup on cavity 1 and 4 cutters
C/M- It was a trial trim press, pulled it and put a different trim die in What- Trim damage cavities 1 and 4 (59B 1RKR trim die #3)
Why- ?
C/M- Adjusted cutters What- Trim damage cavities 2&3
Why- Overflow block on top of trim press for cavity 2 is missing and top block for cavity 3 is crooked, one of the bolts broke. Top blocks moving caused the cutters to t What- Trim damage cavities 2, 3, and 4
Why- Cutters needed adjustment
C/M- Readjusted cutters and guide blocks
Reoccur, timing What- Trim damage cavities 3 and 4
Why- Cutters had build up on them
C/M- Took cutters out, cleaned them with wire wheel and put them back in trim die.
Reoccur, timing What- Trim damage cavity #3
Why- Looks like a part got crushed in the trim die
C/M- Tried to clean cutter up but there was too much damage, replaced R/s cutter for cavity #3
Reoccur, yes wear item What- Trim damage cavity #4
Why- Shot breaking around that cavity, found slide core holder was loose for cavity 4
C/M- Tightened slide core holder, shot stopped breaking and trim was OK
Reoccur, unlik What- Trim damage cavity 1 big runner side
Why- Cutters need adjusted
C/M- Adjusted cutter and guide block
Reoccur, timing What- Trim damage cavity 1. Why- Cutters need adjustments. C/M- Took Cutters out of cavity 1 and cleaned up and put back in. Reoccur- In time What- Trim damage cavity 3
Why- Manually pressed shot out and the parts looked good, robot position going into the trim press slightly off.
C/M- Touched up position 26. What- Trim damage cavity 3 and 4 on tapet areas on runner side
Why- Recurring issue
C/M- Adjusted cutters
Reoccur, yes What- Trim damage cavity 3&4
Why- Cutters possibly moved
C/M- Adjusted cutters, verified with quality
Reoccur, possible What- Trim damage cavity 4
Why- ?
C/M- Adjusted cutters
Reoccur, timing What- Trim damage cavity 4
Why- Cutter was worn
C/M- Replaced R/S cutter for cavity #4
Reoccur, yes wear item What- Trim damage cavity 4
Why- Excessive flashing on shots coming out of die caused by lower cavity 4 slide core not moving freely, also needs cutter cleaned and adjusted
C/M- Removed the bottom slid What- Trim damage cavity 4. Why- Build up on guide. C/M- took guild out and polished up and put back in. Reoccur- In time. What- Trim damage on P1 cavity area 1
Why- Damage on cutter
C/M- Replaced cutter for P1 area 1
Reoccur timing What- Trim damage on cavity 1 and 2, and robot faults in trim press
Why- Believe both were caused by trim press not being set squarely in place
C/M- Was able to clear trim damage on cavity 1 but not 2 What- Trim damage on cavity 4 near tapet
Why- Damaged guide block
C/M- Replaced Guide L for cavity 4 and adjusted cutters
Reoccur, possibly What- Trim damage on tap area near big runner side
Why- ?
C/M- Adjusted cutter
Reoccur, possibly What- Trim damage, 59B 1RKR cavity 2 and 4, die #13, trim die #3
Why- ?
C/M- Adjusted cutters, shot had room to move in trim press, tightened everything up so that it wouldn't shift. Issue reoccurred, What- Trim damage, P1 and S1 cavities
Why- Work done on die is putting extra material on the shot right where the trim damage is occurring
C/M- Production pulled die What- Trim damage, P1 cavity
Why- Extra build up on shot near trim
C/M- Adjusted the cutting block enough so that it wasn't digging into the part What- Trim damage, cavity 3.
Why- Trim press blocks need adjusted.
C/M- Adjusted trim press blocks to the shot. What- Trim damage.
Why- Robot claw was loose, set down positions off.
C/M- Tightened shoulder bolts. Touched up PR 59 and 60 several times(line 289 and 291). Cleaned top trim press cutters, adjusted t What- Trim damage.
Why: Trim press not aligned
C/M: Realigned and touched up robot
Recur: Possible in time. What- Trim damage. Why- Cav 1 missing guide and there is damage to Cav 2 not letting shot sit in trim die. C/M- Replaced guide and they are doing a die change because of damage to die. Reoccur- No What- Trim depth (too deep) cavity 1
Why- What- Trim height P2 cavity, area 2
Why- Positioning of trim die blocks, potentially bad cutter
C/M- Changed cutter for P2 cavity trimming area 2, adjusted support block to push the part closer to the What- Trim height S1 and P1 cavity
Why- Shot tight in the trim press.
C/M- Adjusted all trim blocks and adjusted the trim die to the shot. 5BA P/S What- Trim height high on cavity 1 and 3
Why- Trim blocks needed adjusted
C/M- Adjusted trim blocks What- Trim height on P1 and S2 cavities
Why- Trim die needed adjusted
C/M- Adjusted trim press blocks What- Trim height on P1, S1 and S2 cavities.
Why- Cutters needed adjusted due to extra material on shot near the trimming areas coming from the die. Images of extra material on shot attached to work o What- Trim height on all four cavities.
Why- Started after die change
C/M- Adjusted trimming blocks on trim press What- Trim height on cavities 1 and 4
Why- Trim die needs adjusted
C/M- Adjusted and got cavity 4 in spec, passed cavity 1 to 3rd shift. What- Trim height on cavities S1, S2, and P2
Why- Cutters and guide blocks needed adjusted
C/M- Adjusted guide blocks and cutters
Reoccur, possibly What- Trim height on cavity 1
Why- Cutters not aligned correctly
C/M- Adjusted cutter and guide block for cavity 1 What- Trim height too high on cavity 1, area 1
Why- Trim press block not set correctly
C/M- Adjusted cavity 1 trim press block What- Trim height, P1 cavity area 2
Why- Trim press needs adjustment
C/M- Added shim to P1 area 2 cutter and adjusted guide blocks to push part closer to cutter What- Trim press alarm going off continuously, no fault shown.
Why- Scrap press sensor made, reflector is beat up and worn.
C/M- Flipped reflector over so the sensor had a cleaner surface. What- Trim press cylinder drifting down, won't stay up long enough to complete cycle.
Why- What- Trim press cylinder leaking oil.
Why- Front seal blown.
C/M- Replaced cylinder, replaced nut and end piece as well because the threads were so chewed up. What- Trim press drifting down
Why- Found DCV valve pushing up against internal cushion when kicking
C/M- Adjusted return position on up sensor What- Trim press would go down but not return up. Why- Not making down sensor. C/M- adjusted down sensor. Reoccur- No What- Turntable 1 not turning
Why- Rod from sprocket to table broke, table seemed to be dragging against the wall causing extra stress on the rod. Also had two roller bearings under the table complete What- Unloading bucket getting stuck at top then slamming down. Why- Not really sure. C/M- Took apart unloading motor to check gear box. Couldn't get gearbox off so put back together and greased the g What- Unloading table not turning. Why- Spindle rod broke. C/M- Replaced spindle rod. Reoccur- In time. What- Upper crucible hitting the max temp and continuing to climb, not melting very well
Why- Thermocoupler position
C/M- Adjusted thermocoupler
Reoccur, possible What- Upper crucible leak.
Why: Cracked half pipe/spout
Countermeasure: Replace upper crucible ,halfpipe and crucible base.
Reoccur: Yes What- Upper crucible lid won't open and close
Why- Bad solenoid
C/M- Replaced solenoid
Reoccur, timing What- Upper crucible lid won't open.
Why- Tower out of position.
C/M- Tower position was right but the limit switch was out of position. Repositioned limit switch. What- Upper crucible open limit switch stuck on, machine would not load in auto
Why- Shorted wire between plug and junction box
C/M- Reterminated wire x47 What- Upper crucible sensor not seeing ingots
Why- Sensor out of alignment
C/M- Adjusted position of sensor What- Upper crucible, halfpipe change
Why- Buildup around spout of upper crucible and halfpipe, no pathway for aluminum flow. Due to over heating
Counter measure: Replaced upper crucible and half pipe What- Vacum problems operator side. C/M- Changed hoses, air line, Checked filter, checked die release and filters, checked spray points, and added nitrogen. What- Vacuum block stuck in die
Why Excess aluminum
C/M- Removed vacuum block, operator changed block and replaced black vacuum line What- Vacuum block wouldn't go in helper side. Why- Damage around helper side vacuum block area. C/M- ground out damage area to get vacuum to fit.
What- Move 2 core faults. Why- Move core 2 not getti What- Vacuum failure, robot side
Why- Blockage in large air hose, spray cartridge spray point not hitting vacuum block
C/M- Operator changed robot side vacuum hose, adjusted spray point
Reoccur, no What- Vacuum failures operator side. Why- ?. C/M- Got with DH and had her got through and check hoses, filter, and anything else she thought needed checked. I also had operator replaced robot side vac What- Vacuum faults
Why- Vacuum pressure was lower
C/M- Op changed blocks, no change. Vacuum pump was missing a filter, replaced filter. Found pressure was below spec., adjusted pressure
Reoccur, unli What- Vacuum low level to the tank alarms
Why- Level in vacuum tank was low, potentially caused by fluid in the lines
C/M- Drained vacuum and refilled tank, drained fluid from lines. What- Vacuum malfunction, screen on vacuum unit was black and was alarming
Why- Power supply dead
C/M- Replaced power supply
Reoccur, timing What- Vacuum problems
Why- Started on robot side, moved to operator side
C/M- Had operator change both blocks after robot side fault, I changed the operator side chill block due to aluminum blow out.
What- Vacuum problems. Why- Fixed side of die running hot(C. Randall). C/M- Replaced thermocouple. Reoccur- Maybe in time. What- Vacuum trouble Root cause- Vacuum motor filter saturated in oil Countermeasure- Clean filter Reoccur- Time What- Water leak
Why- Broken cooling joint on sleeve
C/M- Replaced cooling joint
Reoccur, timing What- Water leak M2 roller groove. Why- M2 roller groove slide core broke. C/M- Re placed M2 roller groove slide core. What- Water leak P1 slide core. Why- P1 slide core broke. C/M- Replaced P1 slide core. Reoccur- Possibly in time. What- Water leak S1 slide core area. Why- Damaged cooling joint. C/M- Replaced both cooling joints. What- Water leak Why- Cracked sprue bushing. C/M- Replaced sprue bushing. Reoccur- yes in time. What- Water leak around M4 Bottom slide core. Why- Cracked slide core. C/M- Replaced M4 bottom slide core. Reoccur- Yes in time. What- Water leak at P2 Slide core. Why- P2 slide core cracked. C/M- Replaced P2 slide core. What- Water leak at plunger shaft and sprue bushing. Why- Bad fitting on plunger shaft and cracked sprue bushing. C/M- Replaced water fitting on plunger shaft and replaced sprue bushing. Reoccur- Yes What- Water leak at sprue bushing. Why- Bad sprue bushing (8000 shots). C/M- Replaced sprue bushing. Reoccur- In time. What- Water leak at sprue bushing. Why- Cracked sprue bushing (29,901 shots). C/M- Replaced sprue bushing. Reoccur- Yes in time What- Water leak at sprue bushing. Why- Cracked sprue bushing (33,025 Shots). C/M- Replaced sprue bushing. Reoccur- Yes in time. What- Water leak at sprue bushing. Why- Cracked sprue bushing(35,000 shots). C/M- Replaced sprue bushing. Reoccur- Yes in time What- Water leak at sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. What- Water leak at sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. Reoccur- In time What- Water leak at sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. Reoccur- Yes in time What- Water leak at sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. Reoccur- Yes in time. What- Water leak at sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. Reoccur- yes in time. What- Water leak at sprue bushing. Why- Cracked sprue bushing. C/M- replaced sprue bushing. What- Water leak at sprue bushing. Why- Cracked sprue bushing. C/M- replaced sprue bushing. Reoccur- In time What- Water leak at sprue bushing. Why- Sprue bushing cracked at weld. C/M- Replaced sprue bushing. Reoccur- Yes in time. What- Water leak at sprue bushing. Why- Sprue bushing cracked. C/M- Replaced sprue bushing. Reoccur- In time What- Water leak at sprue bushing. Why- Sprue bushing cracked. C/M- Replaced sprue bushing. Reoccur- Yes What- Water leak at sprue bushing. Why- Sprue bushing cracked. C/M- Replaced sprue bushing. Reoccur- Yes in time What- Water leak at sprue bushing. Why- Sprue bushing cracked. C/M- Replaced sprue bushing. Reoccur- Yes in time. What- Water leak at sprue bushing. Why- cracked sprue bushing. C/M- Replaced sprue bushing. What- Water leak at sprue bushing. Why- the weld cracks. C/M- Replace sprue bushing. Reoccur- Yes. What- Water leak at sprue bushing.(3500 shots) Why- Bad weld on sprue bushing. C/M- Replaced sprue bushing. Reoccur- Yes What- Water leak at spure bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. What- Water leak at tip/sleeve area.
Why- Pin hole on line going to sleeve cooling joint.
C/M- Cut bad part of line off, replaced fitting because it was also NG. What- Water leak back side of moveable die. Why- Bad fitting and water line. C/M- Took apart back side of die and replaced fitting and water line. Water tested die ok. Reoccur- No What- Water leak behind ejector plate of moveable side of die. Why- Bad fitting and water line needed cut back. C/M- 3rd shift pulled die and had to wait for 1st shift to fix die. Had to take off ejec What- Water leak behind ejector plate of moveable side of die. Why- Cut back water lines and replaced a couple of fittings. Reoccur- no What- Water leak behind ejector plate. Why- 2 water leaks 1- Loose water fitting 2- Bad water line. C/M- Tightened water fitting and replaced bad water line What- Water leak behind ejector plate. Why- Aluminum blowout top operator side slide core and filled slot and burnt water lines. C/M- I got Die all tore down and cleaned up and pass on to 3rd shift E/ What- Water leak behind ejector plate. Why- Water line got pinched between ejector pin back plate and ejector pin back plate stopper post. C/M- Replaced pinched water line and user zip tie to keep wat What- Water leak cav 2 slide core. Why- Cracked slide core. C/M- Replaced cav 2 RG slide core. Reoccur- Maybe in time. What- Water leak cav 4 bottom slide core. Why- Slide core cracked. C/M- Replaced cav 4 bottom slide core and cleaned up flashing around slide core so it would move freely. Reoccur- Yes in time What- Water leak cav 4 slide core. Why- Cav 4 roller groove slide core broke. C/M- Replaced cav 4 roller groove slide core. What- Water leak cav S1 slide core. Why- Bad fitting to cooling joint. C/M- Replaced water fitting. What- Water leak cav S2 slide core. Why- Broke cav S2 slide core. C/M- Replaced cav S2 slide core. What- Water leak cav S2 slide core. Why- Broke slide core. C/M- Replaced slide core. Grabbed a FTP engineering slide core and it wouldn't slide into cavity. So I had to grind on S2 slide core to get i What- Water leak cav S2 slide core. Why- Cav S2 o-rings to cooling joint were bad. C/M- Replaced cav S2 o-rings to cooling joints. What- Water leak cav. 4 slide core. Why- Cooling joint O-rings bad. C/M- replaced O-rings to cooling joint. What- Water leak fixed side of die. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. What- Water leak fixed side of die. Why- Cracked sprue bushing. C/M- Replaced sprue bushinh. What- Water leak fixed side of die. Why- Cracked sprue bushing. Second time today. C/M- Replaced sprue bushing. What- Water leak fixed side of die. Why- Sprue bushing fittings leaking water. C/M- Replaced both water lines and fittings to sprue bushing. What- Water leak from cav 4 bottom slide core. Why- Slide core broke. C/M- Replaced cav 4 bottom slide core Also bottom slide cores were not moving freely so took slide cores out and cleaned up to get What- Water leak from die
Why- Cracked sprue bushing
C/M- Replaced sprue bushing
Reoccur, timing What- Water leak from die
Why- Cracked sprue bushing
C/M- Replaced sprue bushing, used die maint water tester to check for leaks. What- Water leak from die
Why- Sprue bushing cracked
C/M- Changed sprue bushing, 6A0 MID die #5
Reoccur, timing What- Water leak from die.
Why- Buildup on blue lines
C/M- Replaced line What- Water leak from helper side top slide core
Why- Slide core had just been replaced, cooling joint was no good.
C/M- Replaced cooling joint for helper side top slide core What- Water leak from main hose fitting going into the die
Why- Fitting on hose went bad
C/M- Replaced fitting
Reoccur, timing What- Water leak from moveable side of die
Why- Aluminum splashed between ejector plate and die holder and burned water lines
C/M- Tear die apart, replaced water line. Ran water tester on die before a What- Water leak from plunger shaft
Why- O-ring on copper pipe inside plunger shaft was worn
C/M- Replaced o-ring
Reoccur, timing What- Water leak from plunger shaft.
Why- One of the quick connect water fittings to the plunger rod snapped off in the rod.
C/M- Tried to remove broken fitting from plunger rod with ez out and was n What- Water leak from sleeve
Why- Sleeve cooling joint broke
C/M- Replace cooling joint
Reoccur, timing What- Water leak from slide core P1 cavity
Why- O-rings on cooling tube worn
C/M- Replaced O-rings on slide core cooling tube
Reoccur, timing What- Water leak from spray cartridge
Why- Bad spray valve
C/M- Replace spray valve
Reoccur, timing What- Water leak from spray cartridge
Why- Bad spray valve
C/M- Replaced spray valve
Reoccur, timing What- Water leak from spru bushing
Why- Wear
C/M- Replaced spru bushing
Reoccur, timing What- Water leak from sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing(20,465 shots). Reoccur- Probably in time What- Water leak from sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. What- Water leak from sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. Reoccur- No What- Water leak from sprue bushing. Why- cracked sprue bushing. C/M- Replaced sprue bushing. What- Water leak from sprue pin. Why- Hose clamp loose and water hose bad. C/M- Took apart water line and cut back water hose and tightened hose clamp. Water tested die ok. What- Water leak from top of die.
Why- Water line got pinched in the die.
C/M- Replaced water line and ran it in a way that it wouldn't get pinched in the die. What- Water leak in sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. Reoccur- In time. What- Water leak on fixed side
Why- Sprue bushing
C/M- Changed sprue bushing
Reoccur, timing What- Water leak sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. What- Water leak sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. Reoccur- In time. What- Water leak sprue bushing. Why- Cracked sprue bushing. C/M- replaced sprue bushing. What- Water leak sprue bushing. Why- Cracked sprue bushing. C/M- replaced sprue bushing. Reoccur- Yes in time. What- Water leak sprue bushing. Why- Sprue bushing cracked. C/M- Replaced sprue bushing. Reoccur- Yes in time. What- Water leak top slide core. Why- Bad fitting. C/M- Tore down top slide core to replace bad fitting. What- Water leak top slide core. Why- Fitting broke. C/M- Had to pull die to get top slide core out. Top slide core holder block took big hit causing damage to holder. Had to replaced broken water fit What- Water leak top slide core. Why- Water fitting broke. C/M- Removed top slide core and took apart to replace water fittings. Reoccur- In time. What- Water leak top squeeze pin. Why- water fitting bad. C/M- Replaced water fitting. What- Water leak under fixed side of die
Why- Sprue bushing cracked
C/M- Replaced sprue bushing
Reoccur, timing What- Water leak(plunger shaft). Why- Bad fitting. C/M- replaced water fitting. Reoccur- Yes in time. What- Water leak(sprue bushing). Why- Cracked sprue bushing. C/M- Replaced sprue bushing. Reoccur-Yes What- Water leak. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. Re0ccur- Maybe in time. What- Water leak. Why- Sprue bushing cracked. C/M- Replaced sprue bushing. Reoccur- In time. What- Water leak. Why- Water fitting to top slide core bad. C/M- Replaced the fitting that was leaking. Reoccur- Possibly with time/heat and vibration. After we assembled the die we had an issue with What- Water leaking from bottom of fixed side die.
Why- Cracked sprue bushing
C/M- Replaced sprue bushing and tested for leaks. replaced front water fitting What- Water leaking from bottom of the die
Why- Cracked sprue bushing
C/M- Replaced sprue bushing and tested with dm water tester What- Water leaking from die
Why- Sprue bushing cracked, possible due to water pipes being tightened excessively
C/M- Changed sprue bushing, tested for leaks with die maint water tester What- Water leaking from lines on die and from spray cartridge
Why- Holes in lines and bad spray valve
C/M- Replaced water lines and spray valve
Reoccur, timing What- Water leaking from movable side of die
Why- Worn fitting at quick connect, male end
C/M- Replaced fitting with new What- Water leaking from plunger shaft.
Why- Bad quick connect fitting.
C/M- Replaced plunger shaft with pre-prepared shaft, new tip. What- Water leaking from quick connect fittings on plunger shaft.
Why- Quick connect fittings not meant to be used on the plunger shaft.
C/M- Removed quick connects and went back to screw on fittings. What- Water leaking from slide core. RPY Mid die #8 cavity 4
Why Slide core was broken inside holder.
C/M- Replaced slide core and replaced O-rings on slide core cooling joint. Operator ran confirmati What- Water leaking from spray cartridge
Why- Bad spray valve, several of the spray valve screws will not tighten down due to the holes on the manifold being stripped out
C/M- What- Water leaking from spray cartridge
Why- Spray manifold was missing multiple O rings and one of the spray valves was bad.
C/M- Put new O rings on the spray manifold and replaced the bad spray val What- Water leaking from sprue bushing
Why- Cracked sprue bushing, likely just cracked from normal wear.
C/M- Replaced sprue bushing What- Water leaking from the bottom of the fixed side of the die.
Why- Cracked sprue bushing
C/M- Changed sprue bushing, checked for leaks with DM water tester What- Water leaking from the moveable side of the die.
Why- Loose fitting on water tower
C/M- Tightened ftting What- Water leaking from tip/sleeve area.
Why- Sleeve cooling joint starting to break.
C/M- Replaced sleeve cooling joint. What- Water lek at sprue bushing. Why- We had put a new sprue bushing in and it still was leaking water. So we tried a new sprue bushing and we water tested it and it was good. But when we put die ba What- Went to test spray cartridge after previous repairs, and operator door safety switch would not lock correctly.
Why- Switch ng, harsh conditions.
C/M- Replaced safety switch. What- What P2 slide core very loose in holder. Why- P2 slide core broke at base of slide core. C/M- Replaced P2 slide core(4300 shot life). Reoccur- Yes in time. What- Wiring for high aluminum probes was broken off of the terminal.
Why- Heat exposure, worn.
C/M- Reterminated aluminum level probes. What- Wiring for safety lock door for the ingot loader was melted.
Why- Timing for ingot loading was set to 25 minutes, should never be lower than 27 minutes. This caused an ingot to not get properly What- air leak from filter bowl by helper door solenoid
Why- Bowl is cracked
C/M- Replace bowl
Reoccur, no What- broken plunger rod, cooling pipe and fitting Root cause- aluminum worked it way into fitting Countermeasure-replaced plunger rod cooling pipe and fitting Reoccur- no What- burr on cav P1 and S2. Why- Cav P1 and S2 are cracked. Replaced caav P1 and S1 slide core. What- cav 1 burr by back side slide core. Why- Cav 1 back side slide core chipped out. CM- Replaced cav 1 back side slide core. What- die release tank not filling up. Why- Breaker turned off inside panel. C/M- Reset breaker. Reoccur- No What- excessive blow back
Why- Bad tip, was run sunday night with no water
C/M- Replace tip
Reoccur, timing What- heavy flashing on M4 bottom slide core. Why- aluminum got behind slide core block not allowing it to close all the way. C/M- took M4 bottom slide core out and cleaned aluminum out from behind bl What- hydraulic leak fixed side of die around cav 2 tappit pin hydraulic cylinder. Why- Found bad hydraulic line and fitting going to tappit pin cylinder. C/M- Replaced hydraulic line and fittings to What- hydraulic leak top squeeze pin cylinder. Why- Bad cylinder. C/M- Replaced squeeze pin cylinder top moveable side. What- ingot loader saddle badly bent with broken welds unable to load ingots.
Why - Improperly loaded ingots
Countermeasure- Remove all lift hardware from assy. Re bend and reweld damaged areas.
Reocc What- ladle problems, biscuit thickness alarms
Why- Lower ladle unit going bad
C/M- Replaced lower ladle unit, put new ladle on
Will it happen again, yes timing What- leaking sprue bushing. Why- Sprue bushing cracked(7000 shots). C/M- Replaced sprue bushing. Reoccur- Yes in time What- metal leak in the holding and melting crucible.
Why- damaged crucible. excessive heat causing corundum buildup and cracking on crucible
C/M: Replaced both holding and melting crucibles. Patched What- move core 2 malfunctions. Why- Put tester on die and everything tested ok. C/M- Replaced junction box on moveable side of die and that corrected the problem. What- outlet shuttle not returning home all the way
Why- Alignment on shuttle off, hitting when it returns
C/M- Aligned shuttle rails What- robot faults at trim press. Why- Not sitting shot in correct. C/M- touched up positions 25 and 26. Reoccur- no What- robot trouble. Why- Big chuck claws a bolt broke. C/M- Replaced bolt to big chuck claws, leveled chuck claws, and touched up robot. Reoccur- yes in time. What- sautering on cavity 1, 2, and 3
Why- Aluminum buildup in die
C/M- touched die up and cleaned cavities 1, 2, and 3 What- scrap chute sensor deflector broken
Why- general wear
C/M- replaced deflector What- scrap sensor broke. Why- Shot hit sensor. C/M- replaced sensor. Reoccur- no What- sodering on P2 slide core(57,000 shots). Why- Shot life and wear. C/M- Replaced P2 slide core and pin. Reoccur- In time. What- trim Press wouldn't go up or down. Why- Hydraulic motor over load. C/M- Reset breaker. wouldn't let us reset at first then finally it let us reset. Reoccur- maybe What- vacuum problems. Why- reoccurring problem C/M- Checked nitrogen, die release, spray points. Also wasn't sure if main air gauge was working right, so I was going to replace it but we have none i What- water leak S1 slide core. Why- Clip to cooling joint came loose. C/M- Replaced O-rings on cooling joint and tightened clip. Reoccur- Maybe in time. What- water leak at plunger shaft. Why- Bad water fitting. C/M- Replaced water fitting on plunger shaft. Reoccur- no What- water leak at sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. What- water leak at sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. Reoccur- Yes in time. What- water leak backside of moveable die. Why- Line not in fitting all the way. C/M- Tore down backside of die and cut back all water lines and made sure all lines were in fittings good and water tes What- water leak cav 2 slide core. Why- cooling joint bracket came loose and cooling joint popped out. C/M- Put cooling joint back in and tightened bracket down. What- water leak from sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. What- water leak from sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue bushing. Reoccur- Yes in time.
Had to replace sprue bushing a 2nd time because it was leaking after about 100 shots What- water leak from sprue bushing. Why= cracked sprue bushing. C/M- replaced spreu bushing. What- water leak. Why- cracked sprue bushing. C/M- replaced sprue bushing. What- water leaking from the S1 and P1 slide cores
Why- Broken slide cores causing water to leak
C/M- Replace the broken slide cores
Reoccur- yes What- weld on flapper to scrap conveyor broke. Why- wear and tear. C/M- Welded flapper. Reoccur- no. What-Air line for crucible lid leaking from where the end crimps onto the line
Why- Wear
C/M- Replaced air line
Reoccur, timing What-Blow back and porosity in parts. Why- Tip and sleeve worn. C/M- Replaced tip and sleeve. Reoccur- Yes in time. What-Failed hard hydraulic line causing a leak
Why-The ferrel failed
c/m-Replaced the hard line with a flex line
reoccur-no What-Part stuck in Cavity 3and cavity 3 part detect not working right. Why- Reoccurring problem on Breather Cover dies. C/M- Removed part and adjusted part detect sensor. Reoccur- Yes in time. What-Sprue bushing leaking water. Why- Cracked weld on sprue bushing. C/M- Replaced sprue with a trial sprue bushing Mr. OE. Reoccur- Yes in time. What-The B insert pin on the fixed side broke. "SLIDE CORE A"
Why- Possibly heat? Not sure?
C/M-Replaced the B insert pin
Reoccur-yes What-The operator broke the plexiglass window in the door of the casting machine
Why-He tripped
c/m-Replaced the plexiglass
reoccur- No What. Ok chain conveyor jammed
Why: Chain bad
Counter measure: Replaced chain conveyor What:
6A0 m f-4 Bottom slide core cracked leaking water. 8,216 shots on slide core.
Why: Excess flashing from damaged cavity.
Cm: Replaced slide core.
Reocurr: likley in time. What: 1RKR Trim Die broken cutter
Why: Part double stacked
C/M: Remove broken cutter and bolt. Replaced broken cutter and replaced broken cutter What: Axis 4 faults, High
R/C: Die change, hoses not connected properly.
Countermeasure: Re-connect hoses, adjust "S" pot. for channel 4.
Will it Re-occur: Yes at die change. What: B-400 PC Malfunction Alarm What: Back door refractory failure
Why: Time
Counter measure: Patched refractory
R/c: Yes time What: Blue conveyor stopped
Why: Chain fell off
Counter measure: Tightened chain
R/C: No
Cycle time: Unchanged What: Bottom of ladle break out
Why: Unknown
C/M: Replaced 1 kg LAdle What: Change tip during changeover What: Checked die for blow out per JR otto. One rocker
Why: Having problems with blow outs
Counter measure: Die looked ok What: Cleaning heat exchangers. What: Completion of Countermeasure to prevent exhaust hood from drifting when safety door is opened
C/M: Installed new solenoid for brake activation for a new exhaust hood cylinder. Completed wirin What: Countermeasure work for exhaust hood drift when request to enter pressed
C/M: Fabricated and installed bracket for solenoid valve, mounted solenoid valve plumbed solenoid valve and hood cylind What: Cracked slide cores operator and helper side on Die 30 P part after 1750 parts.
Why: Crack is outside of acceptable limit.
R/C: Unknown good sufficient water supply however cooling joints t What: E-Stop Alarm on DCM that would not clear and reset required indication would not go out on DCM Operator Panel
Why: Wire 07621 broke at termination of the estop push button on DCM operator Pane What: E-stop condition on main console. 06810. What: Excessive backlash and slop in J6
WHy: Cross roller and harmonic drive NG and worn
C/M: Replaced Cross Roller Ring and harmonic drive. Zeroed J6 axis and recalibrated. What: Excessive blow back
Why: Premature wear to tip and sleeve.
R/C: Unknown
C/M: Replaced tip and sleeve verified lubrication and settings. All unremarkable. Shots on tip and sleeve 32,300
What: Excessive blowback
Why: Sleeve showed excessive grooving and scarring Sleeve at 65000 shots
C/M: Replaced sleeve inspected tip. Tip looked good and only has 10000 shots on it
Reoccurance: What: Flow Sensor Integration into Mold Heater
Why: To countermeasure human error causing overheating of dies
C/M: Installed Flow Sensor, added relay to monitor the condition of the mold heater dra What: HB slide core had chip out of it causing burr.
Why: Unknown, maybe bad part of slide core.
Counter Measure: Replaced slide core.
Reoccur: Yes time What: Ingot loader dropping ingot during loading
Why: Ingot get pulled back out when returning
Counter measure: Recovered and adjusted cushion down so ingots don't drop in furnace. Adjusted up sensor What: Install countermeasure for CU error with Maintenance code H50 Read out on the Remote I.O. Master TCCUHSC
Countermeasure: Per Toshiba: Install Jumper wire from SHIELD To FG (Earth ground)on the What: J3 Axis RV Reducer Replacement
Why: Blown seal on J3 RV Reducer found during PM
C/M: Replaced J3 RV Reducer, seals and bearings. Master and Calibrated J3- J6 axis. Greased J3 Axis. What: J3 Axis Rebuild RV Reducer Replacement and J5 Axis rebuild
Why: J3 Axis Rv Reducer had blown seal and a stripped plug on grease vent of RV reducer that was unable to be removed as it had falle What: Jam Ups On Unload OK Conveyor
why: side plates bent, bearings out of tensioner
c/m: Rebuilt unload ok conveyor rails and widened to fit chain tensioner parts that cause jam ups. installed new What: Ladle Bar Malfunction Alarms
Why: Build up of aluminum around lower ladle assembly mount causing probe to detect aluminum whne not in crucible
C/M: Cleaned moutn assembly of excess aluminum an What: Ladle Electrode Malfunction/ Ladle Electrode Broken Wire Alarms
Why: Ground Probe loose, broken wire at copper insert on bulb probe, retaining clip for ladle electrode wire had come loose all What: Ladle Electrode wire came out of catches to the front of ladle
Why: Wire came out of hangers and one hanger was missing
C/M: Replaced missing hanger untangled wire and routed properly throug What: Ladle not working in manual issue started during auto operation.
Why: G562 (Ladle Level Position) NC Contact untrue in logic preventing backward movement.
C/M: Manually cranked ladle out of La What: Ladle will not move from in crucible
Why:
C/M: Manually removed ladle from aluminum, tested no issue found during testing.
Reoccurance: Yes until cause is found
Cycle Time: Unchanged. What: Lift table issues.
Why: starting capacitor defective.
C/M: What: Line Filter Choke alarm.
Why: Line filter clogged
R/C:
C/M: Replaced line filter and tested ok. What: Loader issues
Why:
Counter measure: Cleaned light curtain and put prox sensor back in holder What: Locking Cylinder upgrade for exhaust hood why
Why: To prevent drifting of hood when Request to enter has been pressed
C/M: Replaced old cylinder with locking type cylinder installed new solen What: Lower Ladle unit locked up
Why: Lower ladle unit got dunked under aluminum "Probe unit didn't detect aluminum and didn't stop arm"
Root cause: No PM schedule on ladle units
C/M: Removed and ins What: Lower crucible filter mid section found floating.
Why: Unknown cause
Countermeasure: Dip out aluminum and remove all of old filter And install new filter
Reoccur: Filter failure occurances hav What: OK Conveyor jumped a tooth causing conveyor to jam
Why: Chain was excessively loose and caused chain to come off sprocket
C/M: Put chain back onto sprocket and adjusted tension to prevent reo What: OP and Helper slide cores cracked and out of spec.
Why: Unknown
R/C: Unknown
C/M: Verified all spray points, no changes made to squeeze master settings verified, verified spray lube concentrat What: OPerator reports soldering on P1 and P2 roller groove
Why: inspected die found tat P slide cores NG and the die is chipped at at P1 and P2 at the part.
C/M: Instructed DH to pull die due to t What: Ok conveyor bouncing at advanced end causing robot crashes
Why: Clutch set screws backed off allowing clutch to back off. Conveyor not making slow down sensor.
C/M: Retorqued clutch, secured What: Operator reports shot is crashing into trim press and is unable to get out of preheat shots. What: R/B not able to pick A60 parts
Why:
R/C:
Countermeasure:
Will it Re-occur: What: Rebuild robot hand per Craig Randalls REquest
Why: Excessive slop in hand
C/M: Performed complete rebuild of robot hand and bench tested What: Receptacle and plug broken for ingot lift table
Why: Forklift ran into receptacle and plug for the ingot lifter
C/M: Replaced receptacle and plug. Fabricated cover to reduce reoccurance. What: Replaced Robot Encoder Batteries What: Robot collision detect.
Why: Off shift moved trim blocks not in right position and possible teach points.
recur: Yes in time if associates adjust. What: Safety Project for upper crucible lid drifting when "request to Enter is hit"
C/M: Replumbed solenoid that was previously installed for the brake that is on the new cylinders to countermeasure What: Security noticed Molten Metal was alarmed for temp.
Why: Molten metal thermocouple was reading erratically and caused burner to shot off aluminum had begun to harden
C/M: Replaced thermocoupl What: Shots getting stuck in scrap press.
R/C: Groove joint was installed with too long of bolt causing excessive play in scrap press head.
C/M: Disassembled, installed new shorter bolt and tested. What: Slide Cores not getting advance indication on Toscast
Why: Slide Core Sensor lead wire bare and damaged on operator side and top slide reed switch read open
C/M: Replaced operator and top sid What: Soldering
Why: Aluminum build up
Counter measure: Cleaned die What: Spec issue
Why: Cracked slide core. S-2
Counter measure: Replaced slide core S-2 What: Spray Cartridge nozzle leaking.
Why: Spray Cartrdige spray valve sticking
C/M: Pulled valve cleaned reinstalled and tested. Ok What: Spray Cartridge water valve always supplying water
Why: Valves diaphragm is torn
C/M: started working
Reoccurance:Yes
Cycle Time:unchanged What: Spray valve leaking thru on spray cartridge
Why: Spray cartridge valve moveable side closest to operator side NG
C/M: Replaced valve, reinstalled spray cartridge and tested. OK
R/O: Yes in What: Trim press not trimming part
Why: Punch off not hitting part right
Counter measure: Adjusted robot position What: Turn table sticking an unable to turn.
Why: Pulled table top an inspected found clutch to be slipping under low load.
C/M: Tightened clutch pack and tested OK. Verified no other significant What: Upper crucible Metal Leak
Why: Crucible was cracked just below the spout Area of the crucible. Crucible was fully melted and nearly empty when metal leak detect alarmed occurred. Was likely lo What: Vacuum (Abnormal unreached to tank)
Why: Vacuum pump machine dropping vacuum pressure to low to recover fast enough for next shot
Counter measure: What: Water leak at 6A0 M Cavity 4 at slide core and flashing
Why: Slide core has cracked causing water leak on Cavity 4 bottom slide cores not moving freely causing flashing
C/M: Replaced slide co What: Water leak at sleeve cooling joint.
Why: Coolant joint cracked at threads going into sleeve
R/C: Sleeves female threaded hole for cooling joint does not appear to be drilled perpendicular to What: Will not master on What: Wings of ok conveyor removed to get Die Cast 4 running refer to W057890
Why: Awaiting parts to come in that are on order
C/M: Fabricated replacement wings and installed and tested on ok conve What: ladle brackets bent
Why: Lower unit of DC11 shaft that holds ladle to long
C/M: Took old lower unit original off 9 and replaced it with the inner parts from 11 and waiting for parts What: "Gouge" found in sleeve during change over
Why: Aluminum build up
C/M: change tip & sleeve
Recur: In time/wear What: #1 Axis faults
Why: #1 axis reading high
C/M: Bled squeeze master and checked settings with plex, adjusted accordingly What: #1 flipper broke
Why: Bolt fell out
Counter measure: Replaced bolt
R/C: Yes
Cycle time: Unchanged What: #2 Thermo coupler not reading movable side
Why: Thermo couple bad. Due to wire getting smashed by wire holder in back of die.
Counter measure: Replaced thermo coupler. Had to pull movable half
R What: #2 and #3 axis out in squeeze master ( Change over 5A2 PM)
Root cause: Temp setting on die and pod settings
Countermeasure: Adjusted temp (Mov low 293 to 331 and Fix low 265 to 385) and adjusted What: #2 and #4 Part detect sensor not admitting laser light on part
Counter measure: Replaced both with (YAMATAKE HP7-A13)
R/C: No What: #2 cav sticking in trim die
Why: Cavity #2 Pin Bushing bad
Counter measure: Pulled Die. 1 st shift die maintenance going to fix What: #2 squeeze pin chunking out parts
Why: not sure
C/M: Adjusted on time from .5 to .7
Recur: Possibly in time What: #3 cavity has dent. (Breather cover trim die)
Why: Trim die leaving mark and cracking part
Counter measure: Re worked spring pin that pushes part off of top of trim press has been rigged. Some o What: #3 part not coming out on table
Why: Evacuation chute broke dumping out to blue conveyor
Counter measure: weld chute plate back on
reoccur- in time What: #4 Axis out of spec: Low
Why:
C/M: Bled the squeeze master again & increased flow from 70 to 85 (#4 only) What: #4 flipper broke off in trim press
Why: Weld broke
Counter measure: Welded and aligned #4 flapper What: #5 unload table plastic disk bad
Why: Had hole in and was stopping table from turning
Counter measure: Replaced disk
R/C: No
Cycle time: Unchanged What: (1)Product detect #3 not working. (2)r/b not grabbing shot. (3) r/b wont go into trim press
Why:(1) power wire NG.on product detect sensor R/B position way off. (3) ?
c/m: (1) run new wire (2) t What: (Change over) from Chain tench sleeve to 1 rocker sleeve
Why: Different sleeve. Had broke cooling joint for 1 rocker
Counter measure: Replaced sleeve with used and put new cooling joint in slee What: (Die change for life) Tip and sleeve up for life
Root cause: Tip and sleeve life
Countermeasure: Replaced tip and sleeve
Reoccurrence: Yes life
Cycle time: Unchanged What: 1kg ladle needed
Why: Was missing off change over cart What: 2 Blown (operator) vacuum blocks
Why: Found die lube concentration (way) above specs
C/M: Drained die lube, cleaned tank, flushed system with in spec die lube. Checked die lube & vacuum filters What: 2 Spray cartage valves were stuck on
Why: Got gummed up inside
Counter measure: Replaced
R/C: Yes
Cycle time Unchanged What: 2 top slide cores dripping water
Why: Cracked
C/M: Replace slide cores
Reoccur: Yes timing What: 2nd passed down during start up of crucible seasoning, Melting furnace outer shellbehind dog house glowing red
whY: Upper refactory bricks from doghouse to furnace failed and a chunk fell out ca What: 2nd shift noticed pit was full, water leak
R/C: Found water leak from broken cooling joint on Sleeve
C/M: Removed broken area of old cooling joint, Retapped and installed new cooling joint, veri What: 2nd shift operator called for machine making unusual noise. casting pressure drops and biscuit is huge, faulting out robot
WHY: noise being heard by operator is from tip and sleeve when aluminum What: 3 Blown Vacuum blocks 2nd shift
Why:
C/M: Rebuilt vac block #120
Recur: Yes, timing What: 3 Broken bolts on ok conveyor
Why: Stress, wear
Countermeasure: Realigned conveyor rails and replaced bolts
Will problem reoccur: Possibly
Cycle time: No change What: 3 broken guides
Why: shot not sitting in press correctly
C/M: replaced all 3 guides
Recur: Possibly in time What: 5A2 die runner stuck in die
Why: Runner area badly chunked out
Counter measure: Polished area alot What: 5BA P, cavity 1 trim damage on backside of rocker shaft
Why: Cutter worn, die repaired. Decent amount of excess aluminum on back of rocker shaft. Causing it to snap off jagged rather than a clea What: 5BA P/S #6 Cracked P1 slide core quality said must be changed.
Why; Over 36,000 shots near shotlife.
Cm:replaced with new one.
Reocurr: Likely in time. What: 5BA P/S F-6 Cracked P2 slide core and slide core pin.
Why: Worn
Counter measure:Replaced both.
R/C: yes time
cycle time: Unchanged What: 5BA S cavity 1 crack
Why: Wear
C/M: Replaced cavity 1 slide core What: 5BA S-2 slide core chipped out
Why:
Counter measure: Replaced slide core with MM
R/C:
Cycle time: Unchanged What: 5BA S2 part chipping out Die 13 cavity 2
Why: Broken slide core
Countermeasure: Replace 5BA S2 OB,HT slide core
Reoccur: Possible What: 5BA Trim height
Why: Old curved cutters
Counter measure: Pulled trim die and put other trim die with new style curved raised cutters in it.
R/C: Yes
cycle time: unchanged What: 5YK baffle axis problems
Why: all axis's bouncing around. Pods needed adjusted
Counter measure: Adjusted flow on all pods
R/C: Yes due to setting for 5YK
Cycle time: Unchanged What: 6A0 M F-2 Slide core cracked leaking water.
Cause: unknown
Counter measure: replace with new one.
reoccur: likely What: 6A0-S Cavity 2 trim issues.
Why: Trim die needed adjusted to shot.
Countermeasure: Adjusted trim die 1 so that cavity 2 did not have a trim issue. What: 6A0-S cavity 2 mark on part.
Why: Cutters needed adjusted. Trim Die 1.
Countermeasure: Adjusted Cutters. What: A1 alarm on tower for furnace
Why: Main pug fell off
Counter measure: Attached plug What: ACC Servo valve no good.
Why: Valve Bad "NON INV. TOSHIBA0024"
C/M: Put rebuilt valve on
Recur: Possibly in time What: AL01 alarm on upper crucible
Why: Upper thermo coupler went bad
Counter measure: Replaced thermo coupler
R/C: Yes time
Cycle time: Unchanged What: AL20 alarm on upper crucible
Why: Faulty thermocouple
C/M: Replaced thermocouple
Reoccur: yes timing What: AOL fault on temperature controller for the lower crucible
Why: Bad lower crucible thermocouple
C/M: Replaced thermocouple
Reoccur: Yes timing What: Abnormal Sensor on ok conveyor
Why: slow up sensor and the up sensor both on
C/M: Cleaned off and adjusted
Recur: Possibly in time What: Above normal Tonna V68 lubrication oil usage
Why: Found large amount of oil on a distribution manifold
C/M: Tightened all lines in and out of manifold. Afterwards, found a flex line that was le What: Absolent Filter checks 11A and 11C were out of spec
Why: Filter life
Countermeasure: Replaced both lower and upper level filters What: Access PLC What: Accumulator oil would not fill after checking nitrogen, vacuum trouble
Why: Unknown
R/C: No proper training on accumulator
Will it reoccur: Yes
Cycle time: No change What: Added guarding to side of trim press
Why: Missing
Counter measure: Added guarding to trim press side closest to scrap conveyor What: Added improvement for vacuum block cleaning
Why: Vacuum problems
Counter measure: Added lines to vacuum pump for vacuum block pistons cleaning. Set vacuum pump pistons cleaning to 3.00 sec
R/C: What: Added vacuum improvement for vacuum block cleaning
Why: Vacuum problems
Counter measure: Added lines to vacuum pump for vacuum block pistons cleaning. Set vacuum pump pistons cleaning to 3.00 se What: Adjusting pin on cavity 1 issues
Why: Out of spec
C/M: Matched flow on axis 1 to the others, which threw the shaft hole squeeze pin depth out. Adjusted back down to 60% and parts were running in What: After Change-over part detect was out of alignment.
Root cause: After change-overs normally move sensors so that for each model the parts are detected.
Countermeasure: Adjusted sensors and part What: After changeover, slide cores, OP side, very noisy & won't move out. Also, no tip on plunger shaft
Why: Plunger shaft extension broke inside tip. Unknown why for the slide cores not moving
C/M: What: After changing over from 6MA-Tens. to 59B-Tens. Casting Pressure Low.
Why: Needed nitrogen.
Countermeasure: What: After cleaning their die as they are right now (every 2 hours)called for me to look at.
Why: Both bottom slide cores not moving.
Countermeasure: Cleaned so that slide cores moved.
Will Problem R What: After die change ejector pins not working
Why: After determining reed switches were ok, Found broken wire in cable going from FixCore1 reed switch junction box to terminal box on M/C
C/M: Replac What: Air blow function of spray cartridge does not operate, intermittent issue.
Why: Spray cartridge control I/P X36 does not drop out due to die cast M/C I/P X44B not going true.
C/M: Replaced Spray What: Air blow not blowing all time
Why: Solenoid no good
C/M: Replaced with new What: Air blow not consistently coming on after trim press cycle
Why: Found loose connection at relay base
C/M: Tightened screw for output wire on relay base (Y06F) What: Air blow on spray cartridge not working
Why: Output voltage from PLC rack for air blow solenoid (Y011) is 60VAC, should be 110VAC Solenoid doesn't get enough voltage for operation. PLC is out of What: Air cylinder stopped in trim press
Why: Melted air lines> Due to part hitting
Counter measure: Replaced line and put insulator around line
R/C: Yes time
Cycle time: Unchanged What: Air leak
Why: Air Regulator
Countermeasure: Replaced air regulator
R/C: No
Cycle time: Unchanged What: Air leak
Why: Air bowl at plunger lube line leaking
Counter measure: Replaced bowl
R/C: No
Cycle time: Unchanged What: Air leak
Why: Air bowl cracked for plunger lube
Counter measure: Replaced bowl
R/C: No
Cycle time: Unchanged What: Air leak
Why: Air bowl leaking
Counter measure: Replaced bowl
R/C: No
Cycle time: Unchanged What: Air leak
Why: Air bowl split
Counter measure: Replaced
R/C: No
Cycle time: Unchanged What: Air leak
Why: Air bowl split
Counter measure: Replaced bowl
R/C: No
Cycle time: Unchanged What: Air leak
Why: Air line at product detect had a hole in it
Countermeasure: Trim air line back and reconnect What: Air leak
Why: Air separator bowl split
Counter measure: Replaced bowl
R/C: No
Cycle time: Unchanged What: Air leak
Why: Broken Bowl assembly
C/M: Replaced bowl What: Air leak
Why: Broken air bowl
Countermeasure: Replace air bowl
Reoccur: No What: Air leak
Why: Hose to spray cartage up down cylinder leaking
Counter measure: Replaced hose What: Air leak
Why: Main air line to spray cartage had hole in it
Counter measure: Replaced line What: Air leak
Why: Pusher 1 solenoid valve got aluminum on it and burned hole in it
Counter measure: Replaced solenoid valve
R/C: NO
Cycle time: Unchanged What: Air leak
Why: Regulator bowl busted/cracked
C/M: Replaced with new
Recur: In time What: Air leak
Why: Robot air bowl cracked
Counter measure: Replaced bowl What: Air leak
Why: Scrap conveyor missing paddles
Counter measure; Replaced hose and welded plights in conveyor and guards back on What: Air leak
Why: Shot fell off of scrap conveyor and hit fitting at regulator for flipper air line
C/M: Replaced broken air fitting What: Air leak
Why: Air bowl broken
Countermeasure: Replace air bowl
Reoccur: Possible What: Air leak & Vacuum failure alarm
Why: Plunger lube system: air regulator bowl cracked. Blown vac. blocks RB & OP
C/M: Replaced air bowl. Replaced dirty vac. filter & cleaned vac. screens which we What: Air leak around ingot loader area
Why: Ingot loader air supply line damaged
Countermeasure: Repaired line What: Air leak at ingot pusher
Why: Pipe broke
C/M: Put new pipe in and reconnected
Recur: Possibly in time What: Air leak at product detect.
Why: Hose had hole.
Countermeasure: Replaced hose. What: Air leak at robot
Why: water separator bowl cracked
Counter measure: Replaced bowl and cleaned fan
R/C:
Cycle time: Unchanged What: Air leak on plunger lube line
Why: Broken air fitting on line in valve
Countermeasure: Replaced air fitting and trimmed back line
Will problem reoccur: Possibly
Cycle time: No change What: Air leak trim press
Why: Hole in hose
Counter measure: Replaced hose What: Air leak trim press
Why: Part burn hole in hose
Counter measure: Replaced hose What: Air leak.
Why: Air bowl broke.
Countermeasure: Replaced air bowl under platform. What: Air leaks
Why: Air bowl cracked
C/M: Replaced 2 air bowls What: Air line oiler leaking (check #32A)
Why: Bowl cracked
Countermeasure: Replaced unit What: Air line to robot chuck popping out
Why: Someone put speed control valves in middle of air lines
Counter measure: Replaced air lines to robot chuck fingers. Took out speed control valves
R/C: No What: Air line to scrap press fell off
Why: Air to scrap press blow off was direct from air compressor.
Counter measure: Rerouted on other side of regulator
R/C; Yes time
Cycle time: Unchanged What: Air low fault.
Why: Air to plunger lube solenoid came off. Solenoid stuck on.
Countermeasure: Replaced damaged air fitting. Installed air line. Solenoid DG60 Replaced. Replaced lube fitting. What: Air solenoid for tower lid got broke
Why: Operator dropped ingot on it
C/M: Replaced with new What: Air trim press alarm
Why: Trim goes down but don't come up. Due to air lines on backward
Counter measure: Flipped air lines What: Al01 alarm on furnace melting
Why: Thermo coupler wire got smashed in lid
Counter measure: Ran new wire and seal tight
R/C: No
Cycle time: Unchanged What: Alarm B-552 Speed ACC filling malfunction
Why: Servo valve bad
Counter measure: Replaced Servo valve
R/C: in time
Cycle time: Unchanged What: Alarming out at trim press
Why: Position was off
Counter measure: Touched up P78
R/C: Unknown
Cycle time: Unchanged What: Alban asked for assistance in figuring out why jam detect sensor on scrap conveyor 2 is not working properly
Why: Sensor NG, program rewritten with X93 taken out (found backup when X93 was still What: All 4 Ejector pins out of spec measuring -0.090
Why: Ejector pins not retracting far enough
C/M: Removed material from the end of the ejector pins What: All four cavities getting crushed. What: All parts coming out on the NG conveyor from the trim press
Why: Robot type set on wrong program
Countermeasure: Set robot to correct program What: All parts dropping parts out back
Why: Robot not set to 4 parts
Counter Measure: Flipped switch from 2 to 4 What: All sections of diecast machine shutdown
Why: CBR01 and CBR2 breaker trip
R/C:
C/M: Reset breakers that were tripped, passed down to 2nd shift for follow up
Plugged cable DENC5 back in. Replac What: Aluminum Build up on collar on sleeve.
Why: Collar moved.
Countermeasure: Cleaned and adjusted collar. Drilled out plunger lube spry tip.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Aluminum build up on ladle probes
Why: ?
C/M: Replaced with rebuilt probes we used stainless steel all-thread
Recur: Possibly in time What: Aluminum built up under tip/ large biscuit size.
Why: 90 degree was off on ladle ,also shot delay to fast.
C/M: Adjusted the 90 and slowed down the shot delay from 3-5 and the in furnace time fr What: Aluminum failed K-Mold testing Repeatedly
Why: Left side crucible filter mount broke off into the holding side of the crucible. This filter mount was visibly cracked after the power outage but w What: Aluminum flow into bottom of furnace
Why: Crucible spout broke
C/M: Replace crucible
Recur: Possibly in time What: Aluminum in die
Why: Ladle was left with aluminum in it and hardened. Caused small shot
Counter measure: Pulled die
R/C: No
Cycle time: Unchanged What: Aluminum leak
Why: Lower crucible broke
Counter measure: Replaced lower crucible What: Aluminum leak
Why: Over flow
Counter measure: Cleaned up and reheated What: Aluminum leak (crucible)
Why:
Counter measure:
R/C:
Cycle time: Unchanged What: Aluminum leak back door
Why: Lip of furnace missing
C/M: Re-patch backdoor
Recur: Yes in time What: Aluminum leak detect broke for holding crucible.
Root cause: There was a leak at holding crucible and leak detect rod broke off during the leak.
Countermeasure: Welded leak detect rod to make it What: Aluminum leaking from behind the half pipe dog house What: Aluminum leaking from in between dog house and furnace face
Why:Corundum build up in half pipe area forcing doghouse away from furnace face
Counter measure: Removed dog house, Removed corundum What: Aluminum not flowing through filter
Why: Buildup on back of filter
C/M: Lightly scraped filter to get aluminum flowing What: Aluminum over flow
Why: Operator left loader on at end of shift
C/M: Chipped out the aluminum in leak door and put new metal leak probes in What: Aluminum seized in sleeve
Why:?
C/M: Replaced tip and sleeve
Recur: Possibly in time What: Aluminum upper level probes
Why: Aluminum corrosion
C/M: Replaced with new
Recur: In time What: Aluminum upper limit probe wire broken
Why: Wear
Countermeasure: Reterminated both wires What: Asked by Corey to replace OK conveyor belt for cavity 3/4
Why: Belt severely worn, missing pieces
C/M: Checked bearings, felt OK. Replaced idle sprockets and drive sprockets and belt What: Asked by Taka and Mihara to remove old NG chute and OK chute for new model update to trim press
Why: Needed support, project behind
C/M: Removed chutes per their request What: Asked to investigate issue with dropping parts
Why: Found excessive oil on top of die beneath squeeze pin fittings, found channel 1 male connector worn and hose loose.
C/M: Replaced male fittin What: Assist IT contractors. What: Assist IT's contractors with accessing Control cabinets. What: Assist Travis What: Assisting DH with removal of stuck plunger
Why: Plunger stuck in die
C/M: Removed die and unbolted front half of plunger, also changed sleeve What: At Trim-press after changing over to RPY In-M high trim on parts in cavity 1 and 2.
Root cause: Cutter adjustment and dull cutter.
Countermeasure: Adjusted cutters and replaced the cutter on cav What: Auto oiler hose broke for die close joints
Root cause: Wear over time
Countermeasure: Replaced
Reoccurrence: Time
Cycle time: before 25.7 after 25.7 What: Auto/T1/T2 key broke on the robot panel
Why: Overtime the set screw comes loose
Countermeasure: Took key apart and repaired tumbler. OK What: Axis #1 and #2
Why: Pressure on #1 and #2 were at 16.5 in line display when they should have been at 14.7.
Counter measure: Adjusted pods
R/C: Yes
Cycle time: Unchanged What: Axis #2 alarms
Why: Multiple problems 1st was line were wrong. 2nd was pressure was 11.5 should be 2.0
Counter measure: Reset pods and fixed lines
R/C: No
Cycle time: Unchanged What: Axis 1,2,3 and 4 alarms. Cycle Time Over. Line pressure malfunction. What: Axis 2 Alarms
Why: Possible die getting to hot
C/M: Pulled thermocouple out adjust and to make sure bottomed out
Recur: Possibly in time What: Axis 2 and 4 problems
Why: Die issue
Counter measure: Pulled die What: Axis 2 counting in idle
Why:
Counter measure: What: Axis 2 faults.
Why: Air in line.
Countermeasure: Bleed it. Also switched hoses the top and bottom hose on Axis 4 because they where coming apart.
Will Problem Reoccur?: Yes.
Cycle Time: No Cha What: Axis 2 issue
Why: Axis 2 doesn't stop counting
Counter measure: What: Axis 2 issue
Why: Bad DCV
Counter measure: What: Axis 3 alarms
Why: Directional control valve bad for channel 3
Counter measure: Replaced DCV
R/C: No
Cycle time: Unchanged What: Axis 3 alarms
Why: Flow too high on axis 3 pods
Counter measure: Adjusted zero on all pod to even out
R/C: Yes
Cycle time: Unchanged What: Axis 3 alarms
Why: Hydraulic line got a hole in it
Counter measure: Replaced hose
R/C: No
Cycle time: Unchanged What: Axis 3 alarms
Why: Squeeze master flow was setting wrong
Counter measure: Set setting flow from 80 to 90 in plex.
R/C: No
Cycle time: Unchanged What: Axis 3 alarms
Why: Squeeze pin came loose
Counter measure: Tightened pin and used lock tight
R/C: No
Cycle time: Unchanged What: Axis 3 alarms (59B - 1Rocker Die #1)
Why: Tappet cylinder leaking Robot side bottom
Counter measure: Change die to 59B - 1Rocker Die #4
R/C: No
Cycle time: Unchanged What: Axis 3 alarms and part sticking to squeeze pin.
Why: Pressure and flows don't match settings in squeeze master. From line display which is actual running to setting screen. (Its like doing a off What: Axis 3 alarms.
Root cause: Squeeze master needed bleed.
Countermeasure: Helped Bleed Squeeze Master.
Will Problem Reoccur?: Likely when die change or model change. What: Axis 3 out of spec.
Why: Air in line
Counter measure: Bled line
R/C: Yes
Cycle time: Unchanged What: Axis 4
Why: Bleeding off
Root cause: Upper manifold hydraulic coupler loose
Counter measure: Tightened fitting
R/C: Yes if starts leaking again
Cycle time: Unchanged What: Axis 4 alarm
Why: Hydraulic leak. Hose got hole in it
Counter measure: Replaced hose
R/C: Yes time
Cycle time: Unchanged What: Axis 4 dropping out
Why: Hydraulic hose and fitting leaking
Countermeasure: Replaced hose and repaired fittings
Will problem reoccur: Possibly
Cycle time: No change What: Axis 4 problem
Why: Squeeze pin come loose
Counter measure: Took squeeze pin out and locked tightened it What: Axis Alarms
Why: Needed re-bled
C/M: Bled lines
Recur: possibly in time What: Axis alarm channel #3
Why: Lines were wrong on top of die. Color coated wrong
Counter measure: Changed lines and color coated right
R/C: No
Cycle time Unchanged What: Axis alarms after change over
Why: All axis reading 0
C/M: Cycled power, axis now normal What: Axis alarms, vacuum trouble
R/C: Air in squeeze master, low on nitrogen
C/M: Line bled lines and rebleed squeeze master lines, Added nitrogen and replaced blown vacuum hoses cleaned filters
Will What: Axis and casting alarms
Why: Blow out on robot side vacuum block and chill block
Counter measure: Pulled die to have it spotted
R/C: No
Cycle time: Unchanged What: Axis and casting pressure problems. (RPY Die 5 one RKR)
Why: Sprue bushing leaking water
Counter measure: Replaced sprue bushing
R/C:
Cycle time: unchanged What: Axis and pressure build up alarms
Why:
Counter measure: What: Axis issue What: Axis problem
Why: All axis's high
Counter measure: Replaced 2 spray valves that were leaking bad and sprue bushing cracked What: Axis problem
Why: Pods needed adjusted
Counter measure: Set pods and adjusted pressure knob to fixed slide cores for tappet pins. 8.5 to 7.5
R/C: No
Cycle time: Unchanged What: Axis problem
Why: Pods out of adjustment
Counter measure: Adjusted pods
R/C: Yes
Cycle time: Unchanged What: Axis problem #4 and #2
Why: #4 bad hose and fitting. #2 think hose was pinched
Counter measure: Replaced hose and un pinched other hose.
R/C: Yes
Cycle time: Unchanged What: Axis problem (5BA One rocker die 12)
Why: Bent squeeze pin on helper side bottom
Counter measure: Pulled die
R/C:
Cycle time: Unchanged What: Axis problem after change over
Why: Pods out of adjustment.
Counter measure: Adjusted pods. And changed suction filter
R/C: Yes we have to adjust for baffle die
Cycle time: Unchanged What: Axis problems
Why: Change over from baffle to one rocker. Squeeze master pods are adjusted for baffle and have to be adjusted back
Counter measure: Adjusted pods flow and pressures
R/C:
Cycle t What: Axis problems
Why: Change over from baffles. pressures wrong
Counter measure: Adjusted pods to 14.7 pressure. Was 13.5 What: Axis problems
Why: Cracked sprue bushing
Counter measure: Replaced bushing
R/C: No
Cycle time: Unchanged What: Axis problems
Why: Pods out of adjustment
Counter measure: Adjusted pods
R/C: Yes
Cycle time: Unchanged What: Axis problems
Why: Program in machine wrong. Running 5A2 S. Had settings for 5A2 P/M program in S program
Counter measure: Set to Plex settings for 5A2 S 250 ton
R/C: No
Cycle time: Unchanged What: Axis problems
Why: Changed back to 1RYR from baffles
Counter measure: Bled and had to adjust pods
R/C: Yes when we go to baffles
Cycle time: Unchanged What: Axis problems after die change
Why: Operator side bottom squeeze pin not moving right
Counter measure: Replaced pin bushing and cylinder Cavity #4
R/C:
Cycle time: Unchanged What: Axis problems. All jumping up
Why: Water was off to tip and tip was really loose
Counter measure: Replaced tip
R/C: No
Cycle time: Unchanged What: B temp alarming
Why: fixed side thermocouple NG
Counter measure: replace thermocouple
R/C: no What: B-031 Move Core 2 Limit Switch Malfunction.
Why: Operator side slide core sensor wire broken.
Countermeasure: Replaced Operator side slide core sensor. What: BC cavity 3 out of spec part seems bent.
Why: Part dragging on fixed side at bottom of ring. Had very small soldering. Gave part to Roy Team leader and marked it
C/M: Polished cavity
Recur: Pos What: Back door broke
Why: Roller guide broke off stripped out hole
C/M: Replaced door
Recur: Possible in time What: Back door cylinder bracket broke
Why: Unknown
C/M: Re-welded
Recur: In time What: Back door fell off
Why: Door fell apart
Counter measure: Replaced door and cylinder
3rd- removed dogs and fittings from old door and cylinder, dogs installed on new door.. What: Back door not closing
Why: Robot not home
Counter measure: Homed robot What: Back door not making limit switch
Why: Adjustment out
C/M: Adjusted limit switch and adjusted air pressure
Recur: Yes What: Back door on furnace leaking
Why: Wear
Counter measure: Patch door
R/C: Yes
Cycle time: Unchanged What: Back door on melting furnace had big chunk fall out
Why: Unknown
C/M: Re-patch
Recur: In time What: Back door patch falling out
Why: excessive jackhammering on backdoor nobody knows the correct way to jackhammer
C/M: Had to jackhammer and patch
Recur: Yes in time What: Back door refractory to furnace broke out
Why: Unknown
Counter measure: Patched
R/C: Yes
Cycle time: Unchanged What: Back door was slamming
Why: Cylinder has bad piston seal.
Counter measure: Replace cylinder
R/C: Yes time
Cycle time: Unchanged What: Back door will not open and close
Why- circuit board NG
Counter measure- replace circuit board
R/C: in time
Cycle time: Unchanged What: Back helper door wont move
Why: Mounting bolts for door cylinder fell out
Counter measure: Replaced bolts
R/C:
Cycle time: Unchanged What: Back helper door broke
Why: Cylinder went bad and slammed door open and broke limit sensor guide rail off door
Counter measure: Replaced cylinder and bolt for rail
R/C: Yes time
Cycle time: Unch What: Back helper side door issue
Why: Cylinder bracket came loose
Counter measure: Re attached What: Back ingot door losing close light
Why: Bad solenoid
Counter measure: Replaced solenoid What: Back robot side door wouldnt close
Why: Robot not at home position
C/M: Returned robot to home and explained to operator why door would not shut
Recur: Possibly in time What: Backdoor Drifting up
Why: Cylinder blowing by
C/M: Replaced cylinder
Recur: Possibly in time What: Backdoor Safety door switch on ingot loader no good
Why: Inside mechanism broke
C/M: Replaced mechanism
Recur: Possibly in time What: Backdoor and side door Re-patch
Why: Operator Error
C/M: Replace refractory on both
Recur: Yes in time What: Backdoor and side door damage to the furnace
Why: Excessive jackhammering and possible not knowing how to clean furnace correctly
C/M: Re-patched furnace
Recur: Yes in time What: Backdoor closing and opening slow
Why: flow controls closed to much
C/M: we opened up the flow control valves more and tested now ok What: Backdoor cylinder bracket broke off
Why: Been welded many times and just broke rest of bottom off door
C/M: Travis and I Replace entire door with one we had made had to remove all hardware to n What: Backdoor cylinder drifting down in auto/ and ingot conveyor over travel
Why: Backdoor cylinder blowing by/ And sensor not reading ingots
C/M: Replaced cylinder and adjusted sensor up. What: Backdoor cylinder shaft bracket keeps falling off
Why: Not sure bolts keep falling out
C/M: Tack welded the bracket to the door
Recur: No What: Backdoor leaking aluminum
Why: material worn at edge
C/M: jack hammered both side door and backdoor
Recur: yes in time What: Backdoor not shutting good
Why: Guide rail rollers not touching rails and air controls no good
C/M: Fixed the rail rollers then had to search for flow controls that we do not have so i took from What: Backdoor of furnace NG
Why: Chunk of side wall broke out
C/M: Needs re-patched
Recur: Yes What: Bad blow back and axis problems
Why: Tip and sleeve worn
Counter measure: Replaced tip and sleeve
R/C:
Cycle time: Unchanged What: Bad blow back. (Safety issue)
Why: Lack of lube. Bucket was low
Counter measure: Replaced tip and filled bucket
R/C Yes if no lube
Cycle time: Unchanged What: Bad large water line.
Why: Several large bubbles in it. (safety issue)
Countermeasure: Replaced bad line. What: Bad parts not coming out into tub
Why: NG conveyor mesh belt broke
Counter measure: Replaced mesh belt
R/C: Yes
Cycle time: Unchanged What: Bad pour at sleeve
Why: Sleeve was turned
Counter measure: Turned sleeve and adjusted lube line
R/C:
Cycle time: Unchanged What: Bad shot sensor on DC1
Why: Big scratch on surface face of sensor
C/M: Taking shot sensor from Die cast 4 putting on DC1 What: Bad slide cores S-1 and P-1
why: radius out on both
c/m: replaced both slide cores on 5BA p and s die F-12 What: Bad solder on slide core 4
Why: Slide core was removed and used all clean on back side but didn't work
C/M: Replaced slide core
Recur: Yes, in time What: Bad spray valves for spay cartage
Counter measure: Replaced 2 What: Bending the shot.
Why: Sticking to the tip.
C/M: Replaced the tip and sleeve.
Recur: In time. What: Bent Chuck arm on robot
Why: Biscuit to big robot crashed into biscuit. Why: Going from 1 RKR to 6AO Die
C/M: Replaced arm and operator is to do more preheat shots till biscuit is right size
Re What: Bent end of arm tooling
Why: Biscuit very big robot went in to get and hit biscuit
C/M: Replaced end of arm tooling and let operator know to run more preheats to assure biscuit is normal What: Bent part
Why: Squeeze pin sticking in part when die separates
Counter measure: Bled squeeze master What: Bent part Cavity #4 Breather cover
Why: Unknown
Counter measure: Made temp low so water would run all time for trial. Only 5 degrees under original temp What: Bent part cavity#2
Why: Cavity needs polished
Counter measure: Adjusted air blow point and polished cavity#2.
R/C: Yes
Cycle time: Unchanged What: Bent parts Cavity #3 and #4
Why: Part sticking
Counter measure: Cleaned die and polished Cavity # 3 and Cavity #4
R/C: Yes
Cycle time: Unchanged What: Bent parts F4-2 Chain tench
Why: Bad spot in die
Counter measure: Polished die What: Bent parts. Breather cover
Why: I'm not sure witch thermo coupler we are reading off of both sides have 2 and we only use one. don't show in plex. But after in put tip and sleeve in I noticed th What: Bent robot arm
Why: Hit shot
Counter measure: Replaced arm What: Bent slide core pin tappet pin 5BA S2 die #8
Why: Unknown
Countermeasure: Replace pin
Reoccur: Possible What: Big Scrap conveyor jamming
Why: 2 Cross members broke in conveyor. Damaged chain conveyor belt
Counter measure: Replaced Chain conveyor welded plights to belt and replaced cross members
R/C: Yes What: Big Scrap conveyor stopped
Why: Came off of sprocket
Counter measure: put back on sprocket and un-jammed
R/C:
Cycle time: Unchanged What: Big bang noise from sleeve area
Why: Tip came loose. It bent injection rod and damaged sleeve
Counter Measure: Replaced injection rod, tip, and sleeve. Had operator run injection rod to break in What: Big conveyor issue
Why: Balling up shots
Counter measure: Un balled shots What: Big conveyor issue
Why: Jammed up
Counter measure: Un jammed What: Big conveyor jammed
Why: 2 Links broke
Counter measure: Replaced links.
R/C: Yes time
Cycle time: Unchanged What: Big conveyor link broke
Why: Piece got in and broke link
Counter measure: Replaced 3 links and 6 cotter keys
R/C: Yes
cycle time: Unchanged What: Big conveyor motor overload
Why: Had aluminum jammed at far end
Counter measure: Unjammed
R/C: Yes
Cycle time: Unchanged What: Big conveyor not moving
Why: Links broke
Counter measure: Replaced 2 links and rods What: Big conveyor skipped tooth
Why: Jammed up
Counter measure: skipped back on and tightened belt
R/C: Yes time
Cycle time: Unchanged What: Big conveyor stopped
Why: Main breaker to conveyor tripped
Counter measure: Re set breaker What: Big scrap conveyor
Why: Bad key ways
Counter measure: Replaced 12 rods and 10 rollers 65 cotter pins What: Big scrap conveyor alarm
Why: most of cotter keys missing on trimpress side
Counter measure: Replaced conveyor belt and cut metal that was rubbing them off
reoccur- in time What: Big scrap conveyor alarming motor over load
Why: Scrap stuck in conveyor
Counter measure: Un jammed scrap What: Big scrap conveyor got jammed up
Why: Piece of aluminum go into the drive sprocket
Countermeasure: Cleaned it out
Will problem reoccur: Possibly
Cycle time: No change What: Big scrap conveyor jammed
Why: Big runner jammed in it
Counter measure: Un jammed and tightened chain from motor What: Big scrap conveyor jammed
Why: In side falling apart
Counter measure: Pulled another cross member What: Big scrap conveyor jammed up
Why: Side rail fell off and jammed shots under it
Counter measure: Removed and drilled and tapped new holes
R/C:
Cycle time: Unchanged What: Big scrap conveyor jammed up. (Bad)
Why: worn out guide rail and broken rod
c/m: Tore down and had to fix base and rails
R/C: Yes they raise too high
Cycle time: Unchanged What: Big scrap conveyor jamming
Why: Missing links/bent rods. Conveyor worn and falling apart
C/M: Replace missing link and rollers, pulled broken piece of track out causing conveyor jam What: Big scrap conveyor motor alarm
Why: Jammed up
Counter measure: Un Jammed and monitored
R/C:
Cycle time: Unchanged What: Big scrap conveyor motor overload alarm
Why: Broke links
Counter measure: Replaced 2 links and 10 keys and 1 rod
R/C: Yes
cycle time: Unchanged What: Big scrap conveyor stopped
Why: 18 Cotter keys broke off of links. 7 Links broke. 4 rods bent
Counter measure: Replaced keys links and rods
R/C: Yes time
Cycle time: Unchanged What: Big scrap conveyor stopping
Why: Cotter pins broke off 16 of them all on trim press side
Counter measure: replaced all pins
R/C:
Cycle time: Unchanged What: Biscuit Alarms.
Why: Small biscuit, aluminum pouring on sleeve.
Countermeasure: Adjusted the sleeve, collar and plunger lube nozzle.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Biscuit Size Varying. What: Biscuit alarms ladle pouring very little aluminum
Why: 90 degree was off
C/M: taught 90 and adjusted biscuit size
Recur: Possibly in time What: Biscuit bouncing and blow back
Why: Tip worn
Counter measure: Replaced tip
R/C: Yes time
Cycle time: Unchanged What: Biscuit bouncing around
Why: Lower bearing bad in ladle
Counter measure: Replaced lower unit What: Biscuit bouncing around
Why: Lower ladle unit
Counter measure: Replaced lower unit
R/C Yes time
Cycle time: Unchanged What: Biscuit breaking off
Why: Possible sleeve getting to hot and burning off most plunger lube
C/M: I suggested drilling for sleeve cooling joint sleeve temp almost 670 degrees
Also changed tip and What: Biscuit breaking off when die opens
Why: Plunger lube spray is no good
C/M: Dh Matt Fossen is making a bracket for lube line and with nozzle not just pipe so it didnt quite work out so i had to What: Biscuit issue
Why: Ladle hitting filter and messing with fine pour
Counter measure: Cleaned filter What: Biscuit issue
Why: Under pour at sleeve
Counter measure: Turned sleeve What: Biscuit ripped off
Why: Biscuit sticking to tip
Counter measure; replaced tip
R/C:
Cycle time: unchanged What: Biscuit size fluctuating
Why: Operators couldn't get biscuit size down any lower
Countermeasure: Adjusted fine spill and shot weight to dial in biscuit What: Biscuit size jumping.
Why: Blow Back.
Countermeasure: Replaced tip.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Biscuit size not consistent.
Why: Going low and then high.
Countermeasure: Reset 90 on the Pour. What: Biscuit size problems
Why: Ladle lower unit chains loose
C/M: Adjusted chains on ladle lower unit and also adjusted shot weight What: Biscuit size unstable
Why: Worn tip & sleeve
C/M: Changed tip and sleeve What: Biscuit size variance
R/C: Upper ladle bearing not seated in housing
C/M: Removed whole ladle arm assembly and inspected, reinstalled retaining ring on upper bearing housing
Will it reoccur: T What: Biscuit sticking to fixed side of die when die opens
Why: No plunger lube was being sprayed
C/M: Opened up plunger lube valve to bleed line and then reset valve back to its original position. What: Biscuit thickness alarms.
R/C: Injection timing off and turn buckles were loose.
C/M: Tightened turn buckles then we powered down then back up and did a V check.
R/O: Maybe if ladle goes out or What: Biscuit thickness alarms/air leak
Why: Ladle pour position needed adjusted/ main air line for spray cartridge blown
Countermeasure: Adjusted ladle pour position +1.0 mm/ replaced air line
Will p What: Biscuit thickness varies.
Why:
C/M: What: Biscuits thickness
Why: Ladle arm bearings were bad
Counter measure: Replaced arm with rebuilt one
R/C: Yes time
Cycle time: Unchanged What: Blow Back.
Why: Worn tip.
Countermeasure: Replaced tip, verified plunger lube - Good.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Blow back
Why: Plunger line got plugged
Countermeasure: Unplugged line replaced tip and sleeve
Sleeve was changed during "DIE CHANGE"
R/C: No
Cycle time: Unchanged What: Blow back
Why: Ran without water
C/M: Replaced Tip and Sleeve
Recur: In time What: Blow back
Why: Sleeve had bad washout
C/M: Replaced with new
Recur: Possibly in time What: Blow back
Why: Sleeve had build up inside from wash out
C/M: Replaced both tip and sleeve
Recur: In time What: Blow back
Why: Tip and sleeve. Life
Counter measure: Replaced tip and sleeve
R/C: Yes time
Cycle time: Unchanged What: Blow back
Why: Tip worn
C/M: Replace tip
Recur: Yes timing What: Blow back
Why: Tip worn
C/M: Replaced tip
Recur: In time What: Blow back
Why: Tip worn
C/M: Replaced tip
Recur: Possibly in time What: Blow back
Why: Tip worn and not being able to move freely in sleeve
C/M: Replaced tip and cleaned out coupler had sludge and debris build up inside
Recur: Possibly in time What: Blow back
Why: Worn tip and sleeve
Counter measure: Replaced Tip and sleeve What: Blow back
Why: sleeve worn
C/M: Replaced tip and sleeve
Recur: Yes What: Blow back
Why: worn, wash out
C/M: Replaced tip and sleeve
Recur: In time What: Blow back
Why:Tip worn
C/M: Replaced tip
Recur: yes What: Blow back
Why: Tip and sleeve worn
C/M: Pulled and replaced tip and sleeve
Will it reoccur: Timing
Cycle time: unchanged What: Blow back and Flashing
Why: Tip and sleeve worn
C/M: replaced both with new
Recur: Possibly in time What: Blow back and Vacuum
Why: Tip
Countermeasure: Replaced Tip (41002 shots on tip)
R/C: No
Cycle time: Unchanged What: Blow back and Vacuum faults
Why: Sleeve and tip bad. 102000 shots
Counter measure: Replaced tip and sleeve
R/C: Yes time
Cycle time: Unchanged What: Blow back and flame out of sleeve
Why: ?
C/M: Replaced tip and sleeve Tip- 4300 Sleeve-10,600
Recur Possibly in time
3RD TIME THIS MONTH SLEEVE HAS BEEN CHANGED OUT. What: Blow back and flashing
Why: Tip and Sleeve worn
C/M: Replaced both with new
Recur: Yes in time What: Blow back and flashing
Why: worn tip
C/M: Replaced tip
Recur: in time What: Blow back at sleeve
Why: Bad tip and sleeve ran without plunger lube
Counter measure: Replaced tip and sleeve
R/C: Yes time
Cycle time: Unchanged What: Blow back from sleeve
Why:
Counter measure: Replaced tip
R/C:
cycle time: Unchanged What: Blow back from tip
Why: Worn
Counter measure: Replaced tip
R/C: Yes time
Cycle time: Unchanged What: Blow back from tip and sleeve
Why: Lube line had hole in it
Counter measure: Replaced tip and repaired lube line
R/C:
Cycle time: Unchanged What: Blow back sleeve
Why: Bad tip
Counter measure: Replaced tip
R/C: Yes
Cycle time: Unchanged What: Blow back tip and sleeve
Why: Worn out (64000 Shot life)
Counter measure: Replaced tip and sleeve
R/C: Yes time
Cycle time: Unchanged What: Blow back tip/sleeve
Why: Worn tip/sleeve
C/M: Replaced tip and sleeve What: Blow back.
Root cause: Worn tip and sleeve.
Countermeasure: Replacing tip and sleeve. What: Blow back.
Why: Worn tip.
Countermeasure: Replaced tip, cleaned up blow back. Verified plunger lube.
Will Problem Reoccur?: Wear.
Cycle Time: No Change. What: Blow back.
Why: Worn tip.
Countermeasure: Replaced tip.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Blow back. (37,000 on tip and sleeve.)
Root cause: Plunder lube bracket was loose on sleeve. Heat from sleeve expanded the metal and it become loose and moved lube line. Injection ran with no l What: Blow back/vacuum trouble
R/C: Tip and sleeve worn (55500 shots), water lines to plunger shaft reversed
C/M: Removed 1/2 die and installed new tip and sleeve, switched plunger shaft water lines t What: Blow out
Why:
Countermeasure: Clean die
Reoccur: Possible What: Blow out (6A0 M #2)
Why: Sprue bushing to sprue radius not same. Spotted die in D/C#2 and bottom of radius don't match up.
Counter measure: none
R/C: yes
Cycle time: Unchanged What: Blow out 6A0-M
Why: Unknown
Counter measure: pulled both bottom slide cores and cleaned them and die faces
R/C: Yes seems to with m dies
Cycle time: Unchanged What: Blow out 6A0M
Why: Unknown
Countermeasure: Cleaned pockets pulled bottom slide cores and cleaned
Reoccur: yes What: Blow out around chill block area. (Die 14 5BA one rocker)
Why: Spotted die in machine. Found that robot side vacuum block was setting back a little. Found that holding area for vacuum block was What: Blow out at bottom of 6A0-M
Why: Washer thickness
counter measure: Replaced washers with 2.0 washers
R/C: Yes time
Cycle time: Unchanged What: Blow out in die
Why: Upper slide core mating
Counter measure: Cleaned out die and put more wool in slot. What: Blow out on die
Why: Die pocket got flashing. But took hit above vacuum block. Block is stuck in die
Counter measure: Cleaned out pockets. Pulled die due to vacuum block
R/C: Unknown
Cycle time What: Blow out on die 6AO M
Why: Lower slides stuck and heavy flashing
Counter measure: Cleaned die
R/C: Yes
Cycle time: Unchanged What: Blow out on die and sprue leaking
Why: Aluminum build up
Counter measure: Cleaned die. replaced sprue bushing and bottom rb side cooling line What: Blow out on die. 6AO M
Why: Unknown
Counter measure: Cleaned die
R/C: Yes always with this die in this machine. should try in different machine
cycle time: Unchanged What: Blow out on operator side vacuum block
Why: Setting in pods
Counter measure: Reset pods in squeeze master
R/C: No
Cycle time: Unchanged What: Blow out operator side
Why: Build up
Countermeasure: Clean build up off die
Reoccur: Possible What: Blowback
Why: ?
C/M: replaced tip
Recur: Possibly in time What: Blowback
Why: Plugged lube tip
C/M: Unplugged Tip and replaced tip and sleeve
Recur: In timing What: Blowback
Why: Tip and Sleeve worn
C/M: Replaced Both tip and sleeve
Recur: In time What: Blowback
Why: Tip worn
C/M: Replaced with new tip
Recur: Yes in time What: Blowback
Why: Tip worn 41,070 shots
C/M: Replaced tip
Recur: yes in time What: Blowback
Why: Tip worn and joint on plunger rod loose
C/M: Replace tip and O ring and tightened the Joint
Recur: Possibly in time What: Blowback
Why: Washout
C/M: Replaced tip and sleeve
Recur: Possibly in time What: Blowback
Why: Worn tip
Countermeasure: Replaced tip
Will problem reoccur: Possibly
Cycle time: No change What: Blowback
Why: segmented end was loose causing water issue
C/M: Took segment off checked if broke ,,and put new tip
Recur: Possible in time What: Blowback
Why: tip worn
C/M: Replaced with new tip
Recur: In time What: Blowback
Why: Sleeve worn
C/M: Replaced Tip & Sleeve
Recur: In Time What: Blowback Plunger rod
Why: Tip Loose on shaft
C/M: Replaced tip
Recur: Possibly in time What: Blowback Tip and Sleeve Shot life T-576 S-15,848
Why: Air blow was weak and cooling joint no good
C/M: Replaced tip and sleeve and the entire plunger rod and cooling line
Recur: Possible in time What: Blowback When trialing new die
Why: Tip worn
C/M: replaced tip
Recur: Yes in time What: Blowback also having SQM trouble
Why: Sleeve washed out/ Rebled SQM and got all in ok except channel 4 so line bled
C/M: Slowed the fast pour down What: Blowback and sticking to the tip
Why: tip and sleeve worn
C/M: Replaced both tip and sleeve
Recur: In time What: Blowback at tip/sleeve
Why: Found clogged plunger lube spray tip.
C/M: Replaced lube tip, watched machine run several shots with no change in blowback. Replaced worn plunger tip. What: Blowback- shots sticking to stationary side, biscuit size
Why: Worn tip/sleeve - little/no injector lube
C/M: Replace tip/sleeve
Reoccur in time w/wear What: Blowing RB side vacuum block
Why: Root cause unknown, passed down from 1st, filter changed and o ring change. Hose from vacuum machine to mani changed and mani to die changed.
C/M: Verified no What: Blowing Robot side vacuum block.
R/C: Spray timer was set to high and clear hose had a chunk of aluminum in it and hose clamp at the die wouldn't tighten down.
C/M: Adjusted spray timer back to What: Blowing Vacuum Blocks. Both Blocks.
Why: Die Release and filters needed cleaned.
Countermeasure: Cleaned filters. Adjusted Die Release concentration so that it is in range (was too low). What: Blowing robot side vacuum block
Why: Oil in vacuum hose, operator side vacuum block slow to drop off
C/M: Blew out vacuum line and had DH replace both blocks What: Blowing vacuum blocks
R/C: Filters on vacuum pump full of oil due to amount of oil in pump high
C/M: Drained some oil out of pump, replaced both rear houses due to aluminum filled. Pulled and cl What: Blowing vacuum blocks
R/C: R/B side block not sealing completely blowing blocks
C/M: Added 1.00mm shim behind chill block on r/b side chill block
Will it reoccur: Will follow up with operator du What: Blowing vacuum blocks on Robot side.
Why: Nitrogen was low
C/M: Added nitrogen
Recur: Possibly in time What: Blowing vacuum blocks.
Why: Dirty filter, dirty hoses.
Countermeasure: Replaced L2 Filter. Operator replaced both hoses. Cleaned filters. changed main inlet air filter What: Blowing vacuum blocks. Mostly Robot side.
Why:
Countermeasure: adjusted die release concentration from 1.60 to 2.08 should be between 1.86 to 2.08 What: Blown Vacuum Block Operator Side.
Why: Dirty filters.
Countermeasure: Cleaned all filters.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Blown Vacuum block both sides.
Why: What: Blown Vacuum blocks
Why: Die lube pump not working properly
C/M: Installed new die lube pump, checked spray points and matched M/C settings to plex settings. What: Blown fuse in R/B controller.
Why: Cable to pendant defective.
C/M: Replace cable with non-inventory cable. What: Blown vac. blocks, OP side
Why:
C/M: Found aluminum chips in the screens, cleaned them out. Removed and inspected filter, appeared ok. Replaced o-ring on large vac line. trimmed damaged blue an What: Blown vacuum blocks
Why:
C/M: Checked hoses, O-rings, die lube concentration, cleaned die release and vacuum filters, checked nitrogen level which was reading low What: Blown vacuum block (operator side).
Root Cause: Dirty hoses and the oily vacuum pump filter.
Countermeasure: Replaced vacuum pump filter and hoses for vacuum block.
Will Problem Reoccur?: No. What: Blown vacuum block (operator side).
Why: Die release low
Countermeasure: Was 1.03 made 1.70
Will Problem Reoccur: No
Cycle time: Unchanged What: Blown vacuum block op side/spray carriage not spraying
R/C: Water line turned off to die release tank
C/M: Turned water on and checked floats to verify water filling ok
Will it reoccur: No What: Blown vacuum block stuck
Why: Attrition
C/M: Pulled vacuum block What: Blown vacuum block.
Root cause: Low vacuum oil.
Countermeasure: Cleaned sight glass and added vacuum oil.
Will Problem Reoccur?: Possible.
"NON INVENTORY NP2 DIECAST VACUUM UNIT EXH. FILTER" What: Blown vacuum block.
Why: vacuum ejector plugged
Countermeasure: clean vacuum ejector (operator side).
Will Problem Reoccur?: Yes.
Cycle Time: No Change. What: Blown vacuum blocks
Why: Black vacuum lines need trimmed
C/M: Cleaned vacuum and die lube filters, Checked spray points & concentration of die lube. Checked vacuum lines and found the ends of bl What: Blown vacuum blocks
Why:?
C/M: Checked settings and die release filter
Recur: Possibly in time What: Blowout
Why: Buildup in pockets & bottom slide cores not moving freely
C/M: Cleaned pockets, removed slide cores, cleaned core blocks and die
Reoccur: Yes timeing What: Blowout
Why: Possibly something not right with die causing repeated blowouts
Countermeasure: Cleaned aluminum off die What: Blowout OP side
Why: Aluminum buildup on die
C/M: Blowout OP side, clean with WD40 & scotch bright/inspect die What: Blowout OP side
Why: While cleaning the die noticed that the vacuum block was sticking out farther than the RB side (OP said they had just replaced the vac. block)
C/M: Removed and cleaned vacuu What: Blowout PM
Why: 1st shift blowouts
C/M: 3rd shift lunchtime: Cleaned die with scotchbright and inspected die for any aluminum buildup What: Blowout R/B side
Why: Aluminum buildup in pockets
C/M: Cleaned the pockets and entire die. Trimmed/Replaced melted hoses What: Blowout RB side
C/M: Cleared all aluminum out of pockets, Cleaned the die. Replaced/trimmed melted vacuum lines What: Blowout RB side
Why: Noticed chill block RB side sticking out further than the RB side
C/M: Removed chill block and cleaned the debris out from behind and applied pressure to the chill block whi What: Blowouts RB side
Why: After spotting die cavity suspected chill block
C/M: Replaced chill block. Machine is back in production. After running the cooling tube for tip/sleeve broke, replaced cool What: Blue OK conveyor stopping
Why: Guide plates wore out
Counter measure: Replaced guide plates
R/C: Yes time
Cycle time: Unchanged What: Blue Ok conveyor sliding back down
Why: Clutch not adjusted right
Counter measure; Had to take clutch off spare due to gear box being stuck on shaft
R/C: Yes time
Cycle time: Unchanged What: Blue bucket conveyor not moving
Why: Chain skipping
Counter measure: Took clutch off of conveyor cleaned and adjusted What: Blue conveyor
Why: Sensor bracket broke
Counter measure: Made and Replaced bracket What: Blue conveyor
Why: Stopping. Chain stretched
Countermeasure: Replaced conveyor with rebuilt one
R/C: NO
Cycle time : Unchanged What: Blue conveyor issue
Why: Skipped link on sprocket. Jamming at top dump
Counter measure: Skipped back and tightened chain What: Blue conveyor jammed
Why: Chains stretched
Counter measure: Replaced both chain What: Blue conveyor not moving
Why: Chain too tight
Counter measure: Loosened chain
R/C: No
Cycle time: Unchanged What: Blue conveyor not moving
Why: Set screw come loose
Counter measure: Tightened set screw What: Blue conveyor stopping
Why: Bolts fell out of part separator for trim press
Counter measure: put new bolts in separator
R/C: No
Cycle time: Unchanged What: Blue conveyor stopping
Why: Parts getting stuck at dump end due to bucket and guide channels for parts not lining up
Counter measure: Aligned channels to bucket
R/C: No
Cycle time: Unchanged What: Blue conveyor stopping at top
Why: Sensor detect bar fell off
Counter measure: Welded back on
R/C : No
Cycle time: Unchanged What: Blue ok bucket wouldn't move
Why: Stopper s missing
Counter measure: Replaced bucket stoppers What: Blue ok conveyor
Why: Sensor bar broke
Counter measure: Made new bar What: Blue ok conveyor
Why: Sensor detect bolts broke off
Counter measure: Drilled and tapped bolts holes
R/C: Yes Time
Cycle time: Unchanged What: Blue ok conveyor alarm
Why: Set screw for shaft came loose
Counter measure: Tightened set screw What: Blue ok conveyor bucket jamming when dumping
Why: Missing bolts
Countermeasure: Replace missing bolts
Reoccur: No What: Blue ok conveyor chain broke
Why: Master link broke
Counter measure: Replaced master link
R/C: No
Cycle time: Unchanged What: Blue ok conveyor chain jammed
Why: chain fell off
Counter measure: put chain back on and tightened
R/C: No
Cycle time: Unchanged What: Blue ok conveyor got jammed at top
Why: Over traveled
Counter measure: Unjammed
R/C: Yes time
Cycle time: Unchanged What: Blue ok conveyor jamming up
Why: Guide rails bad
Counter measure: Replaced all rails and wings. Replaced rubber stopper pads to for bucket
R/C:
Cycle time: Unchanged What: Blue ok conveyor motor over load
Why: Chain too tight
Counter measure: Loosened chain
R/C: Yes Time
Cycle time: Unchanged What: Blue ok conveyor not moving
Why: Chains stretched
Counter measure: Replaced both chains 176 links each side
R/C:
Cycle time: Unchanged What: Blue ok conveyor rails worn. (Bent)
Why: Has big bucket on it. Too much weight and speed was wrong
Counter measure: Replaced rails and 1st adjusted speed
R/C: Unknown
Cycle time: Unchanged What: Blue ok conveyor stopped
Why: Guide wheel fell off. C clip broke
Counter measure: Replaced clip
R/C: Yes Time
Cycle time: Unchanged What: Blue ok conveyor stopped
Why: One chain slipped on sprocket
Counter measure: Skipped chain back and adjust chain
R/C: Yes time
Cycle time: Unchanged What: Blue ok conveyor stopped
Why: Part got jammed at start position
Counter measure: Un jammed part
R/C: No
cycle time: Unchanged What: Blue ok conveyor stopping
Why: Bolts missing from track
Counter measure: Replaced bolts What: Blue ok conveyor stopping
Why: Rails and guide wings worn. Hitting sensor bracket and stopping
Counter measure: Replaced guides and rails
R/C: Yes time wear part
Cycle time: Unchanged What: Blue ok lift alarm
Why: Guide wheel fell off
Counter measure: Re attached wheel What: Borrowed servo valve
Why: For D/C #3 to verify that was the issue for speed ACC alarm
Counter measure:
R/C:
Cycle time: Unchanged What: Both P Slide cores cracked (5A2 p/m #29 die)
Why: Time
Counter measure: Replaced both P slide cores
R/C: Yes Time
Cycle time: Unchanged What: Both bottom slide cores leaking
Why: Cracked
C/M: Replace with new
Recur: Possible in time What: Both upper slide cores leaking
Counter measure: Changed die What: Bottom of ladle broke over holding crucible
Why: Ladle hit holding crucible
C/M: 1st shift replaced ladle What: Bottom operator slide core leaking
Why: Bolts fell out or loose
Countermeasure: Replaced and tightened bolts What: Bottom robot side slide core guide pin broke
Why: not sure
C/M: Replaced guide pin What: Bottom slide core fell out of M die
Why: Bolts were loose?
Counter measure: Replaced Bolts
R/C: No
Cycle time: unchanged What: Bottom slide cores sticking
Why: Flashing and rust on the side of the operator slide core assembly
C/M: Remove slide cores and cleaned out slots and clean core assemblies
Recur: In time What: Bowl heater not coming on
Why: Emergency stop on
Countermeasure: Reset E stop What: Bowl heater not heating up
Why:
Counter measure:
R/C:
Cycle time: Unchanged What: Bowl heater not heating up past 122 deg
Why: ATV valve was slightly open due to set screw coming loose
Counter measure: tightened set screw on ATV valve (form motor to valve) What: Box on top of robot fell off
Why: bolt holes wore out due to not being tight
c/m: welded new plate on the box and re attached What: Bracket for helper door broke
Why: Made out of aluminum door possibly slamming
C/M: Had to find old steel bracket and fabricate a new on and adjusted air on door opening and closing What: Breaking Giudes
Why: Base that holds guide damaged
C/M: Took base off have welded and then machined
Recur: Possible in time What: Breather cover Cavity #4 out of spec
Why: ?
Counter measure: Cleaned and polished all cavities
R/C: Yes
Cycle time: unchanged What: Breather cover bent #4 and #3 cavity
Why: Sticking to fixed side of die
Counter measure: Polished around all circles on fixed side and other drag marks
R/C: Yes
Cycle time: Unchanged What: Breather covers getting stuck in unload conveyor
Why: Guide rails too narrow
Counter measure: Replaced rails with remade wider ones
R/C: Yes time
Cycle time: Unchanged What: Broke bolt
Why: Safety bar left in
Counter measure: Replaced bolts What: Broke cutter
Why: Overflows getting left on trim die
C/M: Positioned air blow where overflow was left
Recur: In time What: Broke ejector pin
Why: PC malfunction
Counter measure: Pulled die to fix pin. Replaced ejector pins 5-11 and M3 insert core pin.
R/C: Yes same ejector pin that always breaks
Cycle time: Unchange What: Broke ladle
Replaced ladle What: Broke slide core
Why: Started machine in full on after being down
Counter measure: Replaced slide core and talked with 2nd shift team lead about bring it up with 1st shift
R/C: Yes Operators nee What: Broke slide core (6A0 P F-1 die) cavity 4
Why: Unknown
Counter measure: Replaced slide core
R/C: No
Cycle time: Unchanged What: Broke slide core F-7 RPY-M cavity 2
Why: ?
Counter measure: Replaced slide core (Roller)
R/C:
Cycle time: Unchanged What: Broke slide core Ryp M 8-4
Why: Unknown
Counter measure: Operator bottom Replaced M 8-4 slide core What: Broke slide cores
Why: Unknown
Counter measure: Replaced slide cores What: Broken Aluminum leak detect probes for holding crucible.
Root Cause: Back of crucible flooded.
Countermeasure: Made two new probes.
Will Problem Reoccur?: Yes. What: Broken Emergency Stop pushbutton.
Root cause: Must have been hit by something knocking the Red pushbutton off.
Countermeasure: Replaced button part. What: Broken Insert pin
Why: ?
C/M: Went thru and inspected machine
Recur: Possibly in time What: Broken Ladle cup.
Countermeasure: New ladle cup, pour looks good. What: Broken Thermocouple
Why: Cable pinched/snagged during operation
C/M: Replace thermocouple What: Broken Tie bar nut clamp
Why: Old ,worn and broke
C/M: Replaced with used tie bar clamp from Japan
Recur: Possibly in time What: Broken air line fitting
C/M: Replaced fitting at trim press pneumatic selector switch
Reoccur: Not likley What: Broken draw bar
Why: DH was tightening and it broke in die
Countermeasure: Replace draw bar
Reoccur: Possible What: Broken draw bar. During die change
Why: Threads broke off in die
Counter measure: Replaced bar. What: Broken hydraulic hose
Why: Fixed side hose caught on moving side and broke hose in half
C/M: Replaced and re-routed the hose
Reoccur: Possible What: Broken ladle
Replaced ladle What: Broken ladle cup
Why: Unknown
Countermeasure: Replace ladle cup
Reoccur: Possible What: Broken ladle cup
Why: Wear
Countermeasure: Replace ladle cup
Reoccur: Possible What: Broken ladle cup
Why: Wear
Countermeasure: Replaced ladle cup
Will problem reoccur: Yes
Cycle time: No change What: Broken loading door safety latch.
Why: Plastic was brittle where it was bolted.
C/M: Re-anchored using a wider washer to better distribute pressure across plastic. What: Broken melting crucible
Why: Operator loaded empty
C/M: Replaced crucible and will put sensor next week for loading What: Broken safety plug
R/C: Heat from furnace made safety plug brittle
C/M: Removed and installed new non inventory male and female safety plug components
Will it reoccur: Timing
Cycle time: No chan What: Broken slide core operator bottom (cavity4)
WHY: build up from flashing in slide core pocket
C/M: cleaned die and replaced slide core
REOCCER: yes timing What: Broken solenoid for damper lid.
Why: Got an ingot dropped on it
C/M: Replaced valve and confirmed lid works properly. What: Broken springs on spray cartridge
Why: Constant stress/shock
C/M: Removed and replaced springs What: Broken upper crucible
Why: Crucible broke at bottom
Counter measure: Replaced upper crucible What: Broken/Cracked ladle cup
Countermeasure: Got a replacement ladle cup. What: Bucket elevator not getting home position
Why: Tower position switch not made
C/M: Arm on sensor bent, readjusted so hitting plate properly when tower pushed over crucible What: Bulging inlet water line to the die.
Why: Normal wear.
C/M: Drain die and replace line. What: Buzzer going off in semi-auto with damper open
Why: Buzzer CR comes on if damper close swtich isn't made and the selector switch isn't in manual
C/M: Removed X47 for top damper close limit switc What: C/V overload on trim press
Why: Part wedged conveyor, robot stopped with part in press
C/M: Got overload cleared after part was removed. Helped ooperator recover robot What: CH2 on squeeze master wont stroke
Why: Hydraulic connection: After changeover 2 of the hydraulic lines were not fully connected
C/M: Checked all hydraulic lines to ensure good connection, connec What: Cable for dog house door broke
Why: Time
Counter measure: Replaced cable What: Called for a gas line bracket that got knocked off of a beam, also they could not get the upper back on track
Why: This all stemmed from them scrapping the upper for shut down
Countermeasure: Re What: Called for slide core chipped out
Why: Slide core NG (Cavity 2, Die 11)
C/M: Replace slide core What: Can not Turn on Hyd. Pump.
Why: Overload relay of Hyd. pump motor starter tripped.
C/M: Reset overload relay. What: Can not get master ON at robot or trim press, E-stop condition.
Why: R/B A16B-2203 Power supply defective.
C/M: Replace defective Power Supply. What: Can't turn on hydraulics
Why: Bad switch
C/M: Replaced switch What: Cannot close die, getting spray cartridge interference alarm
Why: Plug for water passage spray cartridge on spray unit full of water X34 sensor stuck on because of it
C/M: Cleaned out box and bl What: Cannot master on R/B or Trim press.
Why: Breaker in safety sys. tripped.
C/M: Reset tripped breaker. What: Cannot operate machine.
Why: Circuit board behind operator switches terminal strip came loose.
Countermeasure: Reseated terminal strip.
Will Problem Reoccur?: No.
Cycle Time: No Change. What: Cast pressure alarm. Higher than cast able range
Why: Was over cast range. 91.0 set is 80.0 to 90.0. After filling with nitro wouldn't fill sight glass back up with oil
Counter measure: Checked What: Casting Pressure Alarms.
Why: Setting.
Countermeasure: Adjusted the Dry shot reference to match what the dry shot is. What: Casting Pressure and axis alarms. What: Casting issue
Why: Bad tip
Counter measure: Replaced tip What: Casting issue and machine moving on floor
Why: Machine moving due to welds broke on floor mounts. Casting What: Casting issue when running
Why:
Counter measure: What: Casting pressure alarms
Why: To low
C/M: done a V-check
Recur: Possibly in time What: Cav. 3 HB out of spec
Why: Roller groove, slide core
C/M: Replaced HB slide core What: Cav. P2 out of spec
Why: Trim press issue
C/M: Removed cutter, cleaned cutter and pocket, attempted to adjust several times then replaced cutter. Adjusted cutter so parts in spec. What: Cavity #1 tappet hole deep
Why: Tappet pin dirty
Counter measure: Cleaned tappet pins What: Cavity #1 trim height
Why: Cutter worn
Counter measure: Replaced cutter
R/C: Yes time
Cycle time: Unchanged What: Cavity #2 bent. Breather cover
Why: Cavity needs polished
Counter measure: polished cavity #2
R/C: Yes
Cycle time: Unchanged What: Cavity #2 breaking into part (59B one rocker)
Why: Cutter dull
Counter measure: Replaced cutter adjusted cutters
R/C: Unknown
Cycle time: Unchanged What: Cavity #2 not coming out on table
Why: Flashing on parting line causing part to get stuck in press.
Counter measure: Adjusted press down to push part past parting line flashing
R/C:
Cycle time: What: Cavity #4 out of spec and #3 bent What: Cavity 1 NG-ing at trim press.
Why: Flipper 3 not flipping.
Countermeasure: Re-installed flipper 3 pivot bolt, it came undone.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Cavity 1 Shaft hole depth out of spec to shallow
Why: Cavity 1 robot upper cylinder possibly bad
C/M: Bled out many times and swapped lines stayed on 1
Recur: In time What: Cavity 1 Tappets shallow
Why: Squeeze master settings
Counter measure: Adjusted squeeze master settings for flow What: Cavity 1 breaking off shot, cavity 1 trim issue, product detect not catching missing part
Why: Bad spot in cavity 1 causing part to stick, leaving trim on cavity 1 when making it to the trim pre What: Cavity 1 part out of spec
Why: Trim damage
C/M: Adjusted cutter, parts now in spec What: Cavity 1 roller hole ejector pin leaving marks on the parts
Why: Soldering
Countermeasure: Cleaned die What: Cavity 1 scrape on part
Why: Trim press block had a burr, also tight against part
C/M: Stoned edge of block, pushed block away from part a bit What: Cavity 1 upper air blow fell out of trim press
Why: Aluminum build up pushed on the fitting
Countermeasure: Replaced fitting, cleaned trim press, ensured build up was being blown from area What: Cavity 2 "trim" damage. After Trim press sometimes there is a mark on near the tappet of part.
Why: wear on cavity 2 punch
Countermeasure: tried swapping cavity 2 punch with cavity 3 punch on t What: Cavity 2 and 4 soldering in roller groove
Why: Buildup on slide core
C/M: Sprayed alclean gel on slide cores and cleaned them off What: Cavity 2 dropping parts.
R/C: Ejector pins were moving to fast and there was no plunger lube.
C/M: Slowed ejector pins and cleaned lube lines at the sleeve also turned lube up a bit.
Reoccurrenc What: Cavity 2 had crack in it
Why: Die release pump stopped
Counter measure: Replaced pump
R/C:
Cycle time: unchanged What: Cavity 2 out of spec
Why: Cutter worn
Counter measure: Replaced cutter What: Cavity 2 sticking on upper press
Why: bushing going bad on die causing little tabs be left on part
C/M: Change out die so DM can change bushing
Recur: Possibly in time What: Cavity 2 sticking to trim press
Why: Spring pin came apart
C/M: Milled out cap so pin could thread in better, replaced locate pin on end of shaft What: Cavity 2 trim height NG.
Why: Cutter was loose and moved out of position.
C/M: Repositioned cutter and tightened down.
R/O: NO. What: Cavity 2 trim height issue
Why: Cutter leaving excess material on part
C/M: Adjust cutter on cavity 2 What: Cavity 3 out of spec
Why: Tappit pin leaking hydraulic fluid
C/M: Replaced cylinder with non-inventory cylinder What: Cavity 3 part dropping.
Why: Running M parts bottom slide core not moving freely. What: Cavity 3 slide core has build up
Why: Coating worn off
C/M: cleaned off slide core put alclean on slide cores
Recur: Yes slide core lost coating What: Cavity 3 soldering in roller groove
why: Soldering out of spec per quality
c/m: Removed and replaced cavity 3 slide core, Gave operator QA Inspection paperwork for slide core replacement. Oper What: Cavity 4 block missing
Why: Bolts broke off causing block to fall out
Countermeasure: Replace block
Reoccur: Possible What: Cavity 4 broke R/S side cutter
Why: ?
C/M: Replaced cutter and re- aligned trim press then re-taught position 25 and 26
Recur: Possibly in time What: Cavity 4 flipper broke
Why: Welds broke
C/M: Re-welded and made new flipper
Recur: Possibly in time What: Cavity 4 parallel out
Why: What: Cavity 4 parell out of spec.
Countermeasure: Cleaned die.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Cavity 4 part falling off at die
Why: Shot breakage
C/M: Checked die release concentration, checked spray points, bled squeeze master, polished cavity and cleaned and waxed squeeze pins. Checked What: Cavity 4 parts dropping on NG conveyor when OK parts
WHy: Trim press not pressing part completely out of trim die
c/m:Pulled trim press and verified flipper working properly, adjusted down posit What: Cavity 4 shaft hole cutter broke
Why: Overflow scrap left on press
C/M: Replaced cutter and adjust air
Recur: possible in time What: Cavity M-1 trim height out
Why: Cutter ground down
C/M: Replaced with new cutter
Recur: Possible in time What: Cavity P1 roller groove out of spec
Why: Raised area inside roller groove
C/M: Replaced P1 slide core What: Cavity P1, OT Crack >10mm
Why: Cracked slide core
C/M: Replaced slide core, Confirmed pressure settings on squeeze master were correct, Good coolant flow also confirmed
Recur: In time What: Cavity S2 chunked out
Why: Damaged slide core
Countermeasure: Replace slide core What: Center air blow gone
Why: Fell off during operation at some point
C/M: Replaced with new
Recur: Possibly in time What: Ch. 4 thermo coupler disconnect error.
C/M: Found old work order where the wires for channel 4 and 5 were swapped. Swapped wires back and disconnect alarm went away. What: Chain tench sleeve pitted bad
Counter measure: Replaced tip and sleeve. (DH) did What: Change Upper and Lower crucibles
Why: Leak and corundum growth
Root cause: Lower cracked. Upper had corundum in half pipe spout. Due to lack of cleaning and over heating left over aluminum
Count What: Change over (Robot needed taught)
Why: Model change
Counter measure: Re taught all robot positions What: Change over Baffle to one rocker
Why: Adjustment squeeze master flow
Counter measure: Adjusted flow on all cavities
R/C:
Cycle time: Unchanged What: Change over from chain tens to RPY one rocker. Robot not picking up shot from die
Root cause: R/B finger not installed on correct location on r/b hand
Countermeasure: confirm finger placement wi What: Change over no sleeve and tip on cart What: Change over to breather cover and robot wont go to trim press
Why: Line 278 waiting on press 2 to home What: Change-over to run RPY-1 Rocker and need countermeasure modification put in. What: Changed out spray cartridge due to no spraying
Why: Possible pinched spray line or nozzle plugged
C/M: Replaced spray cartridge
Recur: in time if not cleaned What: Changed over, operator asked to verify product detect for 6MA
C/M: Verified product detect check for operators since no DH on 1st or 2nd today What: Changeover Trim height
why: Cutter adjustment to trim height spec
c/m: adjusted cutters to allow all parts to be within tolerance for trim height max
will it reoccur: yes
cycle time: unchanged What: Changeover from breather cover to 1RKR, trim press sensors needed moved
Why: Breather covers look across diagonally and 1RKR look straight across. Only 1 set of usable sensors
C/M: Moved and adj What: Changeover to 6MA Tensioners What: Changeover to breather baffles, product detect NG
Why: P10 off, product detect not seeing all 4 parts/positioning of shot turned
C/M: Touched up P10, DH adjusted product detect sensors What: Changeover to breather cover, trim press alarming out
Why: Found wires broke off female pins in connector. Connector added in by engineering
C/M: What: Changing vaccum block and bolt is complety filled with aluminum.
C/M: Struggled to remove bolt but got it out and replaced with a new one. What: Channel 2 DCV valve no good
Why: Where the electric part of the valve is where it hooks up to the coil is broke
C/M: Took coil end off DC 4 and put on DC 3 What: Channel 2 on SQM Bleeding out
Why: Cylinder no good need rebuilt
C/M: Changing die
Recur: Possibly in time What: Channel 2 on the SQM not working
Why: Bad Solenoid valve
C/M: Replaced valve What: Channel 3 SQM
Why: The hydraulic lines on die hooked up wrong, and adjusted wrong cavity in SQM.
C/M: Hooked lines up correctly and color match lines to die
Recur: Possible in time What: Channel 3 and 4 not stroking out when trying to set squeeze length
Why: Root cause unknown
C/M: Checked valves die side for squeeze master lines, cycled power and started moving again What: Channel 4 SQM NG
Why: SQM lines hooked up wrong and settings changed
C/M: Hooked lines up correctly and put setting back
Recur: Possible in time What: Channel 4 error
Why: Valve staying open
Counter measure: Replaced cube relay What: Channel 4 stroke speck randomly jumping high out of spec.
R/C: Possible bad cylinder in die
C/M: Adjusted squeeze master on cavity 4 lower to allow parts to stay in spec.
Will it reoccur: Timing What: Channel 6 upper limit alarm
Why: Hydraulic heat exchanger dirty
Counter measure: Cleaned exchanger on die cast machine What: Charge loader stuck at the top with lid open and not doing anything.
Why: Limit switch for tower was not made, causing everything to stop and not be able to move manually.
C/M: Manually got ever What: Charging M/C safety gate slide key assy. damaged.
Why: Door forced open by mis-located hopper getting caught in chute.
C/M: Re-mount original safety switch slide key.
Will it Re-occur: Un-determ What: Charging bucket will not come down from dump position
Why: Tower lost home position
C/M: Adjusted tower home position switch What: Charging lid on furnace not moving
Why: Found large hole in air line in solenoid box
C/M: Replaced several hoses and a fitting What: Charging loader will not move, stuck after dumping
Why: Tower home position switch not made
C/M: Adjusted switch so it was properly made What: Charging machine error
Why: Machine got crashed
Countermeasure: Had to repair both sensors and brackets What: Charging machine sliding door handle broke
Why: Root cause unknown
C/M: Replace slide handle for charging machine door What: Check #30C out of spec
Why: Filter clogged
Countermeasure: Replaced stage 3 hepa filter What: Checked die for blow out Per JR Otto at lunch time
Why: 1st having problems with blow outs
Counter measure: Inspected die for flashing. None What: Chill block piece falling off
Why: no spray
C/M: Replace spray cartridge What: Chipped slide core P-1 5BA die 8
Why:
Counter measure: Replaced slide core
R/C:
Cycle time: Unchanged What: Chipped slide core p-1 5BA die #8
Why:
Counter measure: Replaced slide core with MM slide core
R/C:
Cycle time: Unchanged What: Chipping out squeeze pin hole (S-1 5BA)
Why:
Counter measure:
R/C:
Cycle time: Unchanged What: Chipping out squeeze pin hole. (S-1 5BA)
Why: Coating on squeeze pin worn off. See pic attached to work order
Counter measure: Told team leader die needed pulled
R/C:
Cycle time: unchanged What: Christmas tree getting stuck in trim press
Why: Guard & ramp bent/busted
C/M: remove broken bolt, weld/repair/straighten guards and ramp
Recur: Very possible, it happened last night also (bolt b What: Chuck sensor No good
Why: Broken wire
C/M: Replaced sensor
Recur: Possibly in time What: Chuck sensor not working on robot
Why: Wire pulled from connector
Countermeasure: Reterminate sensor
Reoccur: Possible What: Chunking out 5BA-S 1-1 parts at Rocker shaft area. What: Chunking out Cavity 2 part
Why:
Counter measure: What: Chunking out P-1 and S-1
Why: Die temp. (movable side was not getting any water. )
Counter measure: Adjust movable side and fixed side temps. What: Chunking out P-1 cavity
Why: Squeeze pin not returning all the way
Counter measure: Changed DCV for channel 2 on squeeze master What: Chunking out P-1 part
Why: Chunking out at squeeze pins S-1 and P-1
Counter measure: What: Chunking out parts at slide core
Why: Slide core operator bottom stuck (Very bottom)
Counter measure: Pulled die. Due to not being able to get slide core back in
R/C: Unknown
Cycle time: Unchang What: Chunking parts out
Why:
Counter measure: Bled squeeze master What: Clamping Safety Device Action Malfunction
Why: cylinder seal blown causing too much backpressure (cylinder just locked up)
C/M: replaced safety hook cylinder What: Clamping safety device action malfunction
Why: The solenoid for the hook went bad
Countermeasure: Replaced solenoid
Will problem reoccur: Possibly
Cycle time: No change What: Clamping safety devise malfunction
Why: Sensor for hook went bad
Counter measure: Replaced sensor
R/C: No
Cycle time: Unchanged What: Cleaning alarm constantly going off
Root cause: 2 prong plug assembly is broken
Countermeasure: replaced with a used spare that was non-inventory
Reoccurrence problem: no Cycle time no change What: Cleaning heat exchangers. What: Cleaning of Trim press and squeeze master het exchangers. What: Cloudy oil separating in lube container
R/C: Operator put wrong oil into lube tonna 68, wrong oil in container
C/M: Verified correct oil tag on container, Drained lube container and refilled wi What: Collision Detect at overflow trim
Why: Touching centering pins faulting for collision detect
C/M: Re-taught robot at overflow press
Recur: Possibly in time What: Collision detect
Why: Robot Teaching
Countermeasure: P-5 retaught
R/C: Yes
Cycle time: Unchanged What: Collision detect alarms at trimpress.
R/C: R/B not setting shot down properly in press.
Countermeasure: Touch up positions 24 & 25.
Will it Re-occur: No. What: Collision detect at trim press coming out.
Why: Part wasn't pushed over always when press come down
Counter measure: Sped up push cylinder in press What: Collision detect on robot
R/C: J2 gear reducer locked up. Due to die shot trim pieces getting wedged in housing.2nd shift
C/M: Replaced J2 gear reducer
Will it reoccur: No What: Collision detect on robot
Why: Only happens when knocking off 2nd tab at punch
C/M: Adjusted robot position when knocking tab off, greased J6 according to standard What: Collision detect robot
Why: Take out no good
C/M: RE-taught take out
Recur: Possibly in time What: Collision detects on robot at trim press.
R/C: Trim press was out of position.
C/M: Put trim press back to where it should be, had to touch up positions 24 and 25 at trim press.
R/O: NO
Cycle Ti What: Collision detects on robot at trim press.
Why: Robot not grabbing shot right.
R/C: Pos. 6 robot pick up position isn't taught right.
C/M: Retaught pos. 6.
R/O: NO
Cycle Time:NO Change What: Connection at ladle bar broken.
Why: Atrttion.
C/M: Re-terminate broken wire. What: Constant low aluminum.
Why: Believe thermo coupler was bad. Said it was at temp but wasnt melting completly or fast enough.
C/M: Replaced thermo coupler, confirmed melting got to temp but operat What: Contactor not working
Why: Contactor bad not pulling in
C/M: Replaced with new from inventory
Recur: Possibly in time What: Control panels knobs melting
Why: Filter had gap between it and the door
C/M: Replaced knobs and covered gap with wool
Recur: Possibly in time What: Conveyor 1 overload
Why: Conveyor jammed
C/M: Reset contactor MC2 What: Conveyor install What: Conveyor is out of position
Why: Idk alot of aluminum built up in between furnace and ingot loader causing it to push out
C/M: Lifted up conveyor with the crane Chuck Winter and myself clean out What: Conveyor issue
Why: Guarding ripped off
Counter measure: Removed guarding What: Conveyor issue
Why: Scrap ripped guards off
Counter measure: re attached guards What: Conveyor jammed up
Why: Missing cotter pins missing rollers
C/M: Replace cotter pin ,rollers and steel center rods multiple on everything What: Cooler for die stopped (93 alarm)
Why: Solenoid valve stuck
Counter measure: Cleaned seemed fine. Was just replaced 2 weeks ago on 3rd
R/C: Yes
Cycle time: Unchanged What: Cooler/heater had 01 alarm. (Single phase alarm)
Why: Blew fuses in switch board. Unknown why they blew
Counter measure: Replaced fuses
R/C: Yes time
Cycle time: Unchanged What: Cooling Joint Leaking.
Why: Over pour of aluminum hit fitting and hose.
Countermeasure: Replaced fitting and hose. Adjusted the sleeve the hose sits in so that the hose will not get directly hit What: Cooling Joint to sleeve broke at threads.
Why: Wear.
Countermeasure: Replaced cooling joint.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Cooling joint
Why: Cooling joint missing from change over
Counter measure: Replaced cooling joint
R/C: No
Cycle time: Unchanged What: Cooling joint broke
Why: Flashing and aluminum build up
C/M: Replaced cooling joint and cleaned aluminum out
Recur: Possible in time What: Cooling joint broke
Why: Pouring aluminum while it injects
C/M: Replaced cooling joint and added time to shot delay from .3 to .5
Recur: Possibly in time What: Cooling joint for cavity S #2-1 was leaking (RPY P/S)
Why: Bad O-rings
Counter measure: Replaced O-rings
R/C: Yes time
Cycle time: Unchanged What: Cooling joint for sleeve
Why: Change over and cooling joint missing
Counter measure: Replaced missing cooling joint
R/C: Yes time
Cycle time Unchanged What: Cooling joint for sleeve broke.
R/C: Aluminum build up on plunger shaft broke cooling joint.
C/M: Replaced cooling joint.
Reoccurrence: This issue will reoccur if ladle operations are messed wit What: Cooling joint for sleeve broke.
Root cause: Aluminum rings built up on shaft.
Countermeasure: Adjusted setting so that aluminum rings would not build up.
Will Problem Reoccur?: Yes. What: Cooling joint for sleeve leaking
Why: leaking around thread tape
Counter measure: Took off and rethread taped it
R/C: No
Cycle time: Unchanged What: Cooling joint leak at sprue bushing
Why: scarred fitting
C/M: Removed & retaped fitting
Recur: What: Cooling joint leaking
Why: Threads broke from flashing build up
C/M: Replaced cooling joint also Tip and Sleeve
Recur: Possibly in time What: Cooling joint to sleeve broke
Why: Operator hit when pulling flashing out from under plunger tip
C/M: Replaced with new
Recur: Yes in time What: Cooling tank overflow
Why: Drain pipe was clogged
C/M: Used drain snake and plunger to clear blocked pipe What: Cooling water issues.
Why: Water leaking past seal of sol. valve controlling water flow to die.
C/M: Remove and clean seat of sol. valve. What: Copper lube line broke
Why: Wear
Counter measure: Put new compression fitting on line What: Correct descriptors in Loader PLC program. What: Corundom building up on holding furnace and halfpipe and spout
Why: Aluminum splashing and furnace getting really hot close to 2000 degrees
C/M: Replaced holding and melting furnace and half pip What: Corundom built up around the top of the melting crucible
Why: Splash up of aluminum on to the top of crucible
C/M: Replaced melting crucible half pipe and pedestal What: Corundom on spout , half pipe and holding crucible and metal leaks from cracked halfpipe
Why splashing of aluminum and when it gets hot it grows and it had cracked the half pipe and it leaked
C/ What: Cover for tie bar broke
Why: Weld broke
Counter measure: What: Crack in S1 and P2 5BA Die #9
Why: Unknown
Countermeasure: Replaced both slide cores
Reoccur: Yes What: Crack in Slide core 9-1 (Operator Top Running 5BA-P).
Why: Slide core had a crack in it.
Countermeasure: Replaced slide core in cavity 1, verified spray points - Good.
Will Problem Reoccur?: Po What: Cracked Ladle
Why: Unknown
C/M: Replaced with new 1.0 Ladle
Recur: Yes timing What: Cracked air bowl
Why: Wear and age
Countermeasure: Replaced bowl What: Cracked inside Sprue Bushing
Why: Unknown
C/M: Replaced Bushing
Recur: In time What: Cracked ladle
Why:
C/M: Replaced ladle What: Cracked ladle.
Countermeasure: Replaced ladle. What: Cracked slide core
Why:
Countermeasure: Replace slide core P2 Operator side slide core. Operator given slide core confirmation sheet. What: Cracked slide core
Why: Crack >10mm
C/M: Replace slide core P1. Also, cleaned slide core assembly P2 (using All clean soak tank)
Recur: Possible in time What: Cracked slide core 5BA S-1 Die #8
Why: Unknown
Counter measure: Replaced S-1 slide core
R/C: Yes time
Cycle time: Unchanged What: Cracked slide core cavity 3 had 31,017 shots
WHY: unknown
C/M: replaced cavity 3 slide core
REOCCUR: timing What: Cracked slide core, BH (M3)
Why: Flashing?
C/M: Replace slide core, cleaned die
Recur: What: Cracked slide cores P2, S2
C/M: Replaced OB (S2) and HB (P2)
Recur: In time What: Cracked slide cores. P-1, P-2, S-2.
Replace P-1, P-2, and S-2 What: Cracked sprue bushing (RPY P/S #5)
Why: Unknown
Counter measure: Replaced sprue bushing
R/C: Unknown
Cycle time: Unchanged What: Cracked sprue bushing 6A0 M
Why: Unknown
Counter measure: Replaced sprue bushing
R/C: Yes
Cycle time: Unchanged What: Cracked sprue bushing, Tip and sleeve damaged.
Why: Air blow to plunger lube spray tip line was damaged and leaking Badly. Cooling pipe not lined up internally in the plunger rod for proper cool What: Craig Randel needs help re-terminating igniter cable for holding crucible Why: Cable insulation compromised.
C/M: Cut back cable and terminate in igniter xfrmr. What: Crashed 6A0 M Die Cavity #1
Why: Shot got left in die after robot fault
Counter measure:
R/C: Yes time
Cycle time: Unchanged What: Crashed die
Why: Sensor wire went bad
Counter measure: Replaced sensor
R/C: Yes time
Cycle time: Unchanged What: Crashed die (59B one rocker #7)
Why: Operator left shot in die and closed it
Counter measure: Ran parts to quality lab to be checked. No one was here in quality to check parts. So we pulled die. What: Crashed die with part in die #2 (6A0 M)Cavity #4
Why: Part detect sensor for cavity #4 was set on runner of die. Was in full auto.
Counter measure: Replaced slide core and adjusted part detect What: Crashed robot
Why: Biscuit was big and bent robot tooling arm
Counter measure: Replaced tooling arm
R/C: Yes if operator don't check to see if sleeve is empty
Cycle time: Unchanged What: Crucible Lid wont close
Why: Bad solenoid
Counter measure: Replaced valve What: Crucible Broke
Why: Someone turned burner off to the holding furnace What: Crucible broke What: Crucible change
Why: Side of Furnace glowing Lid stuck to upper crucible
C/M: Replaced both crucibles
Recur: Yes in time What: Crucible change
Why: K-Molds did not pass inclusions
C/M: Replaced both upper and lower crucibles
Recur: possible in time What: Crucible change Broken filter on holding.
Why: Previously damaged.
Countermeasure: Replace upper and lower crucibles and half pipe.. install upper crucible rebuilt lid. Also fabricated and repla What: Crucible corundum blocking leak door
Why: Aluminum leak
c/m: change crusible What: Crucible cracked
Why: Aluminum hardening multiple times and then remelting
C/M: Replaced holding crucible and stand and halfpipe What: Crucible cracked
Why: My thought is getting to hot 2 different thermocouples doing different temps
C/M: Replaced melting crucible and half pipe and pedestal What: Crucible filter broke
Why: Unknown
C/M: Replace crucible
Recur: In time
Cycle time: Unchanged What: Crucible filter broke(Hole in center of filter)
Why: ?
C/M= replace filter
Recur: In time What: Crucible had bad corundom build up all around rim of crucible
Why: Aluminum splash up from loading scrap alot bigger then 350 and 250 ton dc m/c
C/M: Replaced melting crucible and pedestal and h What: Crucible leak lower
Why: Crucible leaking
Counter measure: Replaced lower crucible
R/C:
Cycle time: Unchanged What: Crucible lid drifting open
Why: Bad check valve for lid cylinder
Counter measure: Replaced valve from Die cast 6 What: Crucible lid opens in auto then shuts before ingots can load
Why: Open Limit switch bad
Counter measure: Replaced switch
R/C: NO
cycle time: Unchanged What: Crucible looked hotter than usual
Why: Thermo coupler bad
Counter measure: Replaced
R/C: Yes time
Cycle time: Unchanged What: Crucible upper limit block for the probes broke.
Why: Soft material dont last in the heat
C/M: Replaced block
Recur: Yes What: Crushing parts
Why: robot not sitting in correctly
C/M: Retaught robot
Recur: Possibly in time What: Cutter broke on trim press
Why: Big block got stuck in cutter
Counter measure: Replaced cavity 3 cutter What: Cycle Time Over on Robot.
Why: Robot chuck sensor.
Countermeasure: Replaced robot chuck sensor.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Cycle time
Why: Ladle to slow
Root cause: Setting lower limit frequency (LL) in settings
Countermeasure: INVU1 (LL) setting from 6.0 to 10.0 What: Cycle time
Why: T03A not making in allotted time X503
Counter measure: Tracked down to Y607. R03B coil slow but G44C (Die open motion slow hard slow to change). Changed it from 50% speed to 85% What: Cycle time alarm (Die change)
Root cause: Tappet pins are slow. Due to not bleed tappets. Tappets not home fast enough. Slows whole machine cycle time down
Countermeasure: Bled tappets
Reoccurre What: Cycle time alarm and robot alarm. Die shuts no injection.
Why: Mid stop wrong
Counter measure: Set from1.7 to 6.0
R/C: Yes time
Cycle time: Unchanged What: Cycle time alarm. (Robot sits at open door and some times pulls shot and stops)
Why: What: Cycle time alarms
Why: Plunger rod not returning to home position
C/M: Took shot position sensor apart and cleaned it then Re- installed
Recur: Possibly in time What: Cycle time alarms
Why: Robot to slow. Has too many trim presses to go to. Not at back door when die opens.
Counter measure: Re taught with out scrap press What: Cycle time concern in TYPE 04 program (Line 22 PR[5])
Why: Robot has a point before entering die set to FINE100, causes a hesitation in movement
C/M: Set to CNT100 so it will reach position and What: Cycle time over
R/C: Bottom left product detect sensor is hit or miss on sensing the part.
C/M: Touched up position 11(position at product detects) because part was just out of the sensor range. What: Cycle time over
Why: Eject stroke not going back to zero causing the robot to wait on the machine, flashing on shot sensor
Countermeasure: Pulled shot sensor and cleaned
Will problem reoccur: Po What: Cycle time over
Why: Ladle pour not moving, motor shaft bearings locked up
Countermeasure: Pulled arm and rebuilt unit
Will problem reoccur: Possibly
Cycle time: No change What: Cycle time over
Why Channel 4 squeeze pin not returning in the alotted time
C/M: DM replaced top squeeze pin and bushing
Recur: Possibly in time What: Cycle time over alarms
Why: Die junction box bad for slide cores
Counter measure: Replaced box
R/C: yes
Cycle time: Cycle time What: Cycle time over alarms
Why: Helper door not opening all the way
Counter measure: Adjusted rod cylinder at coupler. So door will hit limit switch better What: Cycle time over alarms on the backdoor
Why: Solenoid valve not working
C/M: Replaced Solenoid
Recur: Possibly in time What: Cycle time over and R/B malfunction faults
Why: Injector lube feed collar fell off of sleeve
C/M: Reinstalled collar. Ran machine with no faults. What: Cycle time over faults
Why: cavity 1 part breaking off coming out of die, causing NG program to run on robot
c/m: Ejector pin depth set to plex at 15mm was set at 30mm causing dent in part. die What: Cycle time over faults
Why: product detect flickering
Counter measure: tightend up connection and cleaned sensor
R/C:
Cycle time: unchanged What: Cycle time over, no die lock. Running 59B 1RKR
Why: What: Cycle time slow
Why: Robot slow
Counter measure: Retaught robot P-49 P-50
R/C: No
Cycle time: B-27.1 A-26.8 What: Cycle time slow.
Why: Air line for robot chuck came out of coating and put itself in a bind causing it to pinch off air flow.
C/M: Replaced air line.
R/O: Timing. What: Cycle time. Ladle not pouring
Why: G51C hit or miss on making
Counter measure: Put pressure switch on PR2 for accumulator. (Note: Make sure when changing there is a small O-ring that goes on end What: Cylinder bad on melting lid.
Why: Cylinder went bad
C/M: Replaced cylinder
Recur: In time What: Cylinder vibration on trim press
Why: Up down coil in valve no good
C/M: Replaced with new
Recur: Possibly in time What: D/C M/C cycle timing over. What: DC machine saying vac not in Auto
Why: original air pressure needed to be set higher then normal
C/M: Turned original air up from .550 to .590 What: DCM faulted for "Vacuum Equipment Failure "Auto Mode Off"
Why: Vacuum machine going into auto mode but alarm still displaying on TOSCAST screen What: DCM alarmed for Vacuum Equipment not on What: DCM control panel monitor not working with touch
Why: Operator sprayed cleaner on it to clean the screen and it got behind the screen
C/M: Put replacement in What: DCM screen says that vacuum system isn't in auto
Why: Vacuum Interlock cannon plug broken off at DCM panel What: DCM showing robot malfunction.
Why: Robot faulted because water flow valve controller faulted out for Line 4 Leak Error
C/M: Found Line 4 valve stuck open when it should be closed, had to power What: DCM,Rectange.SP
Why: Engineer worked on over shut down
C/M: DCM Rectange SP was disabled engineer Enabled it
Recur: No What: DH asked for new turntable cover
Why: Old one worn and warped, causing table to not move
C/M: Replaced turntable cover, table turning OK What: DH asked me to fix upper limit probes
Why: Wire broke off at the ring terminals
C/M: Put new terminals on and adjusted upper limit level down a little bit What: DH called for air leak beneath cat walk (air bowl/regulator and oiler for lid)
Why: Air bowl/regulator not lined up properly, bolt damaged and not clamping sections together properly anymore.
C/ What: DH called for broken draw bar
Why: Root cause unknown, draw bar broken off where it threads into injector plate
C/M: Got DH new draw bar, got broken piece of old draw bar out of die What: DH called said lid wont open to load ingots.
Why: Solenoid valve was melted on the right hand side looking at valve and had an air leak.
C/M: Replaced valved and confirmed our lid open and close What: DH could not get spray robot home
Why: Root cause unknown
C/M: Used robot pendant to send robot home What: DH having issues with product detect after changeover
Why: Bottom left product detect only seeing objects if they are really close, adjustment not working
C/M: Replace product detect sensor What: DH noticed leak from stack on trim press
Why: O-ring bad on cap bolt
C/M: Replace o-ring on bolt What: Damage on part from vibrator
Why- r/b pos off in die
c/m- touch up in die
reoccur- yes What: Damaged parts
Why: Parts being damaged when there is a squeeze master fault
C/M: Checked hydraulic fitting/lines for good connections and leaks. DH bleeding squeeze master. After bleeding no axi What: Damaged plexiglass panel on operator door.
C/M: Replaced plexi glass What: Damper Lid Cylinder intermittently drifting shut while open.
Why: Failing cylinder
Countermeasure: Attempted to install Engineering countermeasure cylinder that has a built in lock in the cylind What: Damper will not open/close, elevator will not move
Why: E-Stop must have been pressed at some point on the ingot loader, this causes a fault to generate on the safety panel. The alarm on the saf What: Die 13 5BA cavity 2 slide core crack.
Why: Crack in slide core.
Countermeasure: Replaced slide core. What: Die 16 reed switch issue
Why: Robot side cylinder not returning all the way
Counter measure: Pulled die What: Die 16 reed switch not making
Why: Cylinder on robot side not returning all the way
Counter measure: Pulled die What: Die 59B #5 leaking water movable side
Why: Leaking at fitting in back of movable side
Counter measure: Pulled die and cut hose at fitting and water tested
R/C: Yes time
Cycle time: Unchanged What: Die Casting Machine Lubricant Shortage (B-121), Die Height Lubricant Shortage (B-123).
Why: Miscommunication of countermeasure implementation of mold heater no XA05 was hooked up to PLC rack pr What: Die Cleaning. Running water passage.
Countermeasure: Cleaned Die.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Die F-11 5BA-P 11-1 Slide core crack.
Why: Wear.
Countermeasure: Replaced 5BA-P 11-1 slide core. What: Die Height load reading too low.
Why: Needed V-check.
Countermeasure: Cycled power to force V-check. What: Die Over temp
Why: solenoid valve
C/M: took valve apart, clean valve
Recurr: mechanical valve, with time What: Die Release Pump
Why: ?
C/M: Replaced with new pump
Recur: Possible in time What: Die Release Pump not working.
Root Cause: Pump worn out.
Countermeasure: Replaced pump.
Will Problem Reoccur?: Yes. What: Die Release dosage pump
Why: ?
C/M: Replaced pump
Recur: Possibly in time What: Die Release pump no good
Why: ?
C/M: Replaced with new pump
Recur: Possibly in time What: Die Release pump not working.
Countermeasure: Rebuilt pump.
Will Problem Reoccur?: Yes. What: Die Release tank flooded.
Root Cause: Air line got loose and blew fluid around.
Countermeasure: Secured air line. What: Die Release weak multiple times.
Root cause: Automatic Spray Unit worn out.
Countermeasure: Replaced with a rebuilt Automatic Spray Unit on the Die Release tank.
Will Problem Reoccur?: No. What: Die blew out at bottom
Why: ?
Counter measure: pulled die cleaned die platen and mounting surface of die
R/C: possible
Cycle time: Unchanged What: Die blow out
Why: Aluminum stuck to die
Counter measure: Cleaned die What: Die blow out
Why: Flashing
Counter measure: Cleaned die What: Die blow out
Why: Unknown
Counter measure: Pulled die What: Die blow out 6A0 M
Why: Flashing on face of die
Counter measure: Cleaned die
R/C: Yes
Cycle time: Unchanged What: Die blow out and movable core 2 malfunction.
Why: Cavity #4 slide core got stuck in. Pin was bent and broke slide core removing
Counter measure: Replaced pin slide core
R/C: Unknown
Cycle time: What: Die blow out operator side
Why: Unknown
Counter measure: Changed vacuum block and reset die Hight and dry shot What: Die cast 3 mist filters out of spec
Why: Dirty
Counter measure: Replaced all filters What: Die cast M/C shutting off for E-Stop
Why: I/O board Mits. WSO-XT1084202 in upper front safety panel was bad
C/M: Replaced with new board
Recur: Unknown What: Die cast lubrication malfunction Alarm
Why: Pressure switch problem. Wire terminals in pump were loose
Counter measure: Tightened wire terminals. Changed pressure switch
R/C: Unknown
Cycle time What: Die cast machine air supply oiler squirting oil out of drip cap.
Why: Drip cap busted allowing oil to squirt out.
C/M: Replace old oiler with new.
Recur: In time What: Die cast machine lubrication malfunction alarm
Why: Filter bowl was loose and sucked in air
Counter measure: Tightened bowl and bled line
R/C: No
Cycle time: Unchanged What: Die change
Why: Sleeve up on life and bad blow back
Counter measure: Replaced sleeve and tip. Cleaned lube tip out too plugged up from blow back
R/C:
Cycle time: Unchanged What: Die change, worn tip & sleeve
Why: tip & sleeve worn
C/M: Tip & sleeve Replacement
Recur: Yes, timing What: Die cleaning What: Die cleaning
Why: Dirty
Counter measure: Cleaned die What: Die cleaning
Why: Soldering
Counter measure: cleaned die What: Die cleaning (Cavity 2 RPY)
Why:
Counter measure: Cleaned die
R/C:
Cycle time: Unchanged What: Die cleaning for soldering, cavity 2
Why: Wear in die, causing aluminum buildup
C/M: Put alclean on die, and cleaned off buildup with stone What: Die close and open safety hook coupler broke off all 4 bolts in safety hook block
Why: Not sure
C/M: Took off the safety unit off machine tore all down to get block out of bracket had to drill o What: Die closing really hard after changeover
Why: Die height setting on changeover paperwork was wrong, after setting die height and putting adjustment in auto it would move the platen too far forwa What: Die closing slow
Root cause: Safety hook cylinder blew seal
Counter measure: Replaced cylinder
Reoccurrence: Yes Time
Cycle time before: 32.3 seconds Cycle time after: 29.8 What: Die crash 5A2 P/M
Why: Broke slide core pin for M bottom core
Counter measure: Change die and investigate
R/C: Unknown
Cycle time: Unchanged What: Die crash on 1st shift (shot was left in die and shut) 59B Die #7 All 4 cavitys
Why: Operator error
Counter measure: Checked die and took parts to lab to be measured
R/C: Unknown
Cycle time: Unc What: Die dirty
Why: Aluminium build up
Counter measure: Cleaned die What: Die dirty
Why: Soldering
Counter measure: Polished die What: Die guide broke
Why: Bolt broke
Counter measure: Replaced bolt for slide core guide on fixed operator bottom, side What: Die had a lot of build up on robot side.
Countermeasure: Cleaned Die.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Die height Fwd. sel. sw. damaged.
Why: Physically impact.
R/C: unknown
Countermeasure: Replace damaged switch.
Will It Re-occur: Yes What: Die height not able to get
Why: Tie bar sensor for tie bar nut not reading
C/m: Cleaned sensor and started working What: Die height to low hitting locate pins
Why: Die slide plates and shoes worn
C/M: Adjusted shoes not much of adjustment
Recur: Yes shoes and plates need replaced soon. What: Die lab quality judged cavity 1 (Die 3) parts as NG
Why: Porosity
Countermeasure: Reduced spray timer and increased blow timer, also adjusted spray and blow points for cavity
Will problem reoccu What: Die leaking water
Why: Fitting on movable side behind ejector plate leaking
Counter measure: Removed die and repaired
R/C: NO
Cycle time: Unchanged What: Die leaking water
Why: Fixed side sprue bushing pipe at Farrell leaking
Counter measure: Replaced pipe What: Die lock alarms
Why: Tie bar load sensor. Jumping around and dropping off
Counter measure: Pulled sensor and found it was loose in compression lock. Re tighten and ok What: Die lock issue
Why: Die stopping when closing then taking off again. Some times hydraulic pump stops Spray cartage bouncing off middle sensor causing die to think spray cartage in way.
Counter What: Die lock malfunction
Why: Unknown
Counter measure: Reset alarm and started What: Die lock malfunction during full auto. Shuts die cast machine hydraulic pump off
Why: Robot faulting at trim press (Line 270 to 280 set down in trim press). Big claw shoulder bolt broke
Counter What: Die lock malfunctions
Why: Load going over 105% and dropping to 80%. It does due to going past locking of scissor point.
Counter measure: Adjusted load in auto not manual. Not sure why it has to What: Die making noise when opening. (Thumping)
Why: sprue bushing sticking to sprue
Counter measure: Blew out sprue bushing and sprue What: Die manifold
Why: Cant bleed dies
Counter measure: Installed manifold
R/C: No
Cycle time: Unchanged What: Die needed cleaned
Why: Soldering
Counter measure: Cleaned die What: Die needed cleaned.
Why: Build up.
Countermeasure: Cleaned die F-8 Water passage. What: Die not heating up
Why: Hand valves were open to fixed and movable sides with bowl heater set at 95 deg.
Counter measure: Closed hand valves What: Die over heating (Temp D)and main runner breaking off in sleeve
Why: Over heating due to mold temp controller running too hot
c/m- replace solenoid valve on mold temp controller. change T/S
reoc What: Die pump not pumping
Why: Air was off
Counter measure: Turned air on
R/C: No
Cycle time: Unchanged What: Die release concentration not stable dropping off below 1.0
Why: Dosage pump failing
C/M: Replaced pump with new
Recur: Possible in time What: Die release mixture off
Why: Float had hole in it
Counter measure: Replaced float
R/C: no
cycle time: Unchanged What: Die release no good stops making pressure in midst of running
Why: Pump no good
C/M: put last one on but it was used
Recur: In time What: Die release not getting injected into tank
Why dosing adomizer not working correctly
C/M: Replaced with new
Recur: Possibly in time What: Die release not working
R/C: Hole in die release hose not allowing vaccum to keep prime to machine
C/M: Replaced line and installed quick connect fittings to allow easy removal and clean out, p What: Die release oiler leaking
Why: Unknown was cracked
C/M: Replaced with new
Recur: In time What: Die release pressure gauge out of spec
Why: Gauge bad
Counter measure: What: Die release problem
Why: Little black hose in tank come out and put water all over 24v power supply.
Counter measure: Dried out 24v power supply What: Die release pump
Why: No Pressure
C/M: Replaced pump with new
Recur: Possibly in time What: Die release pump NG
Why: Not able to build pressure anymore
C/M: Replace with used pump changed out for PM. What: Die release pump issues
Why: Filter clogged
Countermeasure: Unclogged filter What: Die release pump losing prime
Why: Pump NG
C/M: Change pump What: Die release pump no good
Why: Pumping to fast Cavitating
C/M: Replaced pump
Recur: Possibly in time What: Die release pump not working
Why: Bad pump
C/M: Replaced pump
Recur: Possible in time What: Die release pump not working
Why: Solenoid valve burnt up not working
C/M: Bypassed valve
Recur: no What: Die release pump stopped
Why: Filter plugged
Counter measure: Cleaned filter
R/C: Yes time
Cycle time: Unchanged What: Die release pump stopped
Why: Went bad
Counter measure: Replaced pump
R/C: Yes time
Cycle time: Unchanged What: Die release spray cartage valve staying on
Why: One of the little spray valves stuck on
Counter measure: Replaced valve
R/C: Yes time
Cycle time: Unchanged What: Die release tank concentration low
R/C: Die release cylinder not staying primed
C/M: replaced intake line, replaced die release cylinder with non inventory cylinder. Adjusted to correct reading What: Die release tank foaming
Why: Water line to close to surface
C/M: Took line zip tied down close to bottom of tank
Recur: Possibly in time. What: Die release tank leaking water
Why: Piping was loose
Counter measure: Tightened pipes
R/C: No
Cycle time: Unchanged What: Die release tank only water, overflowing
R/C: Float valve NG
C/M: Removed and installed float valve for water shutoff valve.
Will it reoccur: Timing
Cycle time: No change What: Die release tank over flowed
Why: Float stuck. Had hole in it
Counter measure: Replaced upper limit float
R/C: No
Cycle time: Unchanged What: Die release tank over flowed
Why: Upper float had pin hole in it
Counter measure: Replaced float
R/C: No
Cycle time: Unchanged What: Die release tank over flowing.
Why: The float wasn't making contact to tell water to shut off.
R/C: Float had sludge build up on it.
C/M: Drained and cleaned tank.
R/O: Yes if tank is not cleane What: Die release tank pressure valve
Why: Pressure valve broke
Counter measure: Replaced valve
R/C: No
Cycle time: Unchanged What: Die release too high (2.36)
Why: Mixture was wrong
Counter measure: Moved mixture pin to 70 from 60. Now 1.90
R/C:
Cycle time: Unchanged What: Die release unit overflowed
Why: Float sticking-Slime sticking to the floats What: Die slamming.
Why: Moveable side came loose.
Countermeasure: Operator leveled die. What: Die spray no good
Why: Die Release pump fail
C/M: Replaced pump with new
Recur: Possibly in time What: Die temp. is getting to high.
Why: There isn't sufficient water flow.
C/M: Switched well pumps for 2 to lead and 1 to lag and replaced right side water filter for uh diecast.
R/O: Yes. What: Die temperature Low on moveable side
R/C: Thermocouple NG
C/M: DH had to remove die and install another die due to thermocouple was NG not reading correctly
Will it reoccur: No What: Die thumping when separating
Why: Sprue bushing not getting water. Checked with air seemed plugged
Counter measure: Took fittings off and found one was bottomed out in bushing. Reseated pipe
R/C What: Die water leak.
Why: Damaged fitting.
Countermeasure: Replaced fitting.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Die won't close
Why: Ejector limit position control off alarm
C/M: Ran ejector in and back out fault cleared but die still wouldn't close. Cycled power and the die would close but V check is fla What: Die wont close
Why: Multiple problems. 1st cycle start push button (r01a) broke and E stop wire was barely terminated. Key switch 24v wire broke too
Counter measure: Replaced button and re-termi What: Die would not close.
Why: Aluminum blown out of die.
Countermeasure: Cleaned Die, freed jammed slide cores (both the bottom ones), replaced pipe on bottom robot side slide core.
Will Problem R What: Die wrecked, all four slide cores broken.
R/C: No other explanation found other than operator error.
Countermeasure: Verified all product detect sensors, operation and location OK
Will it Re-occ What: Difficulty opening/closing melting furnace lid
Why: Faulty solenoid valve
C/M: Replace valve What: Dig marks by slide core
Why: Trim leaving marks
Counter measure: Replaced guides
R/C: Yes time
Cycle time: Unchanged What: Disconnect abandoned safety circuit wiring.
Why:
C/M: What: Dog door cable broke.
Root cause: Worn cable.
Countermeasure: Replaced steel cable.
Will Problem Reoccur?: No What: Doghouse separated from furnace face with one mounting stud sheared off. Bottom right.
Why: Corundum build up on top of crucible forced doghouse out of position shearing the mounting stud.
Coun What: Door closed and broke safety slide for charging loader
Why: Root cause unknown, operator said it closed before he could pull latch back
C/M: Replace safety slide What: Door hard to close and not lining up with safety lock
Why: Safety lock bracket and actual mechanism on bracket loose
C/M: Tightened up bracket and lock body. Door feels like door on diecast 5. T What: Door open alarm on trim press (Safety equipment)
Why: Contactor
Countermeasure: Tracked NBF-2 to 1719CON1 contactor in grey box on top of trim press. Was stuck in causing the door alarm. Tapped What: Door safety lock for ingot loader has broke
Why: Wear and tear
Countermeasure: Replaced
Will problem reoccur: Possibly
Cycle time: NA machine was down What: Door safety lock for loader door broken
Why: It appears too long of a screw was put into a blind hole
C/M: Replace switch
Recur: Possible in time What: Door switch alarm. (operator door)
Why: door switch bad and terminal strip in side push button door came loose
Counter measure: Replaced door switch and snapped back on terminal strip What: Drain for die water and tip. Box leaking around Plexiglass.
Root cause: Plexiglass cracked
Counter measure: Took off and replaced plexiglass
Reoccurrence: Yes time
Cycle time: Unchanged What: Draw Bar bad
Counter measure: replaced bar What: Draw bar bent
Why: Happened during die change
Counter measure: Replaced draw bar
R/C: No
Cycle time: Unchanged What: Dropping 5BA M parts. Biscuit has hole in it
Why:
Counter measure:
R/C:
Cycle time: What: Dropping Cavity 4, Parallel issues Cavities 2,4
Why: Possible die being to hot
C/M: Changed fixed side thermocouple
Recur: Possibly in time What: Dropping cavity 1
Why: Build up on rocker shaft area
C/M: Polished cavity 1 and waxed also waxed ejector pins
Recur: Possibly in time What: Dropping cavity 1 part
Why : Squeeze pin not returning What: Dropping cavity 2
Why: Part chunked out when it breaks off
Counter measure: Bled squeeze master. polished cavity too What: Dropping cavity 2, S part
Why: Sticking to squeeze pin
C/M: Alclean and waxed pin What: Dropping cavity 2and 4
Why: Chill block no good
C/M: Replaced operator side chill block with brand new and slight adjustment to spray. Taka adjusted ejector pin back from 15 to 30 What: Dropping cavity 3 and going to product detect sitting there then faulting out for hydraulic pump motor overload
Why: no spray hitting that cavity
C/M: Took spray cartridge off blew thru all wate What: Dropping part
Why: Biscuit thickness too thin.
Counter measure: Bumped up to a 18 biscuit from 14. Plus did a lock release in profile to set high speed shot
R/C: Yes time
Cycle time: Unchanged What: Dropping part (3-3 RPY)
Why: Slide core
Counter measure: Took very bottom slide core out and cleaned and put ejector pin speed from 35 to 60 what plex says
R/C: Yes time
Cycle time: Unchanged What: Dropping part (RPY #2)
Why: Blown block due to hole in clear hose and blue piston wash hose had hole in it
Counter measure: Replaced clear hose and vacuum block and blue piston wash hose
R/C:
C What: Dropping part (cavity 2).
cause: Build up on die cavity
countermeasure: Die maintenance polished cavity 2 and connecting area to clean up die
reoccurrence: Yes, this particular die (RPY M die #1 What: Dropping part after change over
Why: Temp wasn't coming on movable side
Counter measure: Set temps on both sides of die
R/C: No
Cycle time: Unchanged What: Dropping part.
Why: Die release filter dirty and Robot bottom side not moving smoothly. Die Release filter was cleaned and die release checked and adjusted into range.
Countermeasure: Freed up b What: Dropping parts
Why:
Counter measure: Adjusted water to come on for movable side and bled squeeze master What: Dropping parts
Why: Bad fittings at top of die leaking water. Both center fittings down face of die when it cycled water
Counter measure: Replaced fitting
R/C:
Cycle time: Unchanged What: Dropping parts
Why: Biscuit was too small
Counter measure: Set to plex 23mm
R/C: Unknown
Cycle time: Unchanged What: Dropping parts
Why: Both bottom slide cores stuck
C/M: Removed both and cleaned
Recur: Possible in time What: Dropping parts
Why: Bushings for squeeze pins worn
Counter measure: Replaced die
R/C: Yes
Cycle time: Unchanged What: Dropping parts
Why: Die release pump not working due to stuck solenoid valve
Counter measure: Put oil in oiler
R/C: No
Cycle time: unchanged What: Dropping parts
Why: Die release pump slow
C/M: Prime die release pump, cleaned squeeze pins & bled out squeeze master (checked for hydraulic leaks)
Recur: What: Dropping parts
Why: Not enough die release
Counter measure: Turned up spray time What: Dropping parts
Why: Setting for ejection wrong
Counter measure: Set to plex settings. Saved program. Speed and pressure wrong. Speed was 80 now 60 and pressure was 10 now 14.7
R/C No
Cycle time: What: Dropping parts
Why: Squeeze master
Root cause: Squeeze master was moved and new lines put on and pods needed adjusted to new diameter of pipes.
Counter measure: Adjusted flow and pressure on all What: Dropping parts
Why: Squeeze master and temp
Counter measure: Re bled squeeze master and adjusted temp so movable side got water What: Dropping parts
Why: Sticking to die
Counter measure: polished fixed die cavity 2 What: Dropping parts 5BA M
Why:
Counter measure:
R/C:
Cycle time: What: Dropping parts Cav 2
Why: Concentration was low & Spray points off
C/M: Adjusted spray points slightly (Cav 2 only), corrected concentration & cleaned die lube filter What: Dropping parts cav. 1
Why: Spray points
C/M: Checked concentration and spray points, Adjusted cav. 1 spray nozzle slightly What: Dropping parts from die 5A2 p/m
Why: Die runners really bad. P part
Counter measure: Polished bad spots on runners What: Dropping parts robot side bottom
Why: Vacuum block robot side was blown. No alarm. The shot was sticking in vacuum block a little. When die separated it was cracking shot around part.
Counter m What: Dropping parts, Tree falling off, vacuum trouble
R/C:
C/M:
Will it reoccur: What: Dropping shot
Why: Biscuit to small robot not able to grab it
Counter measure: Up size of biscuit What: Dropping shot
Why: Plunger lube
Root cause: Not enough lube.
Counter measure: Turned lube up 1/4 turn
R/C: No
Cycle time: Unchanged What: Dropping shot
Why: Shot sticking to tip breaking biscuit off in sleeve. Sleeve and tip worn
Counter measure: Replaced tip and sleeve
R/C: Yes time
Cycle time: Unchanged What: Dropping shot
Why: Sticking in sleeve
Counter measure: Replaced tip and sleeve
R/C: Yes time
Cycle time: Unchanged
SHOT LIFE: ? What: Dropping shot
Why: Water leak
counter measure: Trimmed water line for cooling joint to sleeve. Water was misting over pour hole in sleeve
R/C: No
Cycle time: Unchanged What: Dropping shot and blow back
Why: Sleeve and tip worn
Counter measure: Replace tip and sleeve with used
R/C: Yes Time
Cycle time: Unchanged What: Dropping shot coming out of DCM
Why: Hole in air line
C/M: Cut out bad section of hose causing leak What: Dropping shots
Why: Tip for lube got plugged from over poor
Counter measure: Cleaned tip and adjusted ladle forward limit from 146.8 to 146
R/C: Yes time
Cycle time: Unchanged What: Dropping the chill block overflow robot side
Why: No spray to block
C/M: Put line in so spray on block
Recur: possibly in time What: During a practice die change operator discovered broken draw bar
Why: Root cause undetermined
Countermeasure: Gave operator and Japanese associates a new draw bar What: During change over noticed the sleeve was all pitted.
Why: Wear.
Countermeasure: Got new sleeve and tip. Reminded to check plunger lube and lube the sleeve before running. What: During change over they noticed change-over sleeve was damaged.
Countermeasure: Replaced tip and sleeve for change-over.
Will Problem Reoccur?: Timing. What: During change over, Steve Wagner noticed gouging inside sleeve
Why: Worn
C/M: Replace tip Reoccur: Yes with wear What: During die change, (tie bar) nut open limit not made fault occurred
Why: Slide core hydraulic line fell down and blocked the travel of the tie bar clamp cylinder
Countermeasure: Had to remove ti What: During die changed found broken draw bar. (Broke off in die)
Why: Speculating that it wasn't all the way tight
Counter measure: Replaced draw bar What: E stop at helper side control panel missing button
Root cause: Operator snagged it and it fell off
Countermeasure: Replaced E stop
Reoccurrence: No What: E stop broke by back helper door
Why: Got hit by something
Counter measure: Replaced e stop button
R/C: No
Cycle time: Unchanged What: E- stop alarm
Why:1623CB1 or 1625CB1 were tripped in main safety panel
Counter measure: Reset
R/C: Unknown
Cycle time: Unchanged What: E-Stop alarm on robot, DCM and squeeze master
Why: After cycling power on safety panel Station A would not go into RUN mode, it was just sitting in IDLE
C/M: Logged into MELSEC as Admin and tol What: E-stop alarm
Why: Wiring in seal tight by ladle to safety got melted
Counter measure: Replaced wiring
R/C: No
Cycle time: Unchanged What: E-stop alarm on squeeze master
Why: Safety circuit displayed E-stop alarm coming form robot cage but no doors were open or e-stops were pressed
C/M: Powered everything down besides furnace and p What: Earth quake alarm
Why: sensor bumped allowing reset to trip
C/M: Reset earth quake sensor, showed operator where sensor located. What: Earth quake switch housing broke What: Ejecting shot before robot grabs shot
Why:
Counter measure: What: Ejector pin broke
Why: PC Malfunction Alarm code Maintenance code 0.50
Counter measure: Pulled die and replaced ejector pin What: Ejector pin broke
Why: Part breaks off in cavity where M3 Insert core pin is and when ejector pins come out it breaks.
Counter measure: Complete teardown of moveable die to remove Broken ejector What: Ejector pin broke #7 (6A0 M die)
Why: aluminum build up
Counter measure: Replaced pin
R/C: Yes time
Cycle time : Unchanged What: Ejector pin height out of spec
Why: Some one ground on it.
Counter measure: Pulled die
R/C: No
Cycle time: Unchanged What: Ejector pin sliding on part
Why: Squeeze master
Root cause: Squeeze pin not returning all the way and causing ejector pin to bind on part
Counter measure: Thread taped some leaking fittings on m What: Ejector pins squeaking
Why: Aluminum build up
Counter measure: Cleaned and waxed pins
R/C: Yes
Cycle time: Unchanged What: Ejectors broke
Why: ?
C/M: Replaced both sides
Recur: Possibly in time What: Electrode Fault.
Why: Vacuum hose caught on electrode probes bending them.
Countermeasure: Replaced electrode unit.
Will Problem Reoccur?: Should not.
Cycle Time: No Change. What: Electrode Faults.
Why: Electrode rode loose.
Countermeasure: Tightened Rod. What: Electrode Malfunction Alarms.
Root cause: Ceramics on electrode worn out.
Countermeasure: Replaced electrode assembly with rebuilt one. What: Electrode malfunction
Why: Loose probe
Countermeasure: Retighten probe
Reoccur: Possible What: Electrode malfunction
Why: One of the wires to the probe broke.
C/M: Replaced ladle wire and worked ladle back and fourth to confirm working with no electrode faults. What: Eliminate Safety hazard. Allthread rod / beam clamp set up not adequately sized for supporting D/C 9 crane cable .
Why: Mr. Haney must have had it on his truck to sell.
C/M: Fabricate unistrut h What: Engineering observed robot stuttering during travel. Recent occurances of position reteaching, asked to inspect and evaluate R/B
Why: J5 mechanical gearing had a very slight tight spot not like What: Erratic temp readings holding
Why: Bad thermo coupler
Countermeasure: Replace thermo coupler
Reoccur: No What: Excessive blow back
Why:
Countermeasure: Replace tip and sleeve
Reoccur: Possible What: Excessive blow back
Why: Worn tip
C/M: Changed tip, inspected sleeve and made sure injector lube tip wasn't clogged What: Excessive blow back
Why: Worn tip
Counter measure: Replaced tip
R/C:
cycle time: unchangded What: Excessive blow back at tip and sleeve
Why: Tip worn
Counter measure: Replaced tip
R/C: Yes time
Cycle time: Unchanged What: Excessive blow back from sleeve. 5A2 P/M F-29
Why: ?
Counter measure: Stoned bushing mount. Did run out on rod from tip to end .012 .017 .017 .009 . Replaced tip and sleeve and sleeve bushing
R/ What: Excessive blow out and soldering on Operator side of die
Why: Aluminum build up on die
Countermeasure: Cleaned die
Will problem reoccur: Possibly
Cycle time: No change What: Excessive blowback
Why: Worn Tip And Sleeve
Countermeasure: Replace Tip and Sleeve
Reoccur: Yes at life
Cycle time: No change What: Excessive blowback
Why: Worn tip
Countermeasure: Replaced tip
Will problem reoccur: Possibly
Cycle time: No change What: Excessive blowback reported
Why: Tip and sleeve NG
Countermeasure: Pulled tip and sleeve and gave to production to change What: Excessive blowback. M/C wont run
Why: DCM ran without plunger lube for undetermined amount of time. Plugged plunger lube tip
Countermeasure: Replace damaged Tip and Sleeve
Reoccur: Yes
Cycle tim What: Excessive liquid in pit.
Why: Leaks.
Countermeasure: Replaced leaking spray valve. Repaired leaking hose on die.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Exhaust Temp for Upper crucible is reading low.
Why: Bad thermocouple
Countermeasure: Replaced thermocouple & then wire going to control box.
Will Problem Reoccur?: Timing.
Cycle Time: No Chang What: Exhaust gas smell and gas flow valve not working
Why: Travis and I Investigated in the Terminal box for gas valve and meter and found that alot of wires were melted to the panel and together sho What: Exhaust gas temeperature controller "alarm 1"
Why: Thermocouple issues.
C/M: pulled thermocouple, let it relax (temperature lower way down). Re-inserted it and tightened connections inside head What: Exhaust gas thermocoupler reading low
Why: Set screw that holds rod in place loose and it backed out of lid. fork terminals loose
C/M: Adjusted position of thermocouple and tightened up screws What: Exhaust temp jumping around.
Root cause: Placement of thermo coupler.
Countermeasure: Adjusted thermo coupler. What: Exhaust temp thermocoupler wire broken/shorted
Why: Wear from heat
C/M: Replaced thermocoupler wire from box to thermocoupler head What: Exit conveyor stopped to unload table
Why: Guide rollers bushings damaged
Counter measure: Replaced rollers
R/C: yes time
Cycle time: Unchanged What: Faulting out at trim press because sensor is reading a bent up tree.
Why: Dunk tank had too much stuff in it.
Countermeasure: Removed debris out of dunk tank. What: Faults at the scrap press
Why: Shot not sitting in Press all the way
C/M: Retaught final set position
Recur: Possibly in time What: Faults at trim press
Why: Possibly robot not sitting shot in correctly
C/M: Re-taught robot at trim What: Faults at trim press
Why: Robot not sitting in press correctly causing sensor not to read right
C/M: Retaught positions 25,26 Was off
Recur: Possibly in time What: Faulty Ladle
Why: Cracked
C/M: Replaced 1.5 Ladle
"wrong ladle issued to m/c, should of been 1.0 but 1.5 was given"
correct ladle was given to operator What: Filter Break
Why: ?
C/M: Replaced filter only
Recur: Yes In time What: Filter change. (Taka wanted changed) What: Filter cracked in crucible
R/C: Not sure of r/c
C/M: DH on 2nd ladeled out, started cooling down, Cut and installed filter and patched in
Will it reoccur: Timing What: Filter cracked. Results in inclusions in the aluminum.
R/C: "OPERATOR ERROR" Burner was switched off for cleaning, was not turned back on. Aluminum
cooled completely. When Re-heated, expansion c What: Filter cracked/ clogged
Why: Not getting cleaned properly not sure how cracked
C/M: Replaced crucible with new
Recur: In time What: Filter for mist collector out of range
Counter measure: Replaced stage 2 What: Filter had a hole in it
Why: ?
C/M: Replaced filter only
Recur: Possibly in time What: Filter has a hole in it
Why: Root cause unknown, issue passed on from 1st shift
C/M: Pulled doghouse, and both halves of ring. Pulled crucible and put fans on it What: Filter has hole in it
Why: Operator had ladle hit tool and tool hit filter and put hole in it
Counter measure: Replaced crucibles
R/C: Yes
Cycle time: Unchanged What: Filter in crucible broke
Why:Cracked on one side and collapsed
Counter measure: Replaced filter
R/C: Yes time
Cycle time: Unchanged What: Filter system will not turn on
R/C: Blown fuse in power panel
C/M: Replaced NG fuse and tested motor ok
Will it reoccur: Timing
C/T: No cycle time change, M/C running while filter system being w What: Filters out of range
Counter measure: replaced stage 3 What: Finished cooling joint change on sleeve
Why: Matt F. decided to leave before finishing it
C/M: Changed out cooling joint What: Fix side cooling water not working
Why: Unknown
C/M: Took water cooling valve off machine and cleaned
Recur: Possible in time What: Fixed 1 Temp too low.
Why: Not able to heat up.
Root Cause: Valve always open, water constantly flowing.
Countermeasure: Took Valve apart and cleaned.
Will Problem Reoccur?: Yes, once crud build What: Fixed core 1 not moving
Why: After shot core wont move. Due to Hydraulic hose un coupling fitting when closing
Counter measure: Re routed hoses What: Fixed core alarms 6B2 die #7
Why: top lead switch NG
Counter measure: replaced top lead switch
R/C:
Cycle time: Unchanged What: Fixed core malfunction
Why: Robot side slide core had debris in it. Hit slide core around tab that gets vibrator takes off.
Counter measure: Cleaned out debris
R/C: Unknown
Cycle time: Unchanged What: Fixed die is getting too hot and that water float balls are not moving.
Root cause: Water flow thru die not correct
Countermeasure: Pulled die and replaced with another. Replaced die temperatur What: Fixed side die getting too hot.
Why: Water not cooling it down, float balls not moving.
Countermeasure: Blew out die, verified water flow.
Will Problem Reoccur?: Possible.
Cycle Time: No Chan What: Fixed side die leaking
Why: Sprue bushing cracked
Countermeasure: Replaced sprue bushing
Will problem reoccur: Possibly
Cycle time: No change What: Fixed side die not staying up to temp
Why: Die thermocouple dirty
C/M: Pulled fixed side die and cleaned thermocouple. What: Fixed side of die not heating up
Why: Themo couple not reading right
Counter measure: Pulled fix side to check if Themo couple all the way in What: Fixed side running low temp, not going above 90
Why: Bad thermocouple
C/M: Replaced thermocouple, temp normal now on fixed side What: Fixed side slide core (A) broke in die. Water passage #1
Why: Unknown
Counter measure: Replaced fixed slide core (A)
R/C: Yes time
Cycle time: Unchanged What: Fixed side temp issues
Why: Bad thermocoupler wire
C/M: Replaced thermocoupler with non-inventory part from die maintenance What: Fixed side thermocouple bad
Why: Possible broken wire
C/M: Replaced with new
Recur: Wear item What: Fixed side water leak, spray cartridge water leak
Why: Bad fitting, faulty valve
C/M: changed fitting on die and replaced valve on spray cartridge What: Fixed side water valve bad
Why: Time
Counter measure: Replaced valve What: Flame out at melting burner
Why: Melting burner flame relay no good
C/M: Took relay from die cast 5 put into 3 now working Also took igniter rod and replaced it also very corroded and cleaned ph What: Flame out melting (Upper)
Why: Peeper eye. (Photo eye) dirty
Counter measure: Cleaned Peeper eye What: Flame out on holding crucible
Why: Igniter was in wrong. Ceramic star piece fell out.
Counter measure: Replaced igniter "NON INVENTORY"
R/C: No
Cycle time: Unchanged What: Flame out on holding furnace
Why: Ignition rod wiring not good and ignition rod burnt at end
C/M: Cleaned end of ignition rod and electric taped the wire for stability didnt have any bare wires What: Flame out on melting burner
Why: Photo-eye not seeing flame consistently
C/M: Replace photo-eye What: Flame out on melting furnace
Why: Igniter rod was burnt on end and possibly to close to side of burner causing it to flame out
C/M: Took all apart cleaned spark rod end and took burner plate off What: Flame out smelting
why: air fuel ratio off and bad igniter insulator
c/m: replaced insulator with non-inventory and adjusted air fuel ratio along with relay R10 What: Flame out upper crucible
Why: Bad photo eye
Counter measure: Cleaned photo eye What: Flame out upper crucible
why- ignition rod NG
c/m- replace ignition rod "NON INVENTORY"
recur- timing What: Flameout alarm on Melting.
Why: possibly the tower want pushed all the way to the home position after scrape out causing flame out
Countermeasure: pushed tower to home position and adjusted pilo What: Flange bad for sleeve
Why: Worn
Counter measure: Replaced flange What: Flashing
Why: Solder in pockets, Noticed leaking slide core (cracked)
C/M: Clean die and replace slide core M3
Recur: In Time, (just replaced Saturday 15th) What: Flashing & Blowback
Why: Sleeve worn/wash out
C/M: Replace both tip & sleeve
Recur: Yes, timing What: Flashing and Blowback
Why: Washout
C/M: Replace both Tip and Sleeve
Recur: Yes in time What: Flashing at tip Why: tip no good Why: Lube bracket loose not getting consistant lube
C/M: Replaced with new What: Flashing on die (6A0 M #2)
Why: Bottom two slide cores got aluminum behind them
Counter measure: Took them out and cleaned
R/C: No
Cycle time: Unchanged What: Flexible Lube line needs replaced.
Why: Un-determined.
C/M: Install flex lube line.
Will it Re-occur: Un-determined. What: Flipper #1 bushing bad
Why: Wore out
Counter measure: Replaced bushing
R/C: Yes time
Cycle time: Unchanged What: Flipper #3 fell out
Why: Weld broke on flapper
Counter measure: Welded flapper back on mounting
R/C: No
Cycle time: Unchanged What: Flipper #3 not working correctly
Why: Sensor no good/ parts piled and jammed on NG conveyor all way back up in flipper shoot
C/M: Replaced sensor and cleaned all parts out
Recur yes in time What: Flipper 2 not getting sensor light
Why: Sensor need adjustment
C/M: Adjusted and cleaned
Recur: Possibly in time What: Flipper 3 not working
Why: Solenoid valve wiring no good
C/M: Wiggled wiring and it worked What: Flipper 4 was not getting return light
Why: Bracket on bottom of ok bucket fell apart had alot of parts build up
C/M: Travis and I got it cleaned up then put smaller sheet metal screws in it to What: Float bracket broke
Why: ?
C/M: Removed bracket
Recur: Possibly in time What: Flow line
Why: Leaking spray cartage
Counter measure: Replaced two spray valves
R/C: No
Cycle time: Unchanged What: Flow line Cav4
Why: Water leak over cav4 on spray cartridge
C/M: Replaced spray cartridge valve. What: Flow line/soldering
Why:
C/M: Inspected die for any water leaks, cleaned die. What: Forward ladle limit alarm
Why: Turn buckles loose on chains
Counter measure: Tightened turn buckles
R/C: Yes
Cycle time: Unchanged What: Forward ladle malfunction
Why: Sensor loose
Counter measure: Tightened and cleaned arm mating surface
R/C: Yes Don't have deep well socket to get real tight
Cycle time: Unchanged What: Forward limit malfunction
Why: Forward sensor staying on
Countermeasure: Replaced sensor
R/C: No
Cycle time: Unchanged What: Forward limit switch for ladle
Why: Aluminum chips on sensor
C/M: Cleaned off sensor
Recur: In time What: Frequent motor overload, trim press
Why: Turn table 2 not turning
C/M: Removed top, cleaned out flashing and replaced locked up bearing What: Front door bracket broke
Why:
Counter measure: Welded back together What: Front door issue
Why: Bad switch
Counter measure: Replaced switch What: Front door switch alarm
Why: Safety switch bad
Counter measure: Replaced switch and pin What: Front operator door safety switch no good
Why: inside locking mechanism broke
C/M: Replaced door lock with new
Recur: Possibly in time What: Front operator door switch no good
Why: Locking mechanism not engaging
C/M: Replaced switch What: Furnace Damper open switch sticking in position
Why: Bad limit switch
C/M: Replaced open limit switch and took the actuator arm off old switch and put it on the close limit switch to replace it What: Furnace PLC not coming on, unresponsive.
Why: E-Stop on furnace bumped, then started having issues with breaker tripping in safety cabinet when trying to reset robot panel. Found damaged termina What: Furnace alarm
Why: Earth quake alarm
Counter measure: Reset alarm waited for it to heat back up What: Furnace alarm
Why; High temp alarm
Counter measure: Change over they missed changing holding E3 from 1220 to1292 What: Furnace alarm (AL01)
Why: Thermo coupler
Root Cause: Bad thermo coupler in furnace. Melted end off
Countermeasure: Replaced thermo coupler
R/C: Yes Life of thermo coupler
Cycle time: Unchanged What: Furnace and robot issues
Why: Upper furnace not melting and robot stopping
Counter measure: Adjusted furnace valve What: Furnace continuously misfiring.
Why: UV sensor for flame detect possibly damaged when unit filled with aluminum a few days ago.
Countermeasure: Change UV Flame detect sensor
Reoccur:Yes What: Furnace door bad
Why: Bottom of back door falling out
Counter measure: Repair door
R/C: Yes time
Cycle time: Unchanged What: Furnace door for loader not shutting.
Why: Ingot loader not all the way down.
Countermeasure: Got loader all the way down and shut door. What: Furnace door wont open
R/C: Air turned off to door, air bowl leaking at fitting
C/M: removed air bowl and fittings, replaced fitting with pipe in between to remove air leak
Will it reoccur:NO What: Furnace door wont open
Why: Cable to front door broke
Counter measure: Fixed door cable What: Furnace flame outs
Why: Igniter bad and igniter wire
Counter measure: Replaced both
R/C: No
Cycle time: Unchanged What: Furnace gate not locking/unlocking
Why: Cross circuit at I1,2,3,4,5,6 on module 2 above DCM panel. Found melted wires running to plug and took out module 2 IO card
C/M: Replaced cable with Braxt What: Furnace glowing around melting metal leak door
Why: brick on furnace sticking out all looks good
C/M: Tried grinding some material away but still not sealing may need to take backdoor off and te What: Furnace head damper close limit not getting made.
Why: Sensor not made while lid was closed.
Countermeasure: Adjusted Close limit switch sensor so that it was made when lid is closed. What: Furnace head door won't open.
R/C: Sol 1 wire was pulled out of cannon plug.
C/M: Reterminated wire.
R/O: NO
Cycle Time: NO Change. What: Furnace hood not sliding on rails into position correctly
Why: Possible bearings on wheels no good
C/M: Checked bearing they were ok so shimmed up wheels to get more clearance
Recur: Possibly in What: Furnace lid drifting down
Why: Locking cylinder was on free and not lock
C/M: moved lock from free to Lock What: Furnace lid not closing
Why: Bad Flow control valve
C/M: Replaced with new
Recur: Possibly in time What: Furnace loading door seal leak
Why: Bottom seal in door missing
C/M: Replaced door seal
Recur: Yes, timing What: Furnace not fire
Why: Safety circuit has a E stop pushed alarm, Cable to safety sw. at crucible gate damaged.
Counter measure: Replace damaged cable and re-route. What: Furnace not firing
Why:
Counter measure: What: Furnace not firing
Why: Earth quake alarm
Counter measure: Reset alarm What: Furnace not getting up to temp
Why: Input door was not closed allowing furnace to go into high temp burn
Countermeasure: Closed input door What: Furnace not heating up
Why: Bad gas valve
Counter measure: Replaced valve What: Furnace not heating up
Why: Belly thermo coupler bad. Was reading 1652 but was much colder
Counter measure: Replaced coupler
R/C: No
Cycle time: Unchanged What: Furnace not hitting temp
Why: Loading door not closing. Wheel fell off
Counter measure: Put guide wheel back on What: Furnace not melting fast enough
Why: Thermocouple not in all way and furnace needed scraped
C/M: Scraped melting furnace Had alot of build up
Recur: Yes if nobody cleans melting furnace What: Furnace not melting right
Why: Upper crucible lower thermo coupler bad
Counter measure: Replaced thermo coupler What: Furnace rebuild (unscheduled) due to furnace condition. Sending out off-site for repair.
Why: Dog House was not properly secured to furnace causing significant furnace damage.
R/C: Associate or What: Furnace refractory failure behind Doghouse
Why : Refractory has pushed outward from the furnace separating the doghouse from the face of the furnace
Countermeasure: Remove doghouse ,Jackhammer m What: Furnace repair corner chunk missing
Why: Door damaged while air hammering
Counter measure: Patched side door and back door openings
R/C: Yes
Cycle time: Unchanged What: Furnace replaced What: Furnace replacement What: Furnace replacement
Why: Up on life
Counter measure: replaced furnace and crucible What: Furnace replacement and crucible
Why: Life
Counter measure: Replaced crucible 2nd shift What: Furnace side door leaking flame
Why: Chip out of furnace
Counter measure: What: Furnace temp to high
Why: Thermocouple bad
C/M: Replaced thermocouple with new
Recur: In time What: Furnas door would not shut ingot loader side.
Why: Ingot loader did not have down light.
Countermeasure: Got ingot loader down, made light, shut door. What: Gas Leak at furnace pipe
Why: Where the union is pipe not tight
C/M: Took apart and taped and pipe dope and taped again
Recur: No What: Gauge 39 out of spec
Why: Regulator to high
Counter measure: Turned down regulator What: Gauges marked out of spec in red #12,#17,#18,#24,#39,#40
Why QAV
c/m- marked gauges in correct spots What: Getting Fix Die Cooling Flow low alarms
Why: Flow sometimes dropping to 41L/m. Setting is 42-52L/m
C/M: Adjusted down to 41L/m to keep machine running due to high priority. Emailing Taka to info What: Getting blow back
R/C: Plunger tip is bad, looked at the sleeve it seemed ok. Tip is bad due to plunger lube tip getting clogged up.
C/M: Changed Plunger tip.
R/O: Timing.
Cycle Time: NO Change What: Getting blow back out of the sleeve.
R/C: Tip and sleeve are trashed due to not enough plunger lube.
C/M: Replaced both tip and sleeve and adjusted spray tip for plunger lube.
R/O: NO
Cycle Tim What: Getting blow back.
Why: Tip and Sleeve are worn.
R/C: sleeve is at 76,000 life is 90,000
C/M: Replacing tip and sleeve.
R/O: Yes tip and sleeve could prematurely fail due to many diferent varia What: Getting sporadic collision detects in trim press
Why: Position in press off a little
C/M: Touch up set down position in trim press What: Getting temperature D outer signal alarms
Why: Spray timer set too high (.09)
Countermeasure: I adjusted the spray timer per PLEX What: Good part turn table not turning
Why: Broken shaft & bad bearings
C/M: Replaced all bad parts
Reoccur: Yes, timing What: Good parts conveyor jammed
Why: Aluminum between chain & sprocket
C/M: Removed aluminum
Reoccur: Possible What: Got called in due to a metal leak on the melting crucible
Why: the spout on the melting crucible was completely plugged caused it to over flow What: Green tower light out
Why: Blown
Counter measure: Replaced bulb
R/C: No
Cycle time: Unchanged What: Guard fell off big conveyor
Why: Scrap got in behind it
Counter measure: Repaired guard
R/C: Yes
Cycle time: Unchanged What: Guide pin for lower slide core broke
Why: Unknown
Counter measure: Pulled die What: HEPA Change
Why: Trimist HEPA filter out of spec (606)
C/M: Changed filter
Reoccur: Yes, timing What: HEPA Change
Why: Trimist HEPA filters out of spec, 12B (603) & 12D (606)
C/M: Changed filters
Reoccur: Yes, timing What: Had a blow out
Why: Possibly no load on Tie Bar and Tie bar nut loose
C/M: Tighten Tie Bar nut clamp bolts and gonna check load on tie bar
Recur: In time What: Had blow out on die (6A0 M #2
Why: Bottom slide cores locked up
Counter measure: Pulled both bottom slide cores and cleaned. One bolt hole was packed with aluminum. Drilled out and replaced Bott What: Half pipe broke
Why: ?
C/M: replaced half pipe
Recur: Possibly in time What: Half pipe broke
Why: Unknown
C/M: Replaced
Recur: Yes in time What: Half pipe cracked
Why: Not a good style cracked and broke
C/M: Replaced halfpipe What: Half pipe cracked
Why: Possible no support under that part of half pipe
C/M: Replaced half pipe and put mound under end by spout for support
Recur: Possibly in time. What: Halfpipe broke caused metal leak
Why: Corundom build up on Halfpipe and spout Excessive heat and aluminum build up
C/M: Replaced melting crucible and half pipe What: Handle for melting side door broke.
Why: Wear.
Countermeasure: Repaired handle, made washer to be able to close door securely. What: Hard aluminum in sleeve
WHY: 90 off on ladle so when the m/c faulted for the robot the ladle still in auto goes back and forth from furnace to sleeve and was dumping a little aluminum in sleeve What: Hardened aluminum in sleeve
Why: Ladle bar alarm after it poured, machine stopped with aluminum in sleeve
C/M: Tried heating up and pushing out with plunger rod, found it causes fixed die to pus What: Having biscuit trouble
Why: ladle 90 degree was off
C/M: Adjusted the 90 and also check the ladle chains What: Heat alarm 02
Why: Not heating
Counter measure: Pulled thermo coupler and cleaned end
R/C: Yes
Cycle time: Unchanged What: Heating cooling unit getting a 02 alarm (Float)
Why: Float stuck down.
Counter measure: Cleaned float. Will need new one soon
R/C: Yes shaft for float worn
Cycle time: Unchanged What: Heavy burr on P1 roller groove backside on rocker shaft
Why: Slide core problem
C/M: Cleaned die with scotch brite alclean
Recur: Yes in time What: Heavy flashing around spru pin
Why: Spotted die while in machine Spru pin in inset in holding block
C/M: Replace spru Pin
Recur: No What: Heavy flashing, small biscuit
Why: Aluminum buildup & bottom slide cores not moving
C/M: Clean die, remove bottom slide cores & clean slots
Recur: Possible What: Heavy washout, Blowback
Why: Wear
C/M: Replace tip & sleeve (during changeover) What: Helper Door Alarm.
Why: Bracket on helper door came loose not making the sensors.
Countermeasure: Replaced loose bolt, tightened up. What: Helper door
Why: Not closing due to broken bracket
Counter measure: Replaced bracket at bottom for door for cylinder What: Helper door alarm
Why: Bolts fell out of cylinder bracket for door
Counter measure: Replaced bolts and lock tight in What: Helper door alarm
Why: Cylinder came off door
Counter measure: Reattached door to cylinder What: Helper door alarm
Why: Door bouncing
Counter measure: Put in line air valves to control door open and closing What: Helper door alarm
Why: Door slammed open and bounced off sensors
Counter measure: Adjusted Speed and cushion sensor guide rail and found guide wheel had flat spot. Replaced wheel
R/C: Yes time
What: Helper door alarm
Why: Limit switch arm came loose and roller on door came loose
Counter measure: Tightened both
R/C: Yes time
Cycle time: Unchanged What: Helper door alarm
Why: Loose wheel on bottom front
Counter measure: Remover door tightened wheel and checked others What: Helper door bump sensor , and Helper door 2 limit switch
Why: wiring to bump sensor no good and limit switch not working, and in wrong position
C/M: Ran new wiring for sensor and put new limit s What: Helper door came off track.
Why: Worn.
Countermeasure: Got door back on track, worked back and forth several times - not running on 3rd. What: Helper door catching on cover
Why: Door catching cover when returning
C/M: Adjusted air, ground down cover slightly where you could see door has been rubbing What: Helper door close LS2 fault
Why: Suspected faulty limit switch
C/M: Confirmed limit switches operational. Noticed door would close normal speed until the last few inches and door moved very slow What: Helper door fault
Why: Bracket on end of cylinder broke off
Counter measure: Welded bracket What: Helper door faults
Why: Cylinder building up back pressure then slamming shut cause limit switch to stick
C/M: Adjusted limit switch What: Helper door issue
Why: Bottom wheel came loose and let door lean and lose front sensor for close. (Close LS 2)\
Counter measure: Tightened wheel What: Helper door issue
Why: Bouncing of sensor due to missing not on cylinder
Counter measure: Replaced nut and adjusted sensor rail down What: Helper door issue
Why: Limit switch arm came off
Counter measure: Put arm back on What: Helper door limit switch failure
Why: Helper door wheels were bad.
Counter measure: Replaced all 4 wheels and welded bad spot. Put new impact strip on too. Replaced 2 bearing in wheels
R/C: no
C What: Helper door limit switch issues
Why: Not getting Door Close LS2, had door off for test fit. Middle limit switch arm backward
C/M: Loosened LS2 and flipped arm, making Door Close LS2 when door cl What: Helper door not closing
Why: Bad solenoid valve, solenoid base pulled in flashing and plugged air fittings
C/M: Replaced solenoid valve, cleaned out solenoid base and air fittings then replaced What: Helper door not closing
Why: Impact strip damaged
Countermeasure: Replace impact strip
Reoccur: No What: Helper door not closing from operational panel.
Why: Robot not homed correctly interlock on causing robot to not know where it was
Countermeasure: Rehome robot to clear interlock fault
Reoccur: What: Helper door off track
Why: Weld broke
Counter measure: Welded door and Replaced wheel. Had to bend door back from being bent What: Helper door opening before all the way closed
Why: Solenoid for open coming on mid movement
C/M: Swapped relays for door open and close and issue went away. Possible relay issue? What: Helper door slamming
Why: Cylinder blowing by on front end, unable to dial in cushions
Countermeasure: Replaced cylinder What: Helper door stopped.
Why: Cylinder was loose and had blow by in cylinder
Counter measure: Replaced cylinder
R/C: Yes time What: Helper door will not close via the switch at the operator panel
Why: Wire for bump detect on helper door touching terminal box wall causing it to short and think it is closing on something
C/M: What: Helper door wont move
Why: Cylinder bracket on the door broke
Countermeasure: Rewelded bracket and reinstalled What: Helper door wont open
Why: Cylinder came off door. Broke floating joint
Counter measure: Reattached cylinder. Replaced floating joint
R/C: Yes time
Cycle time: Unchanged What: Helper door would not close
Why: Robot Main power not on
C/m:Turned main power on to RB, Cleared all alarms able to manually move helper door(E/S see below)
will it reoccur: no
cycle time: uncha What: Helper side Auto door limit switch malfunction.
R/C: Door cylinder bolts fell out and it was just hanging free.
C/M: Put 4 new bolts in it.
Reoccurrence: NO What: Helper side auto door limit switch malfunction
Why: Bracket for helper door had came loose, also the jam nut for the helper door cylinder cam loose
Countermeasure: Tightened both of these What: Helper side door
Why: Off track and cracked
C/M: re weld crack and adjusted rollers
Recur: Possibly in time What: Helper side door #2 limit switch not making
Why: Door rollers wore. not letting rail for sensors to make contact
counter measure: Replace rollers on helper door What: Helper side door alarm
Why: Bottom wheel came loose
Counter measure: Tightened wheel What: Helper side door alarm
Why: Cylinder bolts were loose
Counter measure: Tightened bolts
R/C: No
Cycle time: unchanged What: Helper side door alarm
Why: Sensor rail bolts fell out
Counter measure: replaced bolts
R/C:
Cycle time: Unchanged What: Helper side door fault
Why: Bracket the holds the cylinder to door broke.
C/M: Welded bracket.
R/O: yes due to unknown reason why bracket broke.
C/T: NO Change. What: Helper side door issue
Why: Close Limit switch 2. Due to limit switch rail fell and door cylinder came loose
Counter measure Fixed rail and cylinder What: Helper side door jamming
Why: Top guides came loose, allowing door to sag
C/M: Pushed up guide wheels and tightened What: Helper side door limit switch faults
Why: Door cylinder broke off r/b side helper door
R/C: No pm schedule to check mechanical parts on machine
c/m: Removed bracket and repaired, reinstalled doo What: Helper side door not moving. In Manual or full auto
Why: Terminal strip TB2 unclipped off of circuit board behind operator panel
Counter measure: Re-clipped it back in and found that main mount What: Helper side door not opening
Why: Cylinder rod had worked free of door mount
C/M: Replaced floating joint on end of cylinder rod due to inability to tighten jam nut. Set and tested. OK
Reoccu What: Helper side lower slide core was locked up. Cavity #3. Die 6 5BA
Why: Bunch of flashing
Counter measure: Pulled die
R/C:
Cycle time: unchanged What: Helper side vacuum block stuck in die
Why: Die smashed around vacuum block slot
C/M: Couldn't get block out, notified operator to pull die What: High Shot speed
Why: Checked plunger lube setting was 0.7 made 0.8
C/M: Checked coupler and shaft movement
Recur: Possibly in time
Cycle time: 26.8 What: High Sp shot alarms, biscuit thickness fluctuating
Why: Worn tip and sleeve
C/M: Replaced tip and sleeve. Replaced 0-ring on inj. shaft cooling tube What: High and low biscuit faults.
Why: Biscuit size fluctuating.
Countermeasure: Adjusted In Furnace from 2.9 s to 5.0s (adjusted to plex settings). What: High casting pressure alarms
Why: Out of casing range
Counter measure: Let some nitro out of accumulator What: High cycle time
Why: Spray cartridge down speed slow
C/M: First shift to turn air cylinder back up slightly What: High pitched squeal coming from trim press
Why: Sounds like a bad bearing in pump, comes and goes
C/M: Told to let them finish running, try to investigate further when machine is down What: High shot speed
Why: Tip worn
C/M: Replaced tip
Recur: Possibly in time What: High shot speed alarms
Why: Lube tip plugged
Counter measure: Unplugged tip What: High shot speed.
Why: Inconsistent lube in sleeve
C/M: Adjusted lube bracket
Recur: In time What: High speed alarms and shot is falling apart
Why: Too much blow back from sleeve
Counter measure: Replaced tip and sleeve
R/C: Yes time
Cycle time: Unchanged What: High speed shot alarm/ pressure buildup alarms
R/C: Ladle pour off, pouring aluminum on top of sleeve and over top
C/M: Reset origin positions for ladle arm at sleeve
Will it reoccur: No What: High speed shots that are low and Axis problems
Why: Sprue bushing leaking
Counter measure: Replaced sprue bushing
R/C: Yes time
Cycle time: Unchanged What: High temp alarms fixed side of die
R/C: Not enough water flow to machine
C/M: Removed floor and adjusted water valve flow from 80% to 90% open allowing more water
Will it reoccur: No
Cycle time What: High trim on P part, cavity 1
Why: No shim in cutters on that cavity
C/M: Added .300 micron shim on both sides of shaft hole side cutter and .150 micron shim on tap hole side cutter What: High trim on cavity 4
Why: Block in trim die needed adjusted
C/M: Adjusted block in trim die What: High trim on end of part causing machine trouble
Why: Cause we dont use cutters it uses pusher punches
C/M: Trying to come up with a Countermeasure to lower the trim height What: Hold crucible temperature fluctuation
Why: Bad thermo coupler
Countermeasure: Replace thermo coupler What: Holding Burner flame outs
Why: Photo eye very dirty
C/M: Took apart photo eye cleaned with alcohol cleaned the motor shroud completely clogged, also there was a filter just sitting on burner so What: Holding Faulting out for metal leak.
Why: No metal leak present.
Countermeasure: Terminated wiring. Verified it would fault if there was a metal leak it would. What: Holding Furnace Alarm addon not working, reads SEN ERROR
Why: Temp controller wires from controller to addon unit swapped. No idea on who or why they were swapped
C/M: Swapped wires back so 11 - What: Holding and Melting burner turned off on their own.
Why: Found that the Melting thermocoupler reading was jumping all over.
Countermeasure: Replaced thermocoupler wire.
Will Problem Reoccur?: What: Holding burner flameout
Why: Checked for spark at firing rod, found PLC not getting correct signal from Flame detection relay (FR1)
C/M: Replaced FR1, Crucible is now heating up What: Holding burner issues, not firing.
Why: M8 "Combustion Stop On" had been set in program. This bit can be set by either M70 "Leak out" (molten metal leak) or by pressing the Reset and Buzzer stop What: Holding burner misfire issues.
Why: Burner units needs to be taken out and cleaned, What: Holding burner not firing
Why: Temperature controller settings issue
C/M: Found old paperwork from Aisa and Tanaka with original values, tried getting settings back to proper ranges. Furnace fir What: Holding burner not firing, ingot loader not getting "Charging M/C On" condition.
Why: Lift not able to make lower limit due to an ingot having dropped into space below lift.
C/M: Suspended lif What: Holding crucible change
Why: Big hole in the filter
C/M: Replace crucible and half pipe What: Holding crucible filter break
Why: It was a filter trial with only little paste
C/M: Replaced crucible and pedestal
pasted whole filter in
Recur: Possibly in time
Recu What: Holding crucible filter got a hole in it
Why: Not sure
C/M: Replaced holding crucible and stand and halfpipe What: Holding crucible metal detect wire broken
Why: Heat related, wires just break from ring terminals
C/M: Reterminated both wires to each probe What: Holding crucible metal leak
Why: Back side of filter overflow
C/M: None, just helped with getting smoke under control What: Holding crucible metal leak
Why: Root cause unknown, no leak and probes are clean. Fault not resetting
C/M: Fault does not reset, it will randomly just clear. Possible timer issue? What: Holding crucible molten level upper limit made
Why: Wrong brick used to hold upper limit probes, worn out and grounding on metal bracket
C/M: Cut new brick and replaced old one What: Holding crucible temp reading issues
Why: Bad thermocoupler wires
C/M: Replaced wires from thermocoupler to terminal box What: Holding crucible thermocouple bad.
Why: Wear.
Countermeasure: Replaced holding crucible thermocouple. What: Holding crucible thermocouple not reading
Why: Thermocouple broke off
C/M: Replaced with new thermocouple What: Holding crucible upper limit not working
Why: Bad wire connections at the probes & no electrode on the center
C/M: Cleaned wire terminals, replaced the center wire terminal as well as the thread What: Holding crucible upper limit wire broke
Why: Terminal broke off of wire
C/M: Reterminate What: Holding crucible upper limit wire broke.
Why: Wear.
Countermeasure: Reterminated wire. What: Holding furnace thermocouple broke
Why: Old and worn
C/M: Replaced thermocouple
Recur: In time What: Holding temp bouncing around
Why: Thermocouple no good
C/M: replaced with new
Recur: In time What: Holding temp low
Why: Thermo coupler
Root cause: Holding crucible thermo coupler broke off
Countermeasure: Replaced thermo coupler
R/C: Yes Time
Cycle time: B 26.5 A 26.5 What: Holding temp spiked to 1700 degrees
Why: Thermocouple wire was bad
C/M: Replaced wiring from thermocouple to terminal box What: Holding temperature dropping and set point at 600 degrees
Why: Found that the blue rest mode button had been pushed on the furnace control panel
C/M: Turned rest mode off What: Holding thermocouple not reading correctly
Why: Wiring burnt and melted together
C/M: Replaced wiring from junction box out to thermocouple and still not working after investigating i found that What: Hole in Holding crucible filter
Why: Its a Mystery
C/M: Replace melting crucible ,Half Pipe and Holding stand
Recur: Possibly in time What: Hole in crucible filter
Why: ?
C/M: replace filter
Recur: Possibly in time What: Hole in filter
Why: ?
C/M: Replace upper and lower crucibles
Recur: Possibly in time What: Hole in filter
Why: ?
C/M: Replaced upper and lower crucible
Recur: Yes in time What: Hole in holding crucible filter
Why: ?
C/M: Replaced holding crucible with new
Recur: Yes in time What: Hole in the filter
Why: Possibly cleaning filter when aluminum hardened
C/M: Took some Lumicast and pasted both sides of filter What: Hole in the holding crucible filter
Why: Possible associate scraping
C/M: Patched filter and operators are to call DH for filter scraping. What: Hood fell off track
Why: Operator pulled on it possibly pulled to hard
C/M: Got back on track operator can run
Recur: Possibly in time What: Hot spots on backside of melting furnace
Why: Wool on melting crucible covered over from furnace to inside crucible
C/M: Cut section between furnace and crucible in wool
Recur: No What: Hyd pump overload fault
Why: T1 terminal loose on safety starter
Countermeasure: Retighten terminals
Reoccur: Possible What: Hyd. pump shuts down while running
Why: Set screw of coupling for "die closing sensor" encoder loose. This encoder in on the East side of the M/C and can be seen looking directly over main hydr What: Hydraulic Coupler for tappets not working
Why: Dent in coupler
Counter measure: Replaced coupler
R/C: Yes time
Cycle time: Unchanged What: Hydraulic Leak
Why: Metal tube/pipe weld cracked
C/M: Re-weld
Recur: In time What: Hydraulic Leak Injection pipe
Why: O-ring blew out Why: 4 different size bolts in block
C/M: Replaced o-ring and all 4 bolts
Recur: Possibly in time What: Hydraulic Leak at trim press manifold
Why: Aluminum Manifold P port was cracked and oil running out
C/M: Replaced with new manifold
Recur: Possible in time What: Hydraulic Leak.
Why: Fitting on the squeeze master bleeding block broke.
Countermeasure: Replaced fitting. What: Hydraulic and ladle button melted
Why: Heat
Counter measure: Replaced buttons
R/C: Yes time
Cycle time: Unchanged What: Hydraulic block bolts broke.
Why: Wear.
Countermeasure: Repaired and replaced bolts. What: Hydraulic filter change
Why: PM What: Hydraulic filter fault.
Why: Normal wear.
C/M: Replace filter What: Hydraulic hose broke
Why: Time
Counter measure: Replaced hose
R/C: Yes time
Cycle time: Unchanged What: Hydraulic hose leak on trim press
Why: Hole in hose
C/M: Replaced hose
Recur: In time What: Hydraulic injection leaking
Why: cracked and re-welded many times
C/M: Company come in and up-graded piping
Recur: No What: Hydraulic leak
R/C: Hydraulic line going to plunger cylinder leaking
C/M: Removed line and welded area where leak occurred, reinstalled and verified no hydraulic fluid leaking
will it reoccur: What: Hydraulic leak
R/C: NG line/fitting on top of die, line used for operator side squeeze pin moveable core
C/M: Removed NG line, Installed new fittings and line off of Die down for repair.
Will it What: Hydraulic leak
R/C: Vibration of machine, cracked weld at fitting for plunger.
C/M: Removed block, die maintence welding worn area to fix leak. Will install once completed and verify no leak
Wil What: Hydraulic leak
Why: Die close cylinder leaking at advance o ring
Counter measure: Put new o ring in What: Hydraulic leak
Why: 2 Squeeze pins cylinders leaking
Counter measure: Replaced both cylinders
R/C: Yes time
Cycle time: Unchanged What: Hydraulic leak
Why: Blew hose to slide sore by operator door
Counter measure: Replaced hose What: Hydraulic leak
Why: Cracked weld
C/M: Welded the top seam, re-installed and verified no leak What: Hydraulic leak
Why: Cracked weld
c/m- weld crack
recur- in time What: Hydraulic leak
Why: Fitting leaking under DG13 valve by accumulator
Counter measure: Cut pipe and put new fittings on
R/C: No
Cycle time: Unchanged What: Hydraulic leak
Why: Fitting on squeeze pin hydraulic line came loose
Countermeasure: Removed hose and tightened fitting
Will problem reoccur: Possibly
Cycle time: No change What: Hydraulic leak
Why: Fix side of die for 1 rocker tappet pins. Fitting at top leaking
Counter measure: Tightened fitting
R/C: No
Cycle time: Unchanged What: Hydraulic leak
Why: Hole in hose for channel #1 squeeze pin
Counter measure: Replaced line
R/C: Yes time
Cycle time: Unchanged What: Hydraulic leak
Why: Hole in steel line for slide cores
C/M: Having it welded/ Gonna talk to Sam Larger on having new manifold blocks made with high pressure hose
Recur: Possibly until new is mad What: Hydraulic leak
Why: Hose for moveable core got hole in it
Counter measure: Replaced hose
R/C: Yes time
Cycle time: Unchanged What: Hydraulic leak
Why: Hose got hole in it for movable core #2
Counter measure: Replaced hose and refilled tank
R/C: Yes time
Cycle time: Unchanged What: Hydraulic leak
Why: Leaking at steel pipe end
Counter measure: What: Hydraulic leak
Why: Metal pipe on die rubbed tie bar and got hole in it. On movable operator side for movable core
Counter measure> Replaced pipe
R/C: No
Cycle time: Unchanged What: Hydraulic leak
Why: Movable core 2 hydraulic line had bad fitting due to wear
Countermeasure: Replaced female fitting
Will problem reoccur: Possibly
Cycle time: No change What: Hydraulic leak
Why: Movable side metal line for movable core #2 split at weld.
Counter measure: Welded line. Tightened bolts
R/C: Yes time
Cycle time: Unchanged What: Hydraulic leak
Why: O ring leaking on advance cylinder for die close.
Counter measure: Replaced o ring What: Hydraulic leak
Why: On die
Counter measure: Cleaned out coupler What: Hydraulic leak
Why: Pin hole in hydraulic steel line
C/M: Pulled off 2 times to weld
Recur: Possibly in time What: Hydraulic leak
Why: Pipe under accumulator
Counter measure: Welded weld on pipe
R/C: Yes
Cycle time: Unchanged What: Hydraulic leak
Why: Slice core Hyd. line leaking, operator side
C/M: Re-tape fitting threads, tighten
Recur: Possible What: Hydraulic leak
Why: Slide core fitting leaking
Counter measure: Tightened fitting What: Hydraulic leak
Why: Slide core hose got a hole in it
Counter measure: Replaced hose
R/C: Yes Time
Cycle time: Unchanged What: Hydraulic leak
Why: Slide core hose got hole in it
Countermeasure: Replaced slide core hose
R?C: Yes
Cycle time: Unchanged What: Hydraulic leak
Why: Steel hydraulic line on rear of moveable side leaking
C/M: Removed and installed repaired steel hydraulic line
Will it reoccur: Timing
Cycle time: unchanged What: Hydraulic leak
Why: Weld on pipe bad. (Movable core)
Counter measure: Welded it What: Hydraulic leak
Why: Welded area has pin hole leaking hydraulic oil
C/M: Take off and weld
Recur: Possibly in time What: Hydraulic leak
Why: Worn line busted
C/M: Replace line with a new one
Recur: In time What: Hydraulic leak
Why: Metal piping weld cracked
Counter measure: Welded pipe at flange What: Hydraulic leak (Movable core 2) RPY one rocker #3
Why: Wrong fitting and hose on die
Counter measure: Replaced metal line
R/C: NO
Cycle time Unchanged What: Hydraulic leak (squeeze master)
Why: Rubber hose broke
Root cause: Hose broke from rubbing
Counter measure: Replaced hose with short one and routed so it wont rub
R/C: Yes Life
Cycle time: Uncha What: Hydraulic leak at die close cylinder pipe
Why: Pin hole
C/M: Weld repair
Recur: Possibly in time What: Hydraulic leak at die opening cylinder
Why: Pin holes
C/M: Had it welded What: Hydraulic leak at directional valve
C/M: Drained oil & nitrogen, removed valve & cleaned surfaces, inspected O-rings
Reoccur: Yes timing What: Hydraulic leak at injection cylinder pipe
Why: Crack in pipe
C/M: weld repair
Recur: Possibly in time What: Hydraulic leak at injection valve
Why: O-rings torn and no good back of machine where valve is located starting to deteriorate
C/M: Replaced o-rings and valve main block What: Hydraulic leak at the Squeeze pin hard line
Why: Had pin holes in it its been welded multiple times
C/M: Took off machine and re-welded
Recur: Possibly in time What: Hydraulic leak at the manifold block for slide cores
Why: Fitting was loose and possible damaged
C/M: Replaced the fitting with new then leaked so put old back on
Recur: Possibly in time What: Hydraulic leak at the trim press
Why: Line to trim press hydraulic tank dripping constant
C/M: Operator cleaned up mess on floor and filled Tank, Turned pump on and tightened line half turn What: Hydraulic leak at the trim press cylinder
Why: Cylinder seals no good
C/M: Put new Hydraulic cylinder on What: Hydraulic leak at trim press
Why: Not sure yet
C/M: Cleaned up press and manifold started back in auto running need to monitor it no obvious leaks What: Hydraulic leak at trim press manifold
Why: Hydraulic line that runs up and down leaking out of fitting
C/M: Replaced the line with new
Recur: Possibly in time What: Hydraulic leak at trim press tank
Why: Hole in rubber line from tank to steel line
Why: Old and had hole in it
C/M: Replaced with new
Recur Yes What: Hydraulic leak at trim press tank
Why: Hose no good dry rotted
C/M: Replaced with new hydraulic hose What: Hydraulic leak coming from above trim press.
R/C: Leak coming from a plug on a proportioning block for the valve stack that controls scrap press and trim press.
C/M: Put a new o-ring on plug and What: Hydraulic leak coming from operator side of die
Why: Hydraulic hoses for slide cores on operator side worn, leaking from holes in hose
C/M: Replaced both hoses with inventory hoses What: Hydraulic leak from Move core 2 hydraulic line
Why: Hole in line due to wear and age of line
Countermeasure: Replaced hydraulic line What: Hydraulic leak in metal pipe weld
Why: Weld cracked on pipe to fixed side core
Counter measure: Welded
R/C: Yes time
Cycle time: Unchanged What: Hydraulic leak on Die Open/Close hard line
Why: O-ring too flat to hold a seal
Countermeasure: Replaced o-ring What: Hydraulic leak on die
R/C: Worn line on op. side main slide core line
C/M: Removed and replaced with line and fittings on compatible die in die maintenance holding area. Tested and verified no l What: Hydraulic leak on fixed side of die
Why: Tiebar clamp cylinder leaking at fitting
C/M: Took off hose, cleaned out hose female end and cleaned off fitting male end on cylinder What: Hydraulic leak on injection cylinder.
Why: Previous weld ran into the bolt Hole not allowing for complete seating of the bolt causing the O-Ring to blow out.
C/M: Replaced O-Ring and ground arou What: Hydraulic leak on the back of the die(end of steel tube at mounting block)
Why: Cracked
C/M: Removed tube assembly & welded crack
Recur: ? What: Hydraulic leak on the valve stack for trim press
Why: O-rings no good
C/M: Replaced with what we had What: Hydraulic leak on valve
Why: No good filled with oil
C/M: Replaced guage with new What: Hydraulic leak.
Why: Squeeze pin return line has a busted weld.
R/C: Unknown reason as to why weld broke.
C/M: Replaced line with a spare one.
R/O: Yes due to unknown reason as to why weld broke What: Hydraulic leak.
Why: Pipe on Robot side leaking at weld.
Countermeasure: had drew weld pipe x2 pipe has been welded on many times we are working on getting new ones ordered What: Hydraulic leak. (DG15 SSOL)
Why: O-Rings bad
Counter measure: Changed O-Rings on Intensifier DCV
R/C: Yes time
Cycle time: Unchanged What: Hydraulic line leak
Why: Broken weld on hardline
C/M: Got die maintenance associate to re-weld line and reinstalled What: Hydraulic line leaking to movable slide core
Why: Got a hole in it
Counter measure: Replaced line
R/C:
Cycle time: Unchanged What: Hydraulic line leaking, Also air separator bowl leak
Why: Metal fatigue on steel hydraulic line, cracked separator bowl
C/M: Removed and welded steel line, replaced separator bowl
Recur: In time What: Hydraulic lines wound in bad position
Why: Cause hoses are way to long
C/M: Re-ran lines so there not wound wrong and had Bert order new ones that are shorter and re-routed water line and put s What: Hydraulic main pump line pressure fault
Why: Suction filter dirty
Countermeasure: Clean filter
Reoccur yes What: Hydraulic manifold leaking
Why: Manifold pipe has been previously Repaired by welding
Root Cause: Stress on piping caused initial leak and after repair it was still dripping.
Countermeasure : What: Hydraulic manifold loose
Why: Manifold bracket broken
C/M: Removed manifold bracket, steel lines and the valve bracket, Repaired/welded brackets, drilled and tapped holes where bolts were broken What: Hydraulic o/l fault
Why: Main 3 phase safety contactor not making good contact, causing single phase condition
C/M= Remove safety contactor from D/C8 to get 3 running What: Hydraulic oil filter replacement
R/C: pm for hydraulic oil count up
C/M: Replaced hydraulic oil filter
will it reoccur: no, not until count is up for next filter replacment What: Hydraulic oil leak on slide core Hydraulic pipe
Why: Been welded on many times getting worn out
C/M: Re-welded old weld where it was leaking
Recur: Possibly in time. What: Hydraulic oil leak.
Why: The filter housing was not tightend and it had a bad o-ring.
C/M: replaced o-ring and installed filter correctly. What: Hydraulic oil temp high
Why: Machine inner cooler plugged
C/M: Took apart inner cooler and drilled out each hole
Recur: Possibly in time What: Hydraulic oil temp out of spec
Why: Heat exchanger on diecast machine was clogged
C/M: Took apart and drilled out What: Hydraulic pressure out of spec reading 12MPa
Why: Filter gauge in the red
C/M: Changed filter, while off the gauge still reading 12MPa so replaced the gauge
Reoccur: What: Hydraulic pump OL tripping on squeeze master
Why: Root cause unknown
C/M: Reset OL and operator fully bled squeeze master with no issue What: Hydraulic pump button light isn't coming on but the pump is on.
R/C: Light in button is burnt out.
C/M: Replaced button.
R/O: Timing.
Cycle Time: No Change. What: Hydraulic pump dropping out when closing the die
R/C: Toggle side cover close(helper side) reset not completed
C/M: Tracked down to x047 not made. Manually used reset button on helper side rear What: Hydraulic pump noise
Why: Interior pump failure unable to maintain pressure
C/M: Removed suction filter, clean, reinstall, replace pump
Recur: Possible in time What: Hydraulic pump not starting
Why: Motor starter L-2 wire was loose at T-2 on safety starter
Counter measure: Replaced wire
R/C: No
Cycle time: Unchanged What: Hydraulic pump over load
Why: Amp pull over load with pump hooked up. Unhooked pump pull was 31.00. Over load set at 85.00. Bad pump Counter measure: 3rd shift: Replace pump, M/C ran for approx. What: Hydraulic pump over loads
Why: Pumps pressure at both gauges 20 only to be 15 max What: Hydraulic pump overload
Why: Contactor off phantom safety system NG
C/m: Replace damaged 120V starter, install ice cube relay to replace defective 24V coil safety system interface relay to drive What: Hydraulic pump overloads
Why: Found hydraulic pressure was higher than spec, was running at 16 MPa upper spec is 15.5 MPa.
C/M: Adjusted hydraulic return valve, verified production What: Hydraulic pump overloads.
Why: Bad contactor labeled CN, has a melted wire.
C/M: 1st change out contactor What: Hydraulic pump stopped
Why: P/C Malfunction. Cause die to be close with shot in die which caused a water leak on backside of movable side. We had to pull to fix
Counter measure: Pulled die to fi What: Hydraulic pump stopping
Why: Ladle bar break alarm
Counter measure: Replaced ladle wire and 2 insulators were broke
R/C: Unknown
Cycle time: Unchanged What: Hydraulic temp 117 degrees
Why: Inner cooler little dirty couple valves turned off from new water chiller
C/M: Cleaned inner water cooler also had couple valves were off from new chiller
Recur What: Hydraulic temp high
Why: Heat exchanger needs cleaned
Counter measure: Cleaned heat exchanger
R/C: Yes
Cycle time: Unchanged What: Hydraulic temp high
Why: Heat exchanger needs cleaned
Counter measure: Cleaned hydraulic heat exchanger
R/C: Yes time
Cycle time: Unchanged What: Hydraulic temp high
Why: Heat exchanger plugged
Counter measure: Cleaned heat exchanger What: Hydraulic temp reading high 126 Degrees
Why: Heat exchanger at machine was possibly plugged
C/M: Had David Wynn and Draven Burris clean out since never done it
Recur: Possibly in time What: Hydraulic temp trouble
Why: Heat Exchanger on 100T chiller needs cleaned and machine heat exchanger dirty.
C/M: Drilled out machine heat exchanger going to schedule 100T to be cleaned
Recur: Pos What: ID / Replace damaged pilot lights , switches and defective pat lights. What: IMSTP SRVO-37 fault
Why: Selector switch on Fanuk panel was in off position
C/M: Switched to auto, fault cleared What: Ingot Loader
Why: Would not load, would not go up.
Countermeasure: Manually loaded got everything home. What: Ingot bucket lift
Why: Main tilting shaft for bucket come out on one side
Counter measure: Put back in
R/C: No
Cycle time: Unchanged What: Ingot charge machine
Why: Jammed half way up.
Root Cause: Bottom left sprocket walked off it's key.
Countermeasure: Adjusted Sprocket and tightened down.
R/C: NO What: Ingot conv. does not advance.
Why: Ingots tripping LS X41 (over travel LS)
C/M: What: Ingot conveyor motor got hit with aluminum and broke the wiring housing, also melted and smashed some wires
Why: Root cause undetermined
Countermeasure: Rewired the motor, What: Ingot conveyor not advancing
Why: Switch damaged
Countermeasure: Replace switch
Reoccur: Possible What: Ingot conveyor running into ingot loader when advancing
Why: Bottom switch not making contact with paddles
C/M: Tightened head of sensor on the bottom side and adjusted position What: Ingot elevator crashed, pulled shaft out of right side and broke bracket of bottom of chain
why: Ingot bucket not seated back against loader elevator
c/m: Removed right side chain bracket and What: Ingot elevator not working.
Why: Damaged power cord, tripped breaker.
C/M: Reset breaker and repaired cord. What: Ingot issue loading
Why: Prox sensor head ripped off
Counter measure: Replaced sesnor What: Ingot lift stopped
Why: Shaft fell out
C/M: Remove bottom support bar and straightened, Reassembled
Reoccur: Not likely What: Ingot loader
Why: Dropping ingot out of door
Counter measure: Put spacers under rollers on plates ingots ride on to be pushed in What: Ingot loader
Why: Safety door popping open in auto
Root cause: Safety switch not latching right due to door alignment
Counter measure: Modified safety door latch points
R/C: No
Cycle time: Uncha What: Ingot loader alarm
Why: Bracket broke for ingot detect
Counter measure: Welded bracket What: Ingot loader alarm
Why: Limit switch for flight location got damaged
counter measure: Replaced limit switch
R/C:
Cycle time: Unchanged What: Ingot loader alarm
Why: Limit switch not working for pusher 2. Due to broken wires
Counter measure: replaced wires to limit switch What: Ingot loader alarm
Why: No ingots in lift and have home light. Sensor bad
Counter measure: Replaced both sensors What: Ingot loader alarm
Why: Over travel switch bent
Counter measure Straightened switch What: Ingot loader alarm
Why: X041 not made (Pusher 1 set back limit). Found that ingots are flipping and hitting sensor.
Counter measure: Bent ingot lift back down
R/C: Yes
Cycle time: Unchanged What: Ingot loader alarmed.
Why: Loader hit one ingot on the way down (to the return position) that was hanging out of the door.
Countermeasure: Got everything home with solenoids. Pushed the ingot What: Ingot loader alarming out when loading. (Never lifts ingots up).
Why: Melted Aluminum got ingot lift next to conveyor over travel limit. When lift raised it tripped limit and faulted
Counter mea What: Ingot loader bolts came out of flight.
Why: Wear.
Countermeasure: Replaced Bolts. What: Ingot loader bracket broke
Why: Got hit when cleaning furnace
Counter measure: Welded back on
R/C: No
Cycle time: Unchanged What: Ingot loader crash
Why:
Counter measure: What: Ingot loader crash
Why: Came down on top of ingot
C/M: Working on straightening out ingot lift What: Ingot loader crash
Why: Cart wasn't all way in
Counter measure: Un jammed cart
R/C: Yes Operator error
Cycle time: Unchanged What: Ingot loader crash
Why: Conveyor forward position not being set by limit switches. Several bent brackets for ingots
C/M: Replaced several brackets and replaced armature on bottom limit switch fo What: Ingot loader crash
Why: Ingot fell out back and took out flights What: Ingot loader crash
Why: Ingot flipped over
Root cause: Improper loading of ingot
Reoccur. Yes if loaded improperly What: Ingot loader crash
Why: Ingot hit sensor on back side of loader and bent bracket
Counter measure: Bent bracket
R/C: Yes might need to move sensor to front side
Cycle time: Unchanged What: Ingot loader crash
Why: Ingot was lifted up and went over sensor
Counter measure: Deformed ingots should not be loaded
R/C: Yes
Cycle time: Unchanged What: Ingot loader crash
Why: Ingots made irregular
Counter measure: Replaced paddles for ingot What: Ingot loader crash
Why: Limit switch arm bent
Counter measure: Replaced limit switch arm and straightened flights What: Ingot loader crash
Why: Plate to keep debris form getting between furnace and ingot loader was holding ingot loader up.
Counter measure: Removed plate. Bent loader and prox sensor bracket strai What: Ingot loader crash
Why: Prox sensor not seeing ingot
Counter measure: Adjusted sensor up What: Ingot loader crash
Why: Unknown
Counter measure: Replacebent paddels
R/C: Yes
Cycle time: Unchanged What: Ingot loader crash
Why: limit switch didnt make for conveyor advance
Counter measure: replaced mangled flights. straightened all other flights so ingots would fit. replaced any missing bolts. ad What: Ingot loader crash
Why; root cause unknown
Countermeasure: Recovered machine and verified. OK What: Ingot loader crashed
Why: Ingot under conveyor when i got there
Counter measure: Un jammed ingot. What: Ingot loader crashed
Why: Ingots jammed up and destroyed 20 plus paddles
C/M: Replaced with new What: Ingot loader crashed
Why: Operator didnt have it pushed all way in
C/M: Got loader unjammed had to straighten out bracket and now ok What: Ingot loader crashed
Why: Unknown
Countermeasure: Straightened out ingot loader
Will problem reoccur: Possibly
Cycle time: No change What: Ingot loader crashed
Why: limit switch out of position
C/M: adjusted limit switch and straightened ingot paddles
Recur: Yes in time What: Ingot loader crashed
Why: Unknown
Countermeasure: Replaced all broken flights and air lines
Will problem reoccur: Possibly
Cycle time: No change What: Ingot loader crashed.
Countermeasure: Bent Loader and flights back, verified sensors.
Will Problem Reoccur?: Yes.
Cycle Time: No Change. What: Ingot loader crashed.
Why: Unsure some ingots were on wrong some were right.
C/M: Removed all ingots from loader test ran all seemed ok. What: Ingot loader crashed.
Root cause: Limit switch arm was bent causing ingot loader to go up too soon causing ingots to tip over.
Countermeasure: Replaced arm on limit switch (inside conveyor). Al What: Ingot loader door safety switch plug broke.
Why: Did not go in smoothly.
Countermeasure: Replaced plug.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Ingot loader door switch
Why: Handle came apart
Counter measure: re assembled What: Ingot loader door wont open
Why: T2 fell off MC30 starter
Counter measure: Re-attached T2 to starter
R/C: No
Cycle time: Unchanged What: Ingot loader elevator bucket jammed sideways at upper level. Motor overload tripped.
Why: Scrap bin not pushed completely against the back stop.
Countermeasure: Unjam the bucket and return to lo What: Ingot loader fault
Why: Ingot loader not moving ingots forward
counter measure: Replaced motor What: Ingot loader fault
Why: Ingot loader not pushing ingots in furnace
Counter measure: Replaced pusher 1 solenoid valve. Adjusted up cylinder down
R/C: Yes
Cycle time: unchanged What: Ingot loader faulting
Why: Over travel
C/M: Adjusted limit switch and found proximity sensor loose so adjusted and tightened
Recur: Possibly in time What: Ingot loader faulting out
Why: Ingots hitting over travel switch
C/M: Adjusted ingot detect switch What: Ingot loader faulting out
Why: New operator got out of cycle
Countermeasure: Recovered machine What: Ingot loader faulting out every time it loads into furnace
Why: Limit switch actuating arm broken. pusher 2 not hitting advance switch
C/M: Replace arm on switch for pusher 2 advance What: Ingot loader faulting out.
Why: Forward limit switch getting stuck.
Countermeasure: Bent Limit switch back up so it would not get stuck. What: Ingot loader flights bent
Why: Crash
Counter measure: Bent flights What: Ingot loader issue
Why: Loader not stopping
Counter measure: Adjusted prox switch up and over travel switch What: Ingot loader issue
Why: Not getting home light
Why: Switch at bottom of door for conveyor not making What: Ingot loader issue
Why: Not moving. Due to bad limit switch
Counter measure: Replaced limit switch What: Ingot loader issues
Why: Loader was brought down onto ingots and got bent
Countermeasure: Repaired loader What: Ingot loader jammed at upper, Top loading unit sitting on a angle
Why: Scrap hanging out over front of loading bucket
c/m: Removed jammed scrap to home ingot loading and lid, Straitened out uppe What: Ingot loader lift frame work had stripped bolts causing it to jam while lifting.
Why : M-16 Bolts that held the support beam had stripped threads
Countermeasure : Removed M-16 bolts and re tappe What: Ingot loader loading no good
Why: Aluminum build up between ingot loader and Furnace
C/M: Ed fowler jackhammered aluminum out between loader and furnace
Recur: yes in time What: Ingot loader loosing home position
Why: Pusher #2 cylinder drifting
Counter measure: Found bad spot in hose. And replaced it
R/C:
Cycle time: Unchanged What: Ingot loader losing home light
Why: Blow by on cylinder. Pusher 1 cylinder
Counter measure: Replaced cylinder
R/C: Yes time
Cycle time: Unchanged What: Ingot loader losing home light
Why: Pusher 2 drifting forward
Counter measure:
R/C: Yes
Cycle time: Unchanged What: Ingot loader main air supply leak
Why: Hose rubbed flippers
counter measure: Replaced hose
R/C: No
Cycle time: Unchanged What: Ingot loader missing flight
Why: Bolts broken off
Countermeasure: Replace flight and install new bolts What: Ingot loader not dumping
Why: Open limit not made for lid
Counter measure: Adjusted limit switch What: Ingot loader not making forward limit switch.
Why: Limit switch melted.
Countermeasure: Replaced limit switch.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Ingot loader not moving
Why: Bottom shaft on lift out of position jamming lift
C/M: Moved shaft back into position and tightened set screws What: Ingot loader not moving
Why: Inner drive sprocket keyway broke damaged shaft
C/M: Welded the shaft to the inner sprocket so machine can run need to order replacement parts
Recur: Possibly In tim What: Ingot loader not moving forward
Why: Peckerhead cover was off motor and aluminum on wires ans limit switch for over travel NG
C/M: Replaced limit switch and cleaned all wiring and aluminum off w What: Ingot loader not working
Why: Limit switch NG, wiring NG
C/M: Removed pusher 2 limit switch and replaced, replaced wiring to limit switch due to wires shorted. Adjusted limit switch and verifie What: Ingot loader op panel was non responsive to manual pb commands
Why: Coil M42 Melt controller flameout was true locking out ingot loader
Countermeasure: Reset melting flame controller
Will proble What: Ingot loader paddle came off causing it to over travel.
Why: Wear.
Countermeasure: Bent back and installed paddle. What: Ingot loader problem
Why: No home light in auto for conveyor. Due to sensors being too close together What: Ingot loader push in limit switch bracket broke.
WHY: UNKNOWN
C/M: re-welded bracket for pusher 2 advance end limit switch What: Ingot loader pusher 2 not advancing
Why: Cylinder no good
C/M: Replaced cylinder with new
Recur: Possibly in time What: Ingot loader pusher assy cannot lower pusher adv. L.S. strikes safety platform support..
Why: Loader assy. shifted out of position apparently during clean out.
R/C: Excessive force applied to e What: Ingot loader pusher came down on plates
Why: Plates bent beforehand, pusher caught them coming down
C/M: Bent plates back, recovered ingot loader What: Ingot loader pusher unit bent down
Why: Broken welds
C/M: Needs welded, Taka and Mihara decided to load several ingots in furnace by hand and only load one ingot in each set of paddles until wel What: Ingot loader safety door not latching
Why: Door latch that holds it got bumped, wouldn't latch door closed
C/M: Adjusted door latch to hold door closed What: Ingot loader safety door opening during loading
Why: Latch not holding
Counter measure: Moved latch What: Ingot loader safety handle broke
Why: Unknown
Counter measure: Replaced handle What: Ingot loader safety switch malfunctioned
why- safety switch in bad location always gets bound up and breaks key off damaging safety switch
c/m- replace safety switch
reoccur- yes What: Ingot loader wont move forward
Why: Prox sensor had melted aluminum on it
Counter measure: Cleaned sensor
R/C: Yes
Cycle time: Unchanged What: Ingot loader would not get down light.
Why: Ingot half under loader.
Countermeasure: Removed ingots. Ran in auto, stopping where it should. What: Ingot loader would not return to home position
Why: Ingot cradle bent and broke
C/M: Cut pusher plate so that it will not hit cradle roller at far end need to get with Engineering to draw one What: Ingot loader, no home light
Why: Bad home light bulb
C/M: Replaced bulb What: Ingot loading
Why: Ingot fell out and Damaged pet cock
Counter measure: Temp fixed pet cock What: Ingot loading boor broke
Why: Safety switch bolts broke
Counter measure: Replaced safety door bolts What: Ingot loading conveyor crashed.
Why: Bent flight/ingot holder
C/M: Re-bent flights and had to weld limit switch back into position
Recur: Yes in time What: Ingot loading door hinge broke
Why: Weld broke on hinge
C/M: Put bolt in hinge so operator could run machine
Recur: possibly in time What: Ingot loading door safety switch will not read as latched
Why: Frayed wiring inside safety switch
C/M: Cut back and re-terminated wiring What: Ingot loading not loading into furnace
Why: Lift bent
Counter measure: Straightened lift out What: Ingot loading problem
Why: Senor seeing ingots that are not there
Counter measure: Adjusted range senor that sees ingots in tower What: Ingot platform door safety switch not alarming when door is opened
Why: Faulty safety switch
C/M: Replaced safety switch and confirmed proper function What: Ingot safety door popped open
Why: Loader almost crashed
Counter measure: Adjusted the prox sensor that sees ingots What: Ingot safety switch broke
Why: Plastic switch broke
Counter measure: Replaced with metal What: Ingots hitting door
Why: Platform bent
Counter measure: Bent back
R/C: Yes
Cycle time: Unchanged What: Injection Hydraulic pipe leaking at flange
Why: Cracked pipe weld
Countermeasure: Remove pipe and repair by welding.New O-rings and tested under pressure OK
Reoccur: Yes What: Injection Pipe leaking
Why: Pin holes on previous welds
C/M: Take off and Re-weld
Recur: Yes in time What: Injection Rod Issues not returning to 0
Why: Injection Rod worn and counting lines exposed
C/M: Replace the Rod and put new rings on intensifier Piston and Injection rod What: Injection cylinder Hydraulic line leak.
Why: Pin holes in weld.
C/M: Weld on pin hole.
Recur: Yes in time .Need new Hydraulic block What: Injection cylinder Hydraulic line repetitive weld failure.
Why: Line fittings have been repaired by welding numerous times.
Countermeasure: Remove temporary countermeasure hose and fittings and What: Injection cylinder leaking
Why: Previous weld cracked
C/M: Re-weld old pipe
Recur: Possibly in time What: Injection not returning
Why: Vacuum fault due to squeeze master not set right
Counter measure: set squeeze master
R/C: no
Cycle time: Unchanged What: Injection pipe leaking
Why: Pin holes in multiple welds
C/M: Replaced with up-grated hose
Recur: No What: Injection rod broke
Why: Unknown
Counter measure: Replaced whole injection rod and tip
R/C: Yes time
Cycle time: Unchanged What: Injection rod leaking water
Why: Hose coupler seal bad
Counter measure: Replaced coupler
R/C: Yes time
Cycle time: Unchanged What: Injection rod leaking water from back side
Why: Cooling rod o-ring bad
Counter measure: Replaced o-ring
R/C:
Cycle time: unchanged What: Injection rod locked up in sleeve
Why:To hot and has washout in bottom of sleeve
Counter measure: Pulled die to get sleeve and rod out/ Put the best looking sleeve back in to run production What: Injection rod not moving in manual
Why: DCV (DG13) bad
Counter measure: Replaced DCV What: Injection rod not returning home position
Why: Sleeve got pitted and aluminum hardened on pitted area and kept injection rod from returning
Counter measure: Replaced tip and sleeve
R/C: Yes time What: Injection rod stuck
Why: Full of aluminum
Counter measure: pulled fixed side and Replaced sleeve
R/C: Unknown
cycle time: Unchanged What: Injection sensor fault
Why: Dirty/damaged sensor
C/M: Removed inspected and cleaned sensor (seemed like no damage), didn't fix. Replaced sensor and set origin. Fault cleared. What: Injection sensor not giving correct reading
Why: Sensor was dirty, sensor was put back in facing the wrong direction
C/M: Checked sensor face and put sensor back in facing the correct way What: Injection servo valve closed position malfunction alarm
Why:
Counter measure: What: Injection too fast in low. Low speed and High speed shots way out of range
Why: DCV NG
Counter measure: changed DCV #11 and #14
R/C: in time What: Injection will not move
Why: Partially stroked out, thinks it is all the way out. After origin set will move 2.0mm forward but will not reverse
C/M: Replaced solenoid per Taka (PCSOL) left new What: Injector alarm
Why: Injector sensor dirty
Counter measure: Pulled sensor and cleaned What: Injector rod making banging noise
Why: Slop between puck and injection rod in coupler.
Counter measure: Put 1.50mm shim between puck and injection rod What: Ink ribbon for temp recorder damaged.
Countermeasure: Replace ink ribbon.
Will Problem Reoccur?; No.
Cycle Time: No Change. What: Inline filter clog
Why: Filter NG
C/M: Replaced all filters What: Inner metal ring on upper crucible lid no good
Why: Weld broke falling apart
C/M: Replaced lid
Recur: Possibly in time. What: Inside door errors
Why: Worn pneumatic cylinder
C/M: Replaced door cylinder
Reoccur: In time What: Install 120V male plug on light fixture.
Why:
C/M: Install non inventory pig tail on light fixture. What: Install receptacle run in new work bench location. What: Installed swing plexy door for crucible and red and green bulbs for tower What: Intermittent spray robot issue, not spraying die release/air blow
Why: Found loose P24M terminal arcing on TB31 block in Spray Valve Panel Remote Box
C/M: Tightened loose terminal and checked al What: Inverter fault (OL1) INVU1 inverter, after safety system install
Why: Overloading motor, Ladle break for traveling inverter not releasing due to wiring
Root cause: Incorrect installation of safe What: Investigate Camera trigger setup. What: Investigate Holding burner issue.
Why: Burner shuts down with out faulting.
C/M: Ashton C. replaced the controller with a non- inventory unit. What: Investigate Hyd. pump issue.
Why: Noise is related to pump cavitating, not sure of the cause of this pulsing cavitation.
C/M: What: Issues in trim press
Why: Spring pusher pin came apart for cavity 2
C/M: Rebuilt spring pusher What: Issues with trim die sensor
Why: Sensors had been knocked off center
C/M: Realigned sensors and re-set the upper and lower limits on the amp What: Issues with turntable stopping
Why: Bottom turn table cover plate warped
C/M: Replace with new plate What: Jam scrap conveyor
Why: Bent bracket
C/M: Fixed bracket, adjustd chain tension What: Japanese associate concerned with trim press shot holder, right side from operator panel for trim press
Why: Spring in holder broken, not pushing on shot correctly
C/M: Replace spring in holder What: Japanese support stopped machine
Why: Saying channel 2 setting were changed. Don't have anything in plex for setting for water passage.
Counter measure: Changed setting in squeeze master and die What: Kicking out good parts to NG c/v
Why: Sensor looking for runners at punch cylinder mounted to trim press staying on too long and causing it to kickout shot
C/M: Wiped cylinder down and cleaned s What: Kicking parts out
Why: F.die cooling F1 alarm. Was running under set point. 52 to 42. Was reading 41
Counter measure: Adjusted set point to 41 What: Lab said porosity in parts
Why: Axis were set way low plex said 70 flow at squeeze master and they were set at 30. Found water leak at sleeve too. And a blown vacuum block
Counter measure: Set s What: Ladle
Why: Change over to 5A2 chain tench
Counter measure: Replace ladle from 1.5 to 1.0. And 1 robot chuck claw
R/C: No
Cycle time: Unchanged What: Ladle
Why: For change over
Counter measure: Replaced What: Ladle Broke.
Why: Life, wear.
Countermeasure: Replaced Ladle. Removed hunk on aluminum.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Ladle Cracked.
Countermeasure: Replaced Ladle. What: Ladle Cracked.
Countermeasure: Replaced Ladle. What: Ladle Cup broke.
Why: Build up.
Countermeasure: Replaced cup. Taught 90. Adjusted sleeve. What: Ladle Electrode Bar Malfunction and Ladle Wire Break Alarm.
Root cause: Kink in cable.
Countermeasure: Replaced cable.
Will Problem Reoccur?: timing What: Ladle Electrode Bar Malfunction.
Why: Electrode Bar had cracked porcelain .
Countermeasure: Replaced electrode bar unit.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Ladle Electrode Break Fault.
Why: Broken wire.
Countermeasure: Replaced Electrode Wires.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Ladle Electrode Fault.
Why: Wire broke.
Countermeasure: Terminated wire.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Ladle Electrode arm faults
Why: Loose probe rod
C/M: Tighten rod and mount cable to arm What: Ladle Electrode fault.
Why: Two wires came off the electrode.
Countermeasure: Terminated wires.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Ladle Electrode faults.
Why: Electrode had cracked insulators.
Countermeasure: Installed rebuild ladle electrode unit.
Will Problem Reoccur?: No.
Cycle Time: No Change. What: Ladle Fault.
Why: Ladle Faulted while traveling. INVU1 had an overload.
Countermeasure: Moved Ladle manually. What: Ladle Faults.
Why:forward limit switch
Countermeasure:replaced faulty limit switch
Will Problem Reoccur?: timing
Cycle Time: unchanged What: Ladle Inverter fault.
Why: Ladle hit ring cover for crucible.
Countermeasure: Got Ladle off of Ring Cover on Crucible.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Ladle Not moving
Why: ?
C/M: Replaced lower unit and fixed chains
Recur: Possibly in time What: Ladle Pour (LadlPourAxisPos) needed reset, but Ladle Arm got reset instead.
Why: Different ladle cup. 90 needed reset.
Countermeasure: Arm and pour are now reset. What: Ladle Still wont work.
Why: Ladle pour motor No good
C/M: Replace with new motor
Recur: Possibly in time What: Ladle alarm
Why: Probe come loose
Counter measure: Tightened nuts on both side insulators What: Ladle arm goes in and starts to pour then stops and alarms (B-069 Ladling and Pouring Encoder Alarm)
Why: Possible aluminum buildup around lower unit housing, always stops mid pour
C/M: Pulled c What: Ladle arm locked up.
Why: Heat
Countermeasure: Replaced ladle arm with rebuild arm.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Ladle arm not making full travel in auto
Why:
Countermeasure:
Reoccur: What: Ladle arm not moving
Why: Upper arm locking up during motion
c/m: Rebuilt whole ladle arm, replaced break replay for ladle. Reset ladle position. DH bled and tested pour ok. What: Ladle arm stuck over sleeve
Why: Unknown root cause, no alarms or trouble indication. Ladle arm will not move manually or in auto
C/M: Recovered ladle arm by turning motor manually, then ladle r What: Ladle bar alarms
Why: Ceramic broke
Counter measure: Replaced ladle bar What: Ladle bar electrode Malfunction
Why: Ladle electrode cable no good
C/M: Replaced cable and electrode bar
Recur: Possibly in time What: Ladle bar faults
Why: Sleeve and plunger lube line turned causing ladle bar to touch plunger
C/M: DH went in and adjusted sleeve and spray nozzle after pointing in out What: Ladle bar faults
Why: Wiring from terminal box out to ladle bar has exposed wiring causing it to short. wire clamp block that ladle wiring runs to turned hitting ladle arm when going to pour
C/M What: Ladle bar issue
Why:
Counter measure: What: Ladle bar issue
Why: Wire broke
Counter measure: Re terminated What: Ladle bar issue
Why: big probe bolt hitting arm base when moving
Counter measure: Adjusted bug probe so wire end would not hit What: Ladle bar malfunction
R/C: Built up on probe
C/M: Removed buildup from probes, checked connections and terminated two wires to insure proper working order
Will it reoccur: Timing What: Ladle bar malfunction
Why: Ceramic insulator broke
Countermeasure: Replaced both ceramic insulators
Will problem reoccur: Possibly
Cycle time: No change What: Ladle bar malfunction
Why: Ladle probes and wire no good
C/M: Replace ladle wire and probes
Recur: Possible in time What: Ladle bar malfunction
Why: Sleeve fell off of electrode
Counter measure: Replaced sleeve What: Ladle bar malfunction
Why: Wire to ladle bar broke
Counter measure: Replaced terminal What: Ladle bar malfunction
Why: Bulb was missing and no ceramic tubing on probes
C/M: Replaced probes
Recur: Possibly in time What: Ladle bar malfunctions
Why: Ladle bar wire NG
C/M: Replaced ladle bar wiring, wired to match diecast 4 with new premade ladle wire What: Ladle bar malfunctions when replacing ladle arm
Why: Wire got pinched
C/M: Replace ladle electrode wire, tighten nuts on electrode What: Ladle bar/ ladle wire brk
Why: pinched wires
C/M: replaced with new wiring
recur: Possibly in time What: Ladle bounce
Why: Short in electrical box on back of ladle arm
Counter measure: Replaced damaged wire
R/C: Unknown
Cycle time: Unchanged What: Ladle bouncing
Why: Electrode malfunction
Countermeasure: Replace ladle electrode with non inventory electrode
Reoccur: Timing as parts wear What: Ladle bouncing
Why: Hot probe too close to normal probes
Counter measure: Made normal probes longer
R/C: Unknown
Cycle time: Unchanged What: Ladle bouncing
Why: Probe became loose
Counter measure: Adjusted probes
R/C: No
Cycle time: Unchanged What: Ladle bouncing
Why: Probes dirty
Counter measure: Cleaned probes
R/C: Yes
Cycle time: Unchanged What: Ladle bouncing
Why: Unknown
Counter measure: Looked back in plex ryan worked on G562 was as far as he got. I found a setting for Pouring start not being used on this machine. All others use this What: Ladle bouncing
Why: old ladle terminal box plug bad connection
c/m: pushed on plug to verify it was all the way in and not loose ladle works properly now
reoccur: possibly What: Ladle bouncing
Why:unknown
Counter measure:still troubleshooting
R/C:
Cycle time: What: Ladle bouncing and build up on probes and dunked lower unit
Why:
Counter measure: Replaced lower unit
R/C: Yes
Cycle time: Unchanged What: Ladle bouncing and dunked lower unit
Why: Ladle probes
Root cause: Ladle probe wires damaged
Counter measure: rewired
R/C: No
Cycle time: Unchanged What: Ladle bouncing in aluminum
Why: Build up on probes
Counter measure: Cleaned off probes. Had operator skim crucible more often.
R/C: Yes Time
Cycle time: Unchanged What: Ladle bouncing in aluminum
Why: Possible build up around probes and ladle pour spout
C/M: Cleaned off probe and around spout of ladle
Recur: yes in time What: Ladle bouncing up and down over aluminum.
Why: Bad electrode assembly.
C/M: Replaced assembly with a brand new one. What: Ladle bouncing when entering aluminum
Why: Terminal strip was bad
Counter measure: Replaced strip and re-terminated ends
R/C: No
Cycle time: Unchanged What: Ladle break What: Ladle break
Why: Build up by sleeve
Counter measure: Cleaned back by sleeve and replaced ladle. Adjusted Ladle forward limit from 146.4 to 146.6 to adjust pour position. to keep from under pouri What: Ladle break
Why: Debris build up
Counter measure: Replaced ladle
R/C: Yes operator error
Cycle time: Unchanged What: Ladle break fault
Why: Wire bad
Counter measure: Replaced ladle probe wires and probes too
R/C:
Cycle time: Unchanged What: Ladle break malfunction
Why: Ladle eloctrode wires broken
Countermeasure: Replaced ladle electrode wires
Will problem reoccur: Possibly
Cycle time: No change What: Ladle broke What: Ladle broke
Counter measure: Replaced ladle What: Ladle broke
Replaced ladle What: Ladle broke
Root cause: Hit debris
Counter measure: Replaced ladle. Told operator to clean out debris more often.
Reoccurrence: Time What: Ladle broke
Why:
Counter measure: Replaced ladle
R/C:
Cycle time: Unchanged What: Ladle broke
Why: 1st didn't empty it when they had metal leak
Counter measure: Replaced ladle
R/C: No
Cycle time: Unchanged What: Ladle broke
Why: Crashed into aluminum build up by sleeve
C/M: Replaced with new ladle
Recur: In time What: Ladle broke
Why: Had leak from hitting something from 1st shift
Counter measure: Replaced ladle
R/C: Yes time
Cycle time: Unchanged What: Ladle broke
Why: Hit build up back by sleeve
Counter measure: Replaced ladle and talk with operator about importance of cleaning back by sleeve
R/C: Yes
Cycle time: Unchanged What: Ladle broke
Why: Hit debris
Counter measure: Replaced ladle
R/C: Yes
cycle time: Unchanged What: Ladle broke
Why: Hit debris
Counter measure: Replaced talked with 1st shift about keeping clean What: Ladle broke
Why: Hit something
Counter measure: Replaced ladle What: Ladle broke
Why: Hit something
Counter measure: Replaced cleaned out
R/C: Yes life
Cycle time: Unknown new model What: Ladle broke
Why: Speculating it hit some thing
Counter measure: Replaced ladle What: Ladle broke
Why: Time
Counter measure: Replaced ladle What: Ladle broke
Why: Time
Counter measure: Replaced ladle
R/C: Yes time
Cycle time: unchanged What: Ladle broke
Why: Time
Counter measure: Replaced ladle 1.5
R/C: Yes time What: Ladle broke
Why: Unknown
Counter measure: Replaced What: Ladle broke
Why: Unknown
Counter measure: Replaced
R/C: Yes time
Cycle time: Unchanged What: Ladle broke
Why: Wear
Countermeasure: Gave operator a new ladle
Will problem reoccur: Possibly
Cycle time: No change What: Ladle broke
Why: Wear
Countermeasure: Replaced ladle
Will problem reoccur: Possibly
Cycle time: No change What: Ladle broke and Unit dipped in aluminum
Why: Think the wiring got burnt up the short probe is to keep ladle from dipping into the aluminum possible that the wiring to it got burnt and shorted ou What: Ladle broke on first shot after shift change, ladle electrode issues
Why: Did not see any issue that would cause it to break, but started getting ladle encoder alarms after changing. Ladle elect What: Ladle broke.
Why: Hit under pour
Counter measure: Replaced ladle. Adjusted under pour
R/C: Yes time
Cycle time: Unchanged What: Ladle broken wire fault
Why:
C/M: Cleaned aluminum level probes, checked wires for break. Fault cleared What: Ladle cable error
Why: Broken ladle wire
C/M: Replaced cable with new
Recur: In time What: Ladle continuously stopping
Why: Bad Switch
C/M: Replace auto/man cam switch
Recur: Eventually What: Ladle cracked
Why:
Counter measure: Replaced Ladle What: Ladle cracked
Why: Hit debris around sleeve
Counter measure: Replaced ladle and cleaned around sleeve
R/C: Yes time
Cycle time: Unchanged What: Ladle cracked
Why: Hit something
Counter measure: Replaced ladle What: Ladle cracked at bottom and leaking
Why:
Counter measure: Replaced ladle What: Ladle cracked, causing shot size to jump around.
Why: Ladle hit yellow cover.
Countermeasure: Reset 90 (stopped hitting cover), replaced ladle cup.
Will Problem Reoccur?: No.
Cycle Time: No Cha What: Ladle cup broke
Why: Age and wear
Countermeasure: Replaced ladle cup
Will problem reoccur: Possibly
Cycle time: No change What: Ladle cup broke
Why: Debris
Counter measure: clean debris and replaced ladle
R/C: Yes time
Cycle time: Unchanged What: Ladle cup broke.
Countermeasure: Replaced ladle cup. What: Ladle cup fell out of bracket into aluminum
Why: Looks like bracket wasn't tack welded after cutting studs
C/M: Had to replace ladle, used last in inventory. What: Ladle cup leaking.
Root cause: Ladle cup worn down.
Countermeasure: New Ladle Cup being put on.
Will Problem Reoccur?: See no reason it should happen early on. What: Ladle elector faults
Why: Side of ladle rubbing electrode's with aluminum on it
Counter measure: Replaced insulation sleeve for ground and replaced ladle coating worn off back side of ladle
R/C: What: Ladle elector problem
Why: 2 insulator for rods bad
Counter measure: Replaced insulators What: Ladle electro bar alarm
Why: Ladle bar insulator broke
Counter measure: Replaced insulator and put wrap on probes
R/C: NO
Cycle time: Unchanged What: Ladle electro bar malfunction
Why: Big bulb porcelain broke
Counter measure: Replaced unit and put new style bulb on end
R/C: Yes if some one hits electro bars
Cycle time: Unchanged What: Ladle electro bar malfunction
Why: Aluminum flashing on ladle electro bars from side of ladle during pour
Counter measure: Put some insulator rap around 2 of the probes
R/C: Unknown yet
Cycle t What: Ladle electro break
Why: Wire broke to electrode probes
Counter measure: Replaced wire
R/C: Yes time
Cycle time: Unchanged What: Ladle electro bulb end fell off
Why: Unknown.
Counter measure: Replaced bulb end
R/C: No
Cycle time: Unchanged What: Ladle electro wire break
Why: Fell out of holders and got pinched
Counter measure: Replaced wire. put new holder on arm
R/C: Yes time
Cycle time: Unchanged What: Ladle electrode
Why: Bad connection
C/M: Replaced ladle bar and re terminated wire
Recur: Possibly in time What: Ladle electrode
Why: Insulator broke
C/M: Replaced ladle probes
Recur: Timing What: Ladle electrode alarm
Why: Insulator broke
Counter measure: Replaced insulator
R/C:
Cycle time: unchanged What: Ladle electrode alarm
Why: Ladle electrode insulator broke
Counter measure: Replaced electrode assy and big probe bulb with new style
R/C: No
Cycle time: Unchanged What: Ladle electrode alarm, ladle electrode wire break alarm
Why: Found broken wire in old terminal box from DCM panel to terminal box
C/M: Swapped electrode and issue persisted, that is when old ter What: Ladle electrode alarm. 6B2 3.0 ladle
Why: Ladle real close to arm and flashing from ladle hits electrodes. About a inch from bottom and berried into nut at top
Counter measure: Raped positive pr What: Ladle electrode alarms
Why: Ladle bar wire NG
C/M: Replace ladle wiring What: Ladle electrode bar malfunction
Why: Aluminum in between probes and ladle body
Countermeasure: Cleaned ladle unit What: Ladle electrode bar malfunction
Why: Insulator broke due to nut coming loose
Counter measure: Replaced with rebuilt one that we double nutted
R/C: Unknown (Trial)
Cycle time: Unchanged What: Ladle electrode bar malfunction
Why: Ladle probes are bad.
R/C: Aluminum build up on the bulb probe couldn't remove aluminum from probe in machine.
C/M: Replaced probes.
R/O: Timing
Cycle Time: What: Ladle electrode bar malfunction
Why: M/C was showing Forward Limit when it was not
C/M: Reset the Arm 90
Reoccur: What: Ladle electrode bar malfunction
Why: Probes were bad all corroded
C/M: Replaced probes with new and also put new non corrosive leveling bulb on
Recur: In time. What: Ladle electrode bar malfunction
Why: Short in Ladle electrode wire
Countermeasure: Replaced ladle electrode wire
Will problem reoccur: Possibly
Cycle time: No change What: Ladle electrode bar malfunction.
R/C: Probes were bent and touching ladle.
C/M: Pulled ng ones off put a none inventory rebuilt one on.
R/O: NO.
Cycle Time: NO change What: Ladle electrode bar malfunction.
Why: Possible bad probes.
C/M: Replaced electrode assembly and confirmed ladle moves as it should. What: Ladle electrode bar, ladle traveling limit switch, ladle traveling forward limit switch malfunction
Why: Not sure
Counter measure: see bottom
R/C: Unknown
Cycle time: Unchanged What: Ladle electrode break
R/C: Broken wire on ladle electrode bar
C/M: Removed and terminated broken wire
Will it reoccur: Timing, wear
C/T before: 32.7
C/T after: 32.8 What: Ladle electrode break
Why: Wire broke inside insulation
C/M: Replaced with new wire harness
Recur: Possibly in time What: Ladle electrode break
why:
C/M: What: Ladle electrode break alarm
Why: Wire terminal broke at electrode end
Counter measure: Replaced terminal end
R/C: No
Cycle time: Unchanged What: Ladle electrode break alarms
R/C: insulator broke on ladle electrode allowing to ground
C/M: Removed ladle electrode bars and installed a rebuilt electrode bar
Will it reoccur: Timing
C/T Before What: Ladle electrode break malfunction
Why: Ladle electrode wires broken
Countermeasure: Replaced ladle electrode wire harness What: Ladle electrode break.
Why: The electrode with the big bulb on the end had a broken wire.
C/M: Re-terminated wire.
R/O: NO. What: Ladle electrode break. ladle electrode malfunction
R/C: Break in ladle electrode wiring
C/M: Removed and installed new ladle electrode wiring from probes to box.
Will it reoccur: Timing What: Ladle electrode faults
WHy: ceramic sleeves on level electrode broken
c/m: Replaced both ceramic sleeves on level bulb electrode, cleaned electrodes.
will it reoccur: timing
cycle time: unchang What: Ladle electrode faults
Why: Broken wire in cable somewhere, can move cable around and fault clears
C/M: Replace ladle electrode cable What: Ladle electrode faults
Why: Debris landing on ladle electrode causing it to fault mid-cycle
C/M: Replace ladle electrode with ceramic sleeved unit What: Ladle electrode faults
Why: Ladle bar wiring missing bracket, wires got pinched and causing faults
C/M: Replaced ladle bar wiring, replaced bracket so wiring doesn't get pinched What: Ladle electrode faults
Why: Wires broken on ladle bar
C/M: Flipped tubes over and re-terminated wires on ladle bar What: Ladle electrode faults.
Why: Cable had damaged wires.
Countermeasure: Replaced ladle electrode cable.
Will Problem Reoccur?: No.
Cycle Time: No Change. What: Ladle electrode malfunction
R/C: Broken ceramic spacers on electrode
C/M: Removed electrode and installed two new ceramic spacers on probe
Will it reoccur: Timing
C/t before: 26.0
c/t after: 26. What: Ladle electrode malfunction
Why: Insulator broke
Counter measure: Replaced probe assy. (New style big probe end)
R/C: Yes time
Cycle time: Unchanged What: Ladle electrode malfunction
Why: Insulator broke on ladle bar
Counter measure: Replaced with rebuilt unit.
R/C: No
Cycle time: Unchanged What: Ladle electrode malfunction
Why: Level bulb on ladle electrode bar loose, ceramic insulator broke
R/C:
C/M: Removed level bulb on electrode bar, replaced with non inventory and new ceramic ins What: Ladle electrode malfunction
Why: Operator installed vacuum hose on back side of machine where the ladle travels and the ladle hit it and broke the ceramic insulators on the big bulb rod (New ope What: Ladle electrode malfunction alarms
R/C: Aluminum buildup crossing electrodes
C/M: Removed buildup aluminum and checked all connections. Cleaned wires. Returned to production to manually move lad What: Ladle electrode malfunction alarms
Why: Two probes on ladle bar were loose and touching ladle arm
C/M: Tightened up probes What: Ladle electrode wire brake alarm
Why: Wire pulled out of terminal
Counter measure: Re terminated wire
R/C: No
Cycle time: Unchanged What: Ladle electrode wire break alarm
Why: Ladle electrode wire broke
Countermeasure: Re terminated ladle electrode wire What: Ladle fell out of bracket
Why: Bolts come loose
C/M: Got new ladle and put small tack weld on nut and ground corner off of bracket so it dont rub on arm What: Ladle forward limit error
Why: Aluminum on sensor
Counter measure: Cleaned sensor What: Ladle forward limit switch
Why: Picking up metal from ladle unit base
Counter measure: Adjusted
R/C: Yes time
Cycle time: Unchanged What: Ladle forward limit switch malfunction
Why: Forward limit was loose
Counter measure: Tightened switch and tightened ladle chains too
R/C Yes time
Cycle time: Unchanged What: Ladle forward limit switch malfunction
Why: Ladle hitting sleeve lube line
C/M: Turned sleeve and lube line and adjusted now ok What: Ladle forward moving limit switch malfunction
Why: Wiring was disconnected
C/M: Reconnected wiring and adjusted sensor What: Ladle full of aluminum
Why: Furnace shut off and temp dropped. to 1053
Counter measure: Checked furnace unknown reason. Replaced ladle
R/C: Unknown
Cycle time: Unchanged What: Ladle in aluminum, not moving
Why: "Ladle traveling inverter protection on" fault
C/M: Ladle inverter INVU1 needed reset What: Ladle insulator broke
Why: Time
Counter measure: Replaced and put new style bulb on
R/C: Yes Time
Cycle time: Unchanged What: Ladle inverter faults
Why: Pour motor no good faulting at pouring
C/M: Replaced motor
Recur: Possibly in time What: Ladle inverter protect fault
Why: Aluminum got too low for ladle to reach
Countermeasure: Manually got ladle out of aluminum and reset inverter What: Ladle issue
Why: Ladle coming out of aluminum and not leveling out
Counter measure: Re set ladle pour 90 What: Ladle issue
Why: Ladle hitting tie bar nut coming back after pour
Counter measure: Tightened chain and reset Ladle 90 What: Ladle issue
Why: Ladle probe loose
Counter measure: Tightened probe What: Ladle issue
Why: Lower unit bearings bad
Counter measure: Replaced lower unit What: Ladle issue
Why: Master link broke on top chain
Counter measure: Replaced master link What: Ladle issue
Why: New ladle bolts hit on machine
Counter measure: Ground off What: Ladle issue
Why: Some put a plastic hose on ladle probes. Melted to probes
Counter measure: Scrapped off and put ceramic sleeve on probes What: Ladle issue
Why: Wire break
Counter measure: Replaced wire What: Ladle issues
Why: Aluminum on the ladle travel prox switch. What: Ladle kept bouncing in aluminum
Why: probes not correct length
C/M: loosened probes made them the correct length no ok
recur: Possibly in time What: Ladle leaking
Counter measure: Replaced What: Ladle leaking
Why: Bottom of ladle cracked
Counter measure: Replaced ladle
R/C: Yes
Cycle time: Unchanged What: Ladle leaking
Why: Cracked
Counter measure: Replaced ladle
R/C: Yes
Cycle time: Unchanged What: Ladle leaking
Why: Cracked
Counter measure: replaced ladle and cleaned out debris
R/C: Yes
Cycle time: Unchanged What: Ladle leaking.
Why: Ladle cracked. Nothing appears to be in the ladle path.
Countermeasure: Gave operator replacement ladle. What: Ladle limit switch error
Why: Forward prox sensor bad
C/M: Replaced sensor
Reoccur: Yes timing What: Ladle limit switch fault
Why: Ladle sensor wire from control panel to ladle terminal box no good (sensor flickering while moving causing fault)
C/M: Ran new wire from main panel back to ladle t What: Ladle limit switch malfunction and ladle bar
Why: Ladle traveling to far hit sleeve
C/M: Retaught ladle into sleeve and showed operator how to set the 90 degree on ladle
Recur: Possibly in time What: Ladle limit switch malfunction, Ladle Traveling forward limit switch malfunction, and Ladle traveling limit switch malfunction.
Countermeasure: Cleaned sensors. Cleaned probes. Moved ladle manu What: Ladle limit switch malfunction.
Why: Sensor loose
C/M: Tightened down
Recur: In time What: Ladle locked up
Why: Back side of ladle massive build up of aluminum. From coating coming off ladle. Jams ladle to arm
Counter measure: Replaced ladle What: Ladle locked up
Why: Heat on bearings
Counter measure: Replaced lower unit What: Ladle locking up and stopping, biscuit thickness alarms
Why: Bearings locking up in lower ladle unit
C/M: Replaced lower ladle unit
Will it reoccur? Yes with time What: Ladle malfunction
Why: Insulator broke on ladle bar assembly
Counter measure: Replaced assembly
R/C: No
Cycle time: Unchnged What: Ladle moving slow, after safety system installed
Why: Ladle would not move out of slow speed due to incorrect wiring sequence on ladle invertors
R/C: Incorrect installation of safety system comp What: Ladle not functioning
Why: Lower unit locked up
C/M: Replace lower unit
Recur: In time What: Ladle not going into aluminum correctly
Why: Lower unit NG
Countermeasure: Replaced lower unit
Will problem reoccur: Possibly
Cycle time: No change What: Ladle not hitting hole during pour
Why: Bent ladle
Counter measure: Replaced ladle What: Ladle not moving
Why: After ladle poured into sleeve the ladle would not return back to upright position
C/M: Manually turned motor shaft to bring the ladle back to upright position. Ladle now O What: Ladle not moving
Why: Ladle locked up
Counter measure: Replaced lower unit What: Ladle not moving (After Phantom left)
Why: Wiring problem (Relay prongs were bent 077fgr1)
Counter measure: Straightened out prongs
R/C: No
Cycle time: Unchanged What: Ladle not moving, parts not coming out on OK turn tables after preheat shots
Why: Root cause unknown on ladle, robot on new program for different part detect sensor
C/M: Moved ladle via the moto What: Ladle not moving.
Why: Safety door on crucible open.
Countermeasure: Closed door. Worked ladle back and forth. What: Ladle not pour not moving in manual or auto
Why: forward ladle sensor NG
c/m: Replaced forward ladle sensor and ladle would pour manually, machine not running to see in auto but manually all ope What: Ladle not pouring
Why: Aluminum build up on turn jamming ladle turn
Counter measure: Cleaned off build up What: Ladle not pouring (Cycle time out and robot alarm)
Why: G51C Not making. What: Ladle not pouring at sleeve. Cycle time problem
Why: Bearings toward gear box. we don't normally have problem with
Counter measure: Replaced bearings
R/C: Yes Time
Cycle time: Unchanged What: Ladle not responding according to operator
Why: Posiitoning off in aluminum
C/M: removed arm from aluminum tested OK.
Reoccurance: Possible unknown reason for stall
Cycle TIme: Unchanged What: Ladle not returning out of machine
Why: Arm not moving
Root cause: Upper bearings went out of ladle arm
Countermeasure: Replaced ladle arm with rebuilt arm
R/C: Yes Wear time
Cycle time: Unchan What: Ladle over pouring
Why: Ladle lower not working correctly
C/M: Replaced lower unit
Recur: In time What: Ladle pin got stuck in pin hole
Why: ladle was completely busted off all left is metal frame to ladle had it bound on lower unit
C/M: Replaced lower unit
Recur: Possibly in time What: Ladle pin seized in place,Ladle electrode bar malfunction
Why:Pin is damaged and ladle electrode wire was bad
Countermeasure: Replace Ladle cup and pin,Replace ladle electrode wiring and electr What: Ladle pour to sleeve not right
Why: Ladle chain loose
Counter measure: Tightened chain. adjusted pour 90 and speed of pour
R/C: Yes time
Cycle time: Unchanged What: Ladle pouring aluminum over lube tip
Why: Lube tip extended out into path of pour
C/M: Loosend lube pipe and pulled in back and adjusted the spray nozzle What: Ladle pouring slow
Why: Operator lowered the fast pour to 4
C/M: Took fast pour back to 22 where it was to be set at What: Ladle probes no good
Why: probe come loose ladle dipping into aluminum to far
C/M: Replaced with stainless probes
Recur: possibly in time What: Ladle problem
Why: Bearings bad in lower unit
Counter measure: Replaced lower unit What: Ladle replacement What: Ladle scraping the filter
Why: Not sure if crucible had moved back
C/M: Operator ladling out then i can remove everything to see if i can move crucible back got it moved back had to patch filter What: Ladle sensor issues.
Why: Broken wire on ladle sensor.
C/M: Replaced terminal on sensor wire.
WHy: What: Ladle stopped
Why: (R562) coil not made in logic due to G562 not made in locic.
Counter measure: G562 was ladle not level What: Ladle stopped
Why: Bearings locked up
Counter measure: Replaced whole ladle arm
R/C: Yes
Cycle time: Unchanged What: Ladle stopped
Why: Bearings locked up
Root cause: Upper arm bearings locked up
Countermeasure: Replaced arm with rebuilt whole arm
R/C: Yes Life of bearing and heat
Cycle time: Unchanged What: Ladle stopped
Why: Bearings locked up in ladle lower unit
Counter measure; Replaced lower unit What: Ladle stopped
Why: Bearings locked up. Had sealed bearing it. Should be unsealed and wofen grease
Counter measure: Replaced arm and greased bearing
R/C:
Cycle time: Unchanged What: Ladle stopped
Why: Dunked lower ladle unit What: Ladle stopped
Why: Key was bad
Counter measure: Replaced key
R/C: Yes time
Cycle time: Unchanged What: Ladle stopped
Why: Lower ladle unit locked up
Counter measure: Replaced with rebuild
R/C: Yes time
Cycle time: Unchanged What: Ladle stopped
Why: Lower unit locked up
Counter measure: Replaced lower unit and set 90
R/C: Yes time
Cycle time: Unchanged What: Ladle stopped
Why: Unknown
Counter measure: Manually moved. Watched for 20 min in auto. Ok What: Ladle stopped
Why: Whole ladle unit locked up
Counter measure: Replaced whole unit with rebuild
R/C: Yes bearings lock up from heat
Cycle time: Unchanged What: Ladle stopped by sleeve
Why: Ladle cup got stuck on bracket on arm
Counter measure: Bent bracket out of way of ladle cup. What: Ladle stopped moving
Why: Ladle locked up
Counter measure: Replaced lower unit What: Ladle stopping
Why: Ladle electrode came loose (fat probe)
Counter measure: Tightened and checked insulator
R/C: Yes
Cycle time: Unchanged What: Ladle stopping in different spots
Why: Chain was loose
Counter measure: Tightened chain
R/C: yes time
Cycle time: Unchanged What: Ladle stopping in mid operation
Why: Possible bad wire, Why bare wire showing
C/M: Replaced ladle wire
Recur: Possible in time What: Ladle stopping issue
Why: Lower ladle unit got dunked under aluminum
Root cause: Ladle electrode probes were adjusted to high
Countermeasure: Replaced Lower unit and adjusted probes down
R/C: n What: Ladle stops ( No alarm)
Why: Metering probe
Root cause: Metering probe staying on to long when ladle comes out of aluminum
Counter measure: Replaced ladle probe wires and probes too
R/C: Yes Li What: Ladle stops in mid pour
Why: Buckles off center
Counter measure: Set buckles to center
R/C:
Cycle time: Unchanged What: Ladle stops. No alarms
Why: Ladle upper bearings bad in arm
Counter measure: Replaced bearings
R/C: Yes time
Cycle time: Unchanged What: Ladle stuck down in aluminum
Why: Holding crucible safety switch loose
C/M: Got safety circuit cleared, got ladle out of aluminum and tightened up safety switch What: Ladle switch up side down
Why: Unknown
Counter measure: Turned switch and re-terminated wires
R/C: No
Cycle time: Unchanged What: Ladle traveling fast and dunked in aluminum
Why: Possible inverter no good
C/M: What: Ladle traveling limit inverter protect
Why: Aluminum too low for ladle to reach, tripped inverter protect
Countermeasure: Reset inverter, returned ladle home. (Machine was being shut down for th What: Ladle traveling limit switch
Why: X060 flickering What: Ladle under pour
Why: Ladle pour spout plugged
Counter measure: Cleaned spout and sleeve area. Checked plunger lube too
R/C:
Cycle time: unchanged What: Ladle unit locked up
Why: Bearings went bad
Counter measure: Replaced upper and lower unit and guide arm
R/C: Yes time due to heat on bearings
Cycle time: Unchanged What: Ladle was replaced
Why: ladle had cracks
C/M: replaced old ladle with new What: Ladle will not move
Why: Ladle arm bearings ng, arm needed rebuilt
C/M: Day shift changed bearings and 2nd reassembled What: Ladle will not move
Why: inverter dip switch in wrong position
c/m- put switch to correct position
reoccur- no What: Ladle will not move.
Why: Huge chunk of aluminum built up between the ladle and ladle arm.
C/M: Removed aluminum and was able to move ladle back and fourth. What: Ladle wire break
Root cause: 2 Wires broke at ladle probes
Countermeasure: Re-terminated ends
Reoccurrence: Timing (wear)
Cycle time: Before 27 after 27 What: Ladle wire break
Why: Got pulled on during ladle unit replacement
Counter measure: Replaced ladle wires and electrode probe
R/C:
Cycle time: Unchanged What: Ladle wire break
Why: Ladle wire broke from insulator
C/M: Re-terminated with new copper
Recur: Yes in time What: Ladle wire break
Why: Ladle wire got snagged
Counter measure: Replaced wire and put new clamps on to hold wire
R/C: No
Cycle time: Unchanged What: Ladle wire break
Why: Wire broke
Counter measure: Re terminated wire What: Ladle wire break
Why: Wire cut
C/M: Replaced with new ladle wire
Recur: Yes in time What: Ladle wire break
Why: Wire got snagged and pulled wires out of electro probes
Counter measure: Replaced wires to probe
R/C: Yes time
Cycle time: Unchanged What: Ladle wire break alarm
Why: Ladle electrode wire got pinched
Counter measure: Replaced wire
R/C: No
Cycle time: Unchanged What: Ladle wire break alarm.
Why: Ladle cable had break in it.
Countermeasure: Replaced cable. What: Ladle wire break fault
Why: Wire broke at terminal
Counter measure: Re-terminated wire
R/C: No
Cycle time: Unchanged What: Ladle wire break faults/ Trim press faults
Why: Wiring seems to be ok aluminum on electrode and cant fix press due to die chunked out
C/M: Cleaned probes of any aluminum and nothing to trim pres What: Ladle wire break.
Why: Two wires broke.
Countermeasure: Terminated both wires. What: Ladle wire broke
Why: Come out of connection
Counter measure: Re terminated What: Ladle wire broke
Why: Pulled out of copper tube no connection
C/M: Replaced copper tube and re-terminated
Recur: Possibly in time What: Ladle wire broke
Why: Unknown
Counter measure Terminated What: Ladle wire broke alarm
Why: Bad wire
Counter measure: Replaced wire What: Ladle wire no good
Why: Got pinched some how
C/M: Replaced with new cable What: Ladle wont move
Why: Aluminum on probes
C/M: Cleaned off probes
Recur: In time What: Ladle wont move
Why: Root cause unknown
Countermeasure: Had to turn ladle out of aluminum by hand What: Ladle wont move
Why: Safety equipment wire come off in plug. Crucible door
Counter measure: Reattached wire
R/C: No
Cycle time: Unchanged What: Ladle would not move.
Why: Flashing on sensor.
Countermeasure: Cleaned sensor. What: Ladle would not move.
Why: Had Ladle electrode fault.
Countermeasure: Cleaned aluminum off of electrodes. What: Ladle would not move.
Why: Safety door not all the way shut.
Countermeasure: Shut door.
Will Problem Reoccur?: Yes.
Cycle Time: No Change. What: Ladle would not operate
why: G562 was made not allowing operation of ladle. G562 Ladle level
c/m: Ladle was manually jogged back to allow ladle to operate.
will it reoccur; yes
cycle time: uncha What: Large scrap conveyor jammed
R/C: Broken plate allowing pin to back out jamming conveyor
C/M: Removed broken plate and installed new, installed new pins
Will it reoccur: Timing
C/T: unchanged What: Large scrap conveyor jamming
Why: Excessive wear in conveyor track, broken support bracket where conveyor flattens out at the top
C/M: Welded piece of steel in to support chain when coming aroun What: Leak on injection rod
Why: Leaking from water fitting on rod
C/M: Replaced fitting What: Leaking Spur Bushing.
Why: Wear. Crack at weld.
Countermeasure: Replaced Spur Bushing.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Leaking air bowl to crucible, won't hold oil.
Why: Leaking adjustment knob.
C/M Replace bowl assembly. What: Leaking cooling joint.
Why: Wear.
Countermeasure: Replaced cooling joint. What: Leaking hydraulic fluid
Why: O-ring on hydraulic filter canister had split
Root cause: Time. Very brittle
Counter measure: Replace o-ring "NON INVENTORY"
R/c: No
Cycle time: B-26.0 A-26.0 What: Leaking oil
Why: Fixed side core gauge leaking
Counter measure: replaced gauge What: Leaking oil from injection rod
Why: Rod seal bushing no good
C/M: Replaced bushing with rebuilt bushing What: Leaking out back boor of furnace
Why: Refractory bad
Counter measure: Air hammered out What: Leaking plunger lube at valve
Why: Bad connection
Countermeasure: Tighten fitting
Reoccur: Possible What: Leaking spray cartage
Why: 4 Bad spray valves
Counter measure: Replaced 4 valves
R/C: No
Cycle time: unchanged What: Leaking spray cartridge
Why: Leaking spray valve
Countermeasure: Gave new spray valve to DH What: Leaking water
Why: Bad spray valve on spray cartage
Counter measure: Replaced spray valve
R/C: Yes
Cycle time:Unchanged What: Leaking water
Why: Cracked slide core. Cavity 4
Counter measure: replaced op bottom slide core. What: Leaking water at cooling joint for OP side top.
Why: Cooling joint bent and O-rings worn.
Countermeasure: Replaced OP top cooling joint 5BA-M Die 7. What: Leaking water line fitting
Why: General wear
C/M: No new fitting in inventory, thread taped and repaired as needed until more parts can be ordered What: Leaking water lines.
Why: Lines and connectors damaged by hot material.
Countermeasure: Replaced bad lines and connectors. What: Leaky spray valve
Why: Bad o-rings
C/M: Replaced with new
Recur: In time What: Leaving overflow on trim
Why: Air blow not hooked up
C/M: Hooked air line up What: Leaving shot in trim press and small overflows
Why: Air blows not blowing off press
C/M: Went back to using the front air blow added 2 more air blows on the manifold and adjusted to blow overflo What: Left side air blow not working on trim press
Why: Solenoid no good
C/M: Replace with new What: Left side slide core mount moving
Why: Unknown
Counter measure: Checked all mounting bolts for tightness. Ok What: Lid closed limit switch NG
Why: Limit switch arm broke
C/M: Replaced with new
Recur: Possibly in time What: Lid not opening on upper crucible
Why: Needle valve needed adjusted
Counter measure: Adjusted open and close needle valves What: Lid opening slowly, does not open in time
Why: Root cause unknown, solenoid switching fine. Just slow to open
C/M: Adjust flow control What: Lid slamming, and sometimes not closing.
Why: Bad inline flow control valve.
Countermeasure: Replaced flow control valve. Adjusted speeds on open and close for the lid. What: Lid wont open
Why: Was waiting on parts
Counter measure: Replaced check valves What: Life on pattern spray pump short. Why: pilot valve sticking. R/C: No air lube unit installed on air supply.
C/M: Install oiler. Reoccur: Unknown, should increase life on pump unit. What: Light curtains not working properly on backside of ingot loader.
Why: Not lined up properly
C/M: Cleaned and realligned light curtains to make it have the green ok lights. What: Line Pressure fault
Why: Line pressure siting at 13.8mpa causing it to alarm
C/M: Replaced filter by pump, replaced cartridge filter by accumulator. Issue still occurs
3rd- Increased pressure by What: Line Pressure faults
Why: Possible out of adjustment/ bad unload relief valve and or pressure relief valve
C/M: Took unloading relief valve from the Canadian machine and took the Pressure relief What: Line Pressure malfunctions
Why: Unknown
C/M: Replaced relief valve and checked to make sure that the gauges read the same as our adjustment What: Line pressure alarms
Why: Dirty filter
Counter measure: Replaced filter below accumulator. What: Line pressure alarms
Why: Pressure to high. knob turned.
Counter measure: Adjusted pressure down . set set screw on knob What: Line pressure fault that will not clear
Why: Pressure not getting high enough to kick pump off when idle
C/M: Restricted flow back to tank to build pressure up What: Line pressure faults
Why: Paper oil filter and line filter no good
C/M: Replace both filters What: Line pressure issue
Why: Hydraulic pressure and flow off
Counter measure: What: Line pressure malfunction fault.
Why: Filter to pump was bad.
C/M: Replaced hydraulic filter. What: Line pressure malfunctions
Why: Not sure still investigating What: Linear bearings on scrap press no good
Why: Wear
C/M: Rebuild press
Recur: Possibly in time What: Liquid metal upper limit broken wire
Why:
C/M: Replaced terminal on end of wire and replaced both probes (old ones about half the length of new). Set probe length to proper spec. What: Little NG conveyor not working
Why: Motor no good
C/M: Replaced motor now ok
Recur: Possibly in time What: Little conveyor jammed
Why: Aluminum
Counter measure: Un jammed What: Little conveyor jammed
Why: Parts stuck in it
Counter measure: Un jammed little scrap conveyor What: Little scrap conveyor fault
Why: Jammed with aluminum
Counter measure: Un jammed and cleaned out What: Little scrap conveyor issue
Why.: Jammed
Counter measure: Un jammed conveyor What: Little scrap conveyor jammed up
Why: Scrap stuck in it
Counter measure: un jammed it What: Little scrap conveyor not moving
Why: Key way fell out
Counter measure: Replaced key way What: Little scrap conveyor stopped
Why: Jammed. shot tree in sprocket
Counter measure: Un jammed conveyor
reoccur: in time What: Load lock problem after lot marks were done
Why: Aluminum on die
Counter measure: Cleaned die and moved die close speed up from 70 to 75 at the 0.5 mark (slow hard)
R/C:
Cycle time: Unchanged What: Loader crash
Why: Didn't see prox sensor
Counter measure: Adjusted sensor up What: Loader crashed
R/C: ingot caught while loading and bent cover bracket
C/M: removed limit switch cover and straitened and reinstalled, manually operated ok
Will it reoccur: NO
T/C: Machine down What: Loader pusher (roller) platform bent
Why: Broken welds
C/M: Removed loader roller platform, straightened best we could, added reinforcement and welded. Reinstalled platform and tested OK What: Loader wont go down all the way
Why: Blowby on cylinder and the linear blocks are broke - Don't have any linear blocks
Cm: Changed the cylinder What: Loader wont load ingots
Why: Air off to loader shut off, main air pressure line had large leak to loader,
R/C: No PM set up for air hoses to verify not leaking
C/M: Removed main air line and in What: Look up spring valve.
Why: Ed can't find the spray valves.
C/M: Look up work order and ID inventory number What: Loosing home light
Why: Return sensor was loose and moved down
Counter measure: Adjusted sensor and tightened
R/C:
Cycle time: Unchanged What: Loosing ingot loader home position
Why: Cylinder has blow by for back door
Countermeasure: Replaced door cylinder What: Loosing load lock during auto operations
Why: Aluminum stuck in die at top under plate on movable side that rides over fixed side. So when die heated up it expanded it. Believe from previous bl What: Losing axis 4
Why: Die overeating bowl heater set to high
Countermeasure: Reset bowl heater to correct setting
Reoccur: Possible What: Losing parts after press
Why: Blue conveyor not coming back far enough. Due to weld on piece to low
Counter measure: Cut piece and adjusted sensor
R/C: Yes
cycle time: Unchanged What: Losing shot home position. Adding to zero
Why: Injection shaft worn and shot sensor has hard time reading
Counter measure: Turned collar to turn shaft to good spot.
R/C: Yes time
Cycle time: Un What: Loss of vacuum.
Why: Excess flashing on vacuum block caused it to over heat and a vacuum line to blow. Vacuum block was not fitting well.
C/M: Cleaned and polished vacuum block cavity. What: Lost master on trim press and robot
Why: Safety circuit A jumper came loose in cabinet
Counter measure: Re seated jumper What: Lost washer to draw bar
Why: Dropped
Counter measure: Gave DH washer What: Lot marks out of spec
Why: All lot marks to deep in die
Counter measure: Operator error What: Low In Tank vacuum alarm.
Why: Operator just replaced a vacuum block.
Counter measure: Cycled back and forth between Auto and Manual until pressure built up above alarm limits. What: Low Shot speed alarm.
Root Cause: Shot sensor dirty.
Countermeasure: Cleaned Shot sensor.
Will Problem Reoccur?: timing What: Low aluminum in holding
Why: Charging unit faulting out, trying to load when ingots in furnace aren't fully melted and faults What: Low aluminum in holding
Why: Upper limit probes touching each other, ran the aluminum too low
C/M: Adjusted probes so they don't touch What: Low and high speed shots. (6A0 S)
Why: Injection settings wrong.
Counter measure: Shot speed M/S Position 5 was 0.52 made 0.45. P-7 2.39 to 2.40 and FML end 0.78 to 0.80 to match plex settings What: Low break on parts
Why: Squeeze setting not right.
Counter measure: Changed squeeze settings for (ON TIME was .6 now .5) (OFF TIME was 4.0 now 4.7) (PRESSURE was 13.0 now 14.7) (FLOW was 40.0 n What: Low casting alarms
Why: High speed switch bad and biscuit thickness too
Counter measure: Replaced switch and adjusted fine spill from .1 sec to .3 sec
R/C: No
Cycle time: Unchanged What: Low casting pressure. NO NITROGEN IN HOUSE TO FILL ACCUMULATOR TANK.
Why: Low on nitro
Counter measure: Added what nitrogen we had in house.
R/C: Yes time
Cycle time: Unchanged What: Low die release pump pressure
Why: Pump no good
C/M: replaced pump with used and no change
Recur: Possibly in time What: Low shot speed alarms
Why: Speed on bottom of set point
Counter measure: Changed shot speed 5 from 0.31 to 0.32 What: Low speed shot alarms
Why: Servo valve bad. Acc pres on toscast screen jumping bad. could not control low speed bouncing a bunch
Counter measure: Replaced servo valve
R/C:
Cycle time: Unchanged What: Low speed shots
Why:
Counter measure: Replaced tip and sleeve. Cleaned collar face sleeve set in
R/C:
Cycle time: Unchanged What: Low temp alarm crucible
Why: Infighter covered in aluminum. Shorting it our
Counter measure: Cleaned aluminum off What: Low temp alarm on holding
Why: Burner not firing when below temp
C/M: Tried getting to fire with no luck, cycled power and it fired first time and got back up to temp What: Low temp issue
Why: Crucible lower was reading low but crucible glowing red
Counter measure: Moved thermo coupler from high post to low post. What: Low temp parts coming out on table. (59B one rocker)
Why: program settings?
c/m: 3rd running die trials, passed to 1st for engineering verify program What: Lower Unit locked up ladle
Why: ?
C/M: Replaced lower unit
Recur: Possibly in time What: Lower crucible broke
Why: Cracked down sides
Counter measure: Replaced lower crucible
R/C:
Cycle time: Unchanged What: Lower crucible broke
Why: Time
Counter measure: Replaced crucible
R/C: Yes time
Cycle time: Unchanged What: Lower crucible change
Why: Due to flames coming out at dog house and ring
c/m: Replaced lower crucible and half pipe. What: Lower crucible door leaking aluminum
Why: From over flow and door not sealing What: Lower crucible hardened
Why: Safety equipment shut it off. Due to 1st working on Die cast door and shutting safety equip down to do job and it shuts furnaces off
Counter measure: Shut door to u What: Lower crucible hole in filter
Why: tool gouge marks around this hole.Possible mistake while cleaning
Counter measure: Replaced crucible
R/C: Yes time
Cycle time: Unchanged What: Lower crucible leak
Why: Cracked
Counter measure: Replaced lower crucible and half pipe
R/C:
Cycle time: Unchanged What: Lower crucible metal leak
Why: Over flow back of filter
Counter measure: Cleaned out aluminum and in stalled new probes
R/C: Yes Until we find a counter measure for splash when loading
Cycle tim What: Lower crucible repair What: Lower crucible showed leak
Why: Unknown. But lots of corundum under dog house
Counter measure: Emptied out lower to investigate corundum build up What: Lower furnace flame out
Why: Photo eye dirty
Counter measure: cleaned photo eye
R/C:
Cycle time: Unchanged What: Lower furnace not firing
Why: Seeing flame when none is there. Because wires melted in box to box
Counter measure: Ran temp wire to heat up then cut out bad spot out of original wires and re hoo What: Lower furnace temp going to high dropping to low
Why:
Counter measure:
R/C:
Cycle time: Unchanged What: Lower ladle bound up
Why: dipped in aluminum/ bearings no good
C/M: Replaced lower unit
Recur: Yes in time What: Lower ladle locked up
Why: Bearings no good possibly from ladle going to far into aluminum or getting left over top of aluminum
C/M: Took lower unit off took apart we dint have the correct beari What: Lower ladle locked up
Why: Lower unit chain turnbuckle nuts come loose turnbuckle tightened up to where it wouldnt move
C/M: replaced lower unit tightened nuts down and moved back in forth to te What: Lower ladle unit in the aluminum
Why: Possible that it faulted and then the aluminum raised.
C/M: Replaced lower ladle unit. Set the arm and ladle 90. 3rd shift didn't run the machine so minor a What: Lower ladle unit locked up
Why: Bearings bad
Counter measure: Replaced lower unit What: Lower ladle unit locked up
Why: Got left over aluminum to long
Counter measure: Let cool down
R/C: Yes time
Cycle time: Unchanged What: Lower ladle unit locked up and broke the chain
Why: Operator opened up half pipe door at that point aluminum came rushing out and came over crucible filter landing on ladle.
Countermeasure: Repl What: Lower ladle unit not working. Bearings locked up.
Why: Heat wear
C/M: Replace with rebuilt unit What: Lower ladle unit stopping and binding
Why: Locking up from being down in crucible with low aluminum too long
C/M: Put rebuilt lower unit on What: Lower leaking. Bottom door damaged
Why: What: Lower than Acc pressure adjustable range.
Why: Casting Pressure is not in range.
Countermeasure: Took nitrogen out til the gauge read what the standard said it should. What: Lower unit dunked in aluminum
Why: Not sure
C/M: Replaced lower unit and new chain also replaced ladle wire What: Lube line bracket broke
Why: operator was adjusting plunger lube spray tip
C/M: removed lube spray bracket cleaned re-welded/
also replaced the tip since we had to take plunger shaft out to do What: Lube line leak
Why: Broken line
C/M: Replace lube line What: Lube line leak
Why: Hole
Counter measure: Replaced hose What: Lube line leaking
Why: Junction stripped out and hose had hole in it
counter measure: Replaced hose and junction
R/C: Yes time
Cycle time: Unchanged What: Lube tip Plugged
Why: Plugged with aluminum
C/M: Put new tip on and adjusted
Recur: Yes in time What: Lubrication Leak
Why: line was worn
C/M: Replaced with new
Recur: Possibly in time What: M parts getting crushed at trim die.
Why: Bottom slide cores not floating.
Countermeasure: What: M slide core cracked Cav-4 die F2 18,095 shots
Why: Unknown
C/M: Replaced with new
Recur: Possible in time What: M/C does not run after second shot. What: MV Core 2 limit switch faults
Why: Showing out and in at the same time
C/M: Found bad spot in operator side reed switch cable. Replaced reed switch What: MV core 2 operation malfunction
Why: Top slide core switch read bad on meter
Countermeasure: Replaced top slide core reed switch
Reoccur: Yes timeing What: Machine Stopping with robot over shot conveyor.
Why: Robot sets shot down on conveyor then gets a SRVO-024 Move Error Excess (G:1 A:2).
Countermeasure: Line 437 was a linear move instead of a j What: Machine cycle stopping after change over
Why: Quality set point set at 311 for temp A to cycle stop and discharge. And die is not hot enough and cycle stops
Counter measure: Set Temp A from cyc What: Machine just stopping
Why: Quality setting for A temp was set to cycle stop if mot between settings
Counter measure: Set to buzz and discharge What: Machine just stops no fault. (Cycle times out) What: Machine moving alittle bit
Why: Anchor bolts loose
C/M: Tightened what i could get to and Having TKI come back in. What: Machine moving excessively
Why: Partial due to slides and shoes worn another part could possibly be die open and close to fast
C/M: Replace both slides and shoes all new What: Machine moving on floor
Why: Weld on brackets by pit broke
Counter measure: welded brackets What: Machine pump stopped. (SS Switch not in neutral) alarm
Why: 24v wire broke off on cycle switch
Counter measure: Re-terminated wire
R/C: Yes time
Cycle time: Unchanged What: Machine stopped while it was running.
Why: Safety door said it was open.
Countermeasure: Tightened terminals on both the crucible and operator door Reset and Reset Required buttons. Made sure bu What: Machine stopping
Why: Bowl heater light flickering
Counter measure: B side filter plugged. Went out side and un plugged float relay and plugged back in. took a while for light to come back on. T What: Machine stopping
Why: Bowl heater water supply light flicking. Due to filters from out side chillers plugged
Counter measure: Replaced filters What: Machine stopping, cycle timing over.
Why: Move Core 2 loosing its light.
Countermeasure: Replaced Robot side reed switch. What: Machine would fault out during start up (fault for robot malfunction without the fault on robot).
Why: Found that the lower ladle unit locked up before the pour.
Countermeasure: Replaced lower l What: Machine would not Run with out breaking shots
Why: Root cause yet to be determined
Countermeasure: Verified settings in PLEX, ran out of time to diagnose issue What: Machine would not get a full auto start position light
Why: Squeeze master was not home
Countermeasure: Returned squeeze master to home
Will problem reoccur: Possibly
Cycle time: No change What: Made light fixture for light
Why: So the operators can see in machine while machine is running
C/M: Put up light inside hood What: Main air bowl had hole in it
Why: Unknown
Counter measure: Replaced bowl
RC: No
Cycle time: Unchanged What: Main hydraulic pump issue. (line pressure alarms)
Why: Making noise and on screen not making pressure. (15 MPA)
Counter measure: Turned pod up card (PVC S side) from 12.8 to 15.5 What: Main hydraulic pump making noise
Why: Pump went bad
Counter measure: Replaced pump
R/C:
Cycle time: Unchanged What: Main scrap conveyor missing cotter pins and bent connecting rods
Why: Scrap conveyor jammed
C/M: Replaced necessary cotter pins and connecting rods while rotating scrap conveyor What: Main scrap conveyor not moving when others are and not faulting.
Why: Piece of trim was under the scale not allowing pressure of the scrap bin to start the conveyor. Didnt think one was there to What: Maint. Request form, melkeeper control panel alarm reportedly going off, operator covering over audible alarm device. What: Major oil leak
Why: One of the hoses from manifold to top of die for squeeze master NG
C/M: Replaced hose What: Making grinding noise when ejecting parts (5A2 S 15)
Why: Ejector pins growling due to pins rubbing bushings
Counter measure: Waxed pins What: Manifold for dies
Why: Some die you cant bleed out right
Counter measure: Added manifold
R/C: No
Cycle time: Unchanged What: Mark on part (6A0 S-3)
Why: Trim die
Counter measure: Polished trim die What: Mark on #4 part. One rocker 59B
Why: Bad punch
Counter measure: Replaced punch
R/C: No
Cycle time: Unchanged What: Mark on 2 parts . Cavity 2 and 1. (M 5BA die 9)
Why: High spot at parting line
Counter measure: Polished die What: Mark on P1 and P2 side of part
why: plunger in trim press buildup causing mark while pressing part out
c/m: Cleaned off plungers for P1 and P2 cavities
will it reoccur; timing
cycle time: uncha What: Mark on cavity #1
Why: Back cutter moved inward
Counter measure: Moved cutter back
R/C:
Cycle time: unchanged What: Mark on cavity 1
Why: Scape from die
Counter measure: What: Mark on mounting hole surface
Why: Build up on upper plate on trim die
counter measure: Stoned it off
R/C:
Cycle time: Unchanged What: Mark on part
Why: From robot finger
Counter measure: Ground on finger guide. Had a sharp edge
R/C: No
Cycle time: Unchanged What: Mark on part
Why: Trim press damage
Counter measure: Adjusted cylinder on trim die What: Mark on part
Why: Vibrator hitting part. Vibrator stopped working. Blew seals
Counter measure: Replaced vibrator
R/C: No
Cycle time: Unchanged What: Mark on part
Why: From vibrator. Robot gripper not holding part steady
c/m- put original chuck claw back on ,adjusted set screw on claw re-taught positions at put in place, loading at trim pre What: Mark on part RPY die 13 cavity 1
Why: Coming from die separation
Counter measure: Polished fixed side of die 13-1 around squeeze pin area What: Mark on part. (5BA one rocker)
Why: Upper punch leaving mark
Counter measure: Ground on punch. (Cavity 1) What: Mark on part. Multiple areas
Why: Trim press cutter was gummed up and set down pin had aluminum imbedded it
Counter measure: Cleaned pin and replaced cutter #4
R/C; Yes time
Cycle time: Unchange What: Marking Part at set down before trim press.
Why: Burr on pin.
Countermeasure: Polished pin.
Will Problem Reoccur?: No.
Cycle Time: No Change. What: Marks on part (Water passage)
Why: Robot pick up points at mid point
Counter measure: Leveled out tooling arm and taught points from mid point to in trim die. Adjusted screws on robot chuck arm
What: Marks on part cavity 1,2 and 3
Why: Shot sticking in die
C/M: Die E/S Cleaned, polished die
Will it reoccur: Possible
cycle time: no change What: Massive hydraulic leak
Why: Bottom slide core hose has a hole rubbed in it
C/M: Replaced both hoses for bottom slidecore cylinder What: Master push button for hydraulic melted and not lighting up
Why: Button got melted from crucible heat
Counter measure: Replaced button "CHARGED OUT ON SEPERATE WORK ORDER"
R/C: Yes Heat
Cycle ti What: Max casting problem
Why: Cast pressure too high
Counter measure: Cycled machine and did V tech. What: Melting Crucible Cracked and leaking
Why: ?
C/M: Replace with new crucible and half pipe and lower melting thermocouple
Recur: In time What: Melting Metal Leak
Why: Crucible cracked
C/M: Replaced crucible ,stand, and half pipe What: Melting Thermocouple reading Bad
Why: Broken wire
C/M: Replaced with new
Recur: yes in time What: Melting burner controller running burner but not increasing temp.
Why: Tower set LS X57 not made, LS arm had gone past target.
C/M: Move LS arm to correct side of target. What: Melting burner flame failure.
Why: Flameout
C/M: Turn TMR / Off/ON sw to TM then back to On. What: Melting burner flameout alarm
Why: Operator stated it would not fire again after air hammering furnace
C/M: Reset flame relay timing module What: Melting burner misfire
Why: Photo eye and flame igniter
C/M: Replaced both
Recur: Possibly in time What: Melting burner not firing
Why: Upper limit probe wires NG, wires touching
C/M: Removed section from wiring wear wire jacket was gone and put back on What: Melting burner shutting off before it gets to temp.
Why: One of the wires to the holding metal leak probes was broken from ring terminal.
C/M: Re-terminated wire and fired up burner, confirmed m What: Melting burner stuck at low fire.
Why: EV! on Ex gas temp controller set to -928 instead of -10.
C/M: Set EV1 to -10 What: Melting burner temperature low not melting ingots causing low aluminum
R/C: Melting burner eye not reading burner correctly
C/M: Replaced melting burner eye, adjusted air/gas ratio to allow temp What: Melting burner will not come on
Why: Holding crucible upper limit made with aluminum below probes
C/M: Cleaned aluminum buildup off of block causing probes to short to each other What: Melting burner will not fire
Why: Crucible temp. thermocoupler reading jumping up high and then controller gets ALO1 alarm
C/M: Waiting on shipment of thermocouplers, was able to get thermocoupl What: Melting crucible Leak
Why: Molten metal leaking from crucible side Cracked
Countermeasure:Remove and replace upper crucible and crucible stand. Remove leaked metal material replace wedges as ne What: Melting crucible break
Why: Not sure had big crack down side only in for almost 2 months
C/M: Replaced with new melting crucible pedestal and half pipe What: Melting crucible damaged
Why: Improper ingot loading
C/M: Replaced crucible
Recur: In time What: Melting crucible getting too hot.
Why: Coupler cable worn.
Countermeasure: Replaced coupler cable.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Melting crucible over temp
Why: Thermocouple bad What: Melting crucible plug that gets removed during ladle out got aluminum on it and melted.
Why: When ladling out hot aluminum got splashed onto plug.
Countermeasure: Ran temporary wiring to by pa What: Melting crucible spout broke off filled bottom of furnace with aluminum
Why: Possibly manufacture faulty crucible
C/M: Replaced with new and repatched back door and new leak detect probes What: Melting crucible temp controller flashing
Why: Thermo coupler bad
Countermeasure: Replace thermo coupler
Reoccur: No What: Melting crucible thermo coupler 01 Alarm
Why: Thermo coupler bad
Counter measure: Replaced thermo coupler
R/C: Yes
Cycle time: Unchanged What: Melting damper lid losing closed light
Why: Limit switch no good
C/M: Replaced limit switch with new
Recur: Possibly in time What: Melting flame outs
Why: Igniter rod no good
C/M: Changed out with new What: Melting flame outs
Why: Unknown
C/M: Took Flame relay apart did not have one in inventory What: Melting furnace damper not closing
What: Found a piece of metal wedged in between the damper cylinder and furnace
C/M: Removed material What: Melting furnace door wont open
Why: Solenoid valve no good
C/M: Replaced valve What: Melting furnace exhaust temp high, shutting off furnace
Why: Exhaust gas thermocouple bad
C/M: Changed thermocouple What: Melting furnace lid won't close
Why: Pneumatic solenoid valve not working
C/M: Replaced valve What: Melting furnace lid wool liner blow out
Why: Thin piece of wool
C/M: Replaced with thicker piece
Recur: Possible in time What: Melting furnace not firing
Why: Broken insulator on metal level probe broken so it was grounding out
C/M: Made and installed a new insulator block What: Melting furnace not melting
Why: Thermocouple not good wires broke
C/M: Pulled new wire and re-terminated with new Thermocouple What: Melting furnace not reading temp.
Why: Tested thermocouple, bad
C/M: Replaced with new thermocouple
Recur: In time What: Melting furnace temp is all over.
R/C: Thermo coupler for melting furnace is bad.
Fix: Replaced thermo coupler.
Reoccurrence: Timing. What: Melting furnace temperature not giving accurate readings
Why: What: Melting furnace thermocouple failure.
Why Thermocouple tip disintegrated.
Countermeasure: Replace thermocouple , set distance at 58mm.
Reoccur: Timing What: Melting furnace tower lid NG
Why: Connecting rod wore out holes in lid and on tower
C/M: Old lid removed from spare in warehouse, welded on ear for cylinder and welded new ears on tower. Machine What: Melting hood lid not opening
Why: Cylinder no good
C/M: Replaced cylinder What: Melting issue
Why: Temp climbing to fast
Counter measure: Replaced center thermo coupler. Adjusted main gas valve to slow climb and drop off of temp What: Melting lid stays open after loading
Why: Limit switch no good/Damaged
C/M: Replaced broken limit switch What: Melting lid will not go up or down
Why: Solenoid valve bad
C/M: Replaced Solenoid valve What: Melting not getting up to temp or firing.
Why: Upper limit probes touching for holding.
Passed on to next shift What: Melting temp bouncing around
Why: Thermocouple Bad was bent
C/M: Replaced with new What: Melting temp bouncing around
Why: Thermocouple no good
C/M: Replaced with new
Recur: Yes in time What: Melting temp high
Why: Thermocouple bad
C/M: Replaced it with new
Recur: In time What: Melting temp high
Why: Thermocouple blown out on end
C/M: Replaced with new What: Melting temp no good
Why: Possible thermocouple not reading correctly
C/M: Replaced with new What: Melting temp not reading correctly
Why: Thermocouple no good in back of furnace
C/M: Replaced thermocouple with new
Recur: Possibly in time What: Melting temp not rising
Why: Thermocouple tip blew out
C/M:Replaced thermocouple
Recur: Possibly in time What: Melting thermocouple
Why Not working correctly
C/M: Replaced
Recur: In time What: Melting thermocouple reading ng
Why: Possible broken wire
C/M: Replaced with new Thermocouple
Recur: Possible in time What: Melting thermocouple wiring no good
Why: Not tight needed new forks put on
C/M: Reterminated with new forks What: Metal Leak
Why: Aluminum overflow on backside of filter
C/M: ?
Recur: Possibly in time What: Metal Leak(Melting furnace) broken half pipe
Why: Associate loading empty
C/M: Replaced half pipe
Recur: Possibly in time What: Metal leak
Why aluminum overflow/ possibly not cleaning spout
C/M: Replace crucible do to corundom build up on the crucible and in the holding furnace
Recur: Yes What: Metal leak
Why: Cracked spout causing aluminum to leak out the bottom door
C/M: Replaced crucible and pedestol What: Metal leak
Why: Crucible broke in pieces around the spout
C/M: Replace melting crucible and half pipe
Recur: Yes What: Metal leak
Why: Crucible had crack/hole in the bottom
C/M: Replaced holding crucible holding stand and half pipe What: Metal leak
Why: Crucible leaking
Countermeasure: Replaced crucible What: Metal leak
Why: Half pipe broke
C/M: Replaced half pipe
Recur: In time What: Metal leak
Why: Half pipe cracked
Counter measure: Pulled upper crucible and half pipe
R/C: Yes time
Cycle time: Unchanged What: Metal leak
Why: Over flowed behind filter. Due to Half pipe getting plugged from bisket
Countermeasure: Cleaned up aluminum, made new leak detect rods
R/C: Yes
Cycle time: Unchanged What: Metal leak
Why: upper limit probes not working
C/M: Replaced with new
Recur: Possibly in time What: Metal leak
Why:
Counter measure: Drain aluminum What: Metal leak (Upper crucible)
Why: Unknown
Counter measure: Cleaned very little out. And fired back up
R/C: Unknown
Cycle time: Unchanged What: Metal leak (Lower crucible)
Why: Over flow behind filter
Counter measure: Cleaned probes
R/C: Yes
Cycle time: Unchanged What: Metal leak (Lower)
Why: Over flowed back of crucible
Counter measure: Cleaned out lower door
R/C: Yes
Cycle time: Unchanged What: Metal leak (Upper)
Why: Crucible cracked half way around. Think problem came from exhaust thermo coupler failed and super heat crucible to 2950 at crucible during installation
c/m- replace upper What: Metal leak (holding)
Why: Unknown
Counter measure: Re set alarm What: Metal leak (upper)
Why: Dropped ingot into empty crucible
Counter measure: Replace crucible
R/C: Yes Operator error
Cycle time: Unchanged What: Metal leak alarm on the holding furnace
Why: Past metal leak aluminum got in between the metal leak probes caused it to alarm
C/M: Took door off and chipped out all aluminum from metal leak hous What: Metal leak from melting furnace
Why: Crucible broken
C/M: Helped monitor leak until melting was empty, DH taking over to get cooled so crucible can be pulled and replaced What: Metal leak lower
Why: Over flow due to upper limit probes to short
Counter measure: Replaced probes What: Metal leak lower
Why: Wire broke
Counter measure: Replaced lower crucible metal leak wires. What: Metal leak lower
Why; Over flow
Counter measure: Cleaned up mess and fixed door block and new probes What: Metal leak lower crucible
Why: Aluminum over flowed back of filter. Due to splash. And wire was broke to metal leak detect. Was a lot for hard aluminum around detect probes
Counter measure: Bust What: Metal leak lower crucible
Why: Over flow
Counter measure: Cleaned out lower over flowed aluminum
R/C:
Cycle time: Unchanged What: Metal leak lower crucible. (From 1st shift)
Why: Over filled on back side of crucible
Counter measure: Replaced lower metal leak probes and repaired door
R/C:
Cycle time: Unchanged What: Metal leak on holding crucible
Why: ?
C/M: Craig scraped back of filter and i adjusted loading sensor
Recur: Possibly in time What: Metal leak on holding furnace
Why: Half pipe cracked in 3 spots
C/M: Replaced halfpipe What: Metal leak on melting crucible
Why: Cracked on side and spout broke
C/M: Replace melting crucible and half cut pipe.
Recur: In time. What: Metal leak on the holding furnace
Why: over flow when opened the door aluminum was hard and pulled leak detect probes out
C/M: Replaced both probes had to pull the pan out it had aluminum attach What: Metal leak on the melting
Why: Spout broke on crucible
C/M: Replace melting crucible stand and Half pipe What: Metal leak over weekend from holding crucible causing crucible to solidify
Why: Likely crack in crucible What: Metal leak upper crucible
Why: Splash over
Counter measure: Told operator to load 2 ingots in bottom before dumping. And we check every break to make sure their is a bed in crucible
R/C: Yes
Cyc What: Metal leak wire came off of probe.
Why: Broke off.
Countermeasure: Reworked probe and terminated wire.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Metal leak would not clear but burner stayed on
Why: Metal leak probes were no good and were touching
C/M: Made new probes and ran them thru ceramic sleeve I also made them so it would throw th What: Metal leak. (Lower crucible)
Why: Over flowed back filter
Counter measure: Cleaned out lower door
Cycle time: Unchanged What: Metal leak. Lower
Why: Wire to leak detect was broke. Operator just hit it into probe to make it alarm
Counter measure: Re terminated wire and Drained and cleaned over flow. Was thick and hard
What: Metal level upper limit probe wire broken
Why: Heat/wear
C/M: Reterminate probe wire for metal level upper limit What: Metal lines moving
Why: Lines came loose at mounting bolts on movable side for movable core
Counter measure: Tightened bolts
R/C: Yes time
Cycle time: Unchanged What: Metal low
Why: Upper limit probe making
Counter measure: Made new block
R/C: No
Cycle time: Unchanged What: Metling burning kicking on and off quickly
Why: Temp controller reading jumping around and alarming
C/M: Replace melting thermocoupler What: Mini Ng conveyor was bad
Why: Holes in chain
C/M: Replaced conveyor chain
Recur: Possibly in time What: Mini scrap conveyor jamming up
Why: Lots of hole in wire chain mesh
C/M: Replaced it with new What: Minor trim damage to cavity 2 (still in spec).
Why: Dirty cutter.
Countermeasure: Cleaned cutter and moved outward (away from part).
Will Problem Reoccur?: Yes.
Cycle Time: No Change. What: Misfires on holding burner
Why: Found ignition rod did not have rubber sleeve allowing rod to spark in tube rather than at the end
C/M: Put rubber tube over rod sleeve and cut down to so a porti What: Mispoured shot
Why: Ladle bar malfunction broken wire on ladle bar
Countermeasure: Reterminate broken wire confirm all connections
Reoccur: Possible What: Miss fire
Why: Spark plug wire connection at coil bad
Counter measure: fixed connection What: Miss fires upper crucible
Why: Found that it wasn't getting enough gas from pilot valve for mixture
Counter measure: Adjusted pilot valve up. Marked it before moving
R/C:
Cycle time: Unchanged What: Missing #5 block from die
Why: Unknown
Countermeasure: Replace #5 removed from trim die on shelf
Reoccur: Possible What: Missing a die vacuum line.
Why: I assume it was removed to replace.
Counter measure: Located necessary parts to allow the operator to rebuild one. What: Missing keys
Why: Operators lost. Took key from D/C#2 ladle switch and put in ladle auto switch for D/C#3 that was missing
Counter measure: Replaced ladle switch and cycle switch. Added cable ti What: Missing pawl for changeover
Why: Root cause unknown, just missing from changeover cart
C/M: Got replacement pawl What: Missing upper limit probe
Why: Unknown
Counter measure: Replaced probe What: Mist collector
Why: Filters in red
Counter measure: Replaced 606 and 603 filters
R/C: Yes Time
Cycle time: Unchanged What: Mist collector Filter # 606 no good
Why: Out of range
C/M: Changed both filters out What: Mist collector filter
Why: Dirty out of spec
C/M: Replaced
Recur: yes What: Mist collector motor tripping overload relay.
Why: Motor single phasing, "C" phase fuse blown in load center.
C/M: See below. What: Mist filter out of range (606)
Root cause: Life of filter
Countermeasure: Replaced filter
Reoccurrence: Yes life of filter
Cycle time: Unchanged What: Mold Heater no warming up
Why: Inside drain Open
C/M: Shut drain now ok
Recur: Yes in time What: Mold Heater shut off while running, causing machine to fault.
Why: Breaker tripped in Mold Heater.
Countermeasure: Reset Breaker. What: Mold heater contactor H1 does not pull in.
Why: No coil voltage.
C/M: Turn on coil voltage. What: Mold heater contactor burnt up
Why: Loose wiring caused to short out
C/M: Jr Otto took old contactor apart and cleaned contacts inside now ok
Recur: In time What: Mold heater does not power on.
Why: GFCI tripped, 5A control fuse blown
C/M: Reset GFCI, replace blown control fuse. What: Mold heater leaking
Why: Mechanical seal bad
Countermeasure: Replaced mechanical seal
Will problem reoccur: Possibly
Cycle time: No change What: Mold heater lost power
Why: Root cause unknown, tripped breaker
Countermeasure: Reset breaker, tested. OK What: Mold heater not heating up
Why: Contactor no good was not pulling in when lowering temp setting
C/M: Replaced with new contactor now ok
Recur: In time What: Mold heater not heating up
Why: Contactor not pulling in
C/M: Replaced with new
Recur: Possibly in time What: Mold heater not heating up
Why: Valve slightly stuck open letting cool water in
Counter measure: Run set number below set point. Wait a minute. Then set set point to heating number to get valve What: Mold heater not heating. What: Mold heater temperature not rising to 155.
Why: Suspected heating/cooling valve was sticking
C/M: Manipulated temperature to open/close valve several times. Mold heater is now rising normally. What: Mold heater tripped out
Why: ?
C/M: Reset breaker
Recur: Possibly in time What: Mold heater tripping 15A breaker
Why: Loose power wire in strip
C/M: Reclipped wire into strip What: Molten metal high temp alarm
Why: Temp controller showing holding temp up to 1335 degrees, flame relay stuck on
C/M: Verified thermocoupler reading accurate, handheld monitor showed it was corre What: Motor Over Loads.
Why: Scrap conveyor jammed.
Countermeasure: Unjammed conveyor.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Motor Overload
Why: Ok Table not moving
C/M: Took table apart found lots of flashing under steel top and Pulled motor back to add tension on chain
Recur: Possibly in time What: Motor over load alarm
Why: Blue ok conveyor jammed. Due to bolt broke off to guide
Counter measure: Replaced bolt and tack welded guide on
R/C: Unknown
Cycle time: Unchanged What: Motor overload alarms
Why: Turn table #1 stopped. due to flashing in fins of motor
Counter measure: Cleaned out fins
R/C: No
Cycle time: Unchanged What: Motor overload faults
Why: Scrap conveyor 1 jamming because of aluminum in conveyor track
C/M: Turned conveyor by hand until debris cleared What: Motor overloads
Why: Scrap conveyor jamming up and links missing
C/M: Unjammed conveyor fixed links that were not attatched and cotter pins What: Motor overloads at trim press
Why: M2 motor overloads scrap conveyor 1, Extra scrap buildup under conveyor jamming up motor.
R/C: Not part of PM set up for diecast machines
C/M: Removed access p What: Motor overloads at trim press.
Why: Scrap conveyor one jammed.
C/M: Changed out conveyor with good one.
R/O: Yes.
C/T: NO Change. What: Motor overloads.
R/C: Turn table 2 wasn't turning.
C/M: Removed top of table and blew out all the chips, replaced one bearing because it was locked up and another bearing was missing a clip and What: Motor overloads.
Why: Smaller scrap conveyor had a jam
C/M: Removed jam What: Movable 2 faults
Why: Operator reed switch bad and junction box bad too
Counter measure: Replaced reed switch and junction box What: Movable Side Alarming for low temp.
Why: Thermocouple wire damaged.
Countermeasure: Replaced thermocouple on Die F-3 6A0-S.
Will Problem Reoccur?: No.
Cycle Time: No Change. What: Movable core 2 alarm
Why: Reed switch bad
Counter measure: Replaced reed switch What: Movable core 2 alarm
Why: Hydraulic fitting leaking
Counter measure: Tightened line
R/C: No
Cycle time: Unchanged What: Movable core 2 alarm
Why: Read switch wire got smashed
during die change
Counter measure: What: Movable core 2 malfunction
Why: Wire got smashed during operation. Zip tie broke and wire fell in between die faces
Counter measure: Replaced reed switch and zip tied up
R/C: no
Cycle time: Unc What: Movable core 2 malfunctions
Why: Reed switch robot side bad
Counter measure: Replaced switch What: Movable core 2 not getting out light
Why: Bad dummy plug
C/M: Changed dummy plug with non-inventory part What: Movable core malfunction
Why: Stud loose
Counter measure: Tightened cylinder stud on operator side What: Movable core water pipe broke off in die
Why: Unknown
Countermeasure: Removed pipe made and made a new one
Will problem reoccur: Possibly
Cycle time: No change What: Movable side die not holding temp
Why: Thermo coupler NG
Countermeasure: Replace thermo coupler
Reoccur: No What: Movable side of die getting hot
Why: Chiller manual inlet valve stuck closed no pressure
Counter measure: Move valve back and forth
R/C: No
Cycle time: Unchanged What: Movable side of die not getting to temp.
Why: Male plug for thermo coupler on machine was shorted out. Due to plug spinning inside.
Counter measure: Pulled die and checked thermo coupler again. What: Movable side thermo coupler not reading (RPY #8 one rocker)
Why: Wire broke
Counter measure: Replaced coupler
R/C: Yes time
Cycle time: Unchanged What: Movable slide core issue
Why: Fittings on top of die back ward
Counter measure: swapped fitting (male to female and female to male). Replaced op side reed switch too. What: Move core 2 faults
Why: Top core sensor not working per lead switch tester
C/M: Replace lead switch
Countermeasure: What: Move core 2 faults while running
Why: Not getting out light on toscast screen
C/M: Found operator side cylinder not returning fully. Pulled cylinder off RPY 1RKR Die 15 and put on die in machine What: Move core 2 hydraulic line started leaking
Why: A crack developed from excessive wear
Countermeasure: Made new hard line and installed
Will problem reoccur: Possibly
Cycle time: No change What: Move core 2 limit switch malfunction
Why: Junction box had debris and liquid in it
Countermeasure: Cleaned out junction box
Will problem reoccur: Possibly
Cycle time: No change What: Move core 2 limit switch malfunction
Why: Unclear on root cause, potential debris in plug
Countermeasure: Removed all plugs for movable cores and blew them out and reconnected What: Move core 2 malfunction
Why: Found aluminum blocking travel of slide core
C/M: Removed aluminum & checked reed switches for proper signal aluminum
Reoccur: yes, timing What: Move core 2 malfunctions
Why: Helper side move core cylinder drifting off
Countermeasure: Production replaced die
Will problem reoccur: Possibly
Cycle time: No change What: Moveable die high temp. alarms
R/C: moveable side cooling water solenoid not opening correctly
C/M: Removed moveable side cooling solenoid and replaced
Will it reoccur: Timing What: Moveable side was over traveled past the OverTravel Limit switch
Why: OT Limit switch failed
Countermeasure: Replace OT Limit switch and test for operation
Reoccur : No What: Moving Core 2 Malfunction.
Why: Reed switch had short in it.
C/M: Replaced switch.
recur: possible if wiring gets pinched. What: Moving core 2 fault
Why: Reed switch broke
C/M: Did not find in inventory so pulled the one off the bottom cylinder of the new trial die Jr is going to have Bert order cylinder and switches What: Muffin cup bent
Why: Dropped cup
Counter measure: Replaced cup
R/C: Yes Time
Cycle time: Unchanged What: Multiple issues. Temp and damage to part
Why: Damage due to spray point. Temp just falling under set point of 300 on C and D. The readings were lowest 297
Counter measure: Adjusted spray point. What: Multiple problems
Why:
Counter measure: Touched up robot at set down point for collision detect. Had too adjust biscuit size to keep machine from faulting out for to big of a biscuit. Some how What: Multiple slide core cracks
Counter measure: Pulled die up on life too
R/C: Yes Design
Cycle time: Unchanged What: Multiple trim press alarms
Why: OK conveyor jammed
C/M: Removed parts from OK trays, advanced and returned tray- it jammed midway. Adjusted chain What: NG Conveyor would not move
Why: Motor shorted to ground and blew fuses FUU6 and FUW6
Countermeasure: Replaced motor and fuses
Will problem reoccur: Possibly
Cycle time: NA What: NG Part conveyor jammed
Why: Accumalation of debri in track preventing chain from moving properly
C/M: Removed C/V unit pulled chain unable to clear debri from tracks enough to get chain free. What: NG Scrap conveyor metal side guard repair.
Why: Scrap on conveyor got caught on this guard and ripped the bolts out.
Countermeasure: Repaired guard , Drilled and tapped for bolt mounting instead What: NG conveyor chain belt bad. (Little one under trim press)
Why: Part got jammed up in it
Counter measure: Replaced belt, bearings and gear box
R/C: Yes time
cycle time: Unchanged What: NG conveyor jammed.
Why: Scrap bits jammed.
Countermeasure: Cleaned out conveyor and conveyor area.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: NG conveyor not working
Why: Motor quit
Counter measure: Replaced motor
R/C: no
Cycle time : Unchanged What: NG parts
Why: Product detect not reading one of the parts
C/M: Adjusted product detect and cleaned all sensors
Reoccur: Yes timing What: NG parts
Why: Trim damage cavity 4
C/M: Adjusted cutters and cleaned aluminum off of the trim press
Reoccur: Yes, timing What: NG scrap conveyor chain belt
Why: Unknown
Counter measure: Replaced belt
R/C: No
Cycle time: Unchanged What: Natural gas smell
Why: Box leaking. Where main gas pipe meets box.
Counter measure: Put RTV around it
R/C: Unknown What: Needed die cleaning
Why: Soldering on die
Counter measure: Cleaned die What: Needed ladle.
Why: Ladle broke.
Countermeasure: Gave operator ladle. Pour looked good. What: Needed new ladle.
Why: Ladle cracked, wear.
Countermeasure: Gave DH new ladle. What: Ng conveyor jamming up
Why: Chain belt bad
Counter measure: What: Nitrogen leaking out
Why: Possible leak at safety valve
C/M: Put new zip lock bag over valve to see if fill with nitrogen
Recur: Possible in time What: Nitrogen oil level low
Why: To much nitrogen
C/M: Let some out
Recur: Possibly in time What: No #3 parts on unload table
Why: Metal chute weld broke
Counter measure: 1st welded in
R/C: No
Cycle time: Unchanged What: No #3 parts on unload table
Why: Trim press flipper arm pusher broke and ball joint
c/m- replace flipper arm pusher and made temporary ball joint
reoccur- possibly What: No Plunger lube
Why: Plunger lube tip bracket broken
C/M: Removed bracket, cleaned and welded
Recur: What: No Spray
Why: Advance sensor for cylinder NG
C/M: Replaced sensor
Recur: Possibly in time What: No air at the Trim Press
Why: Soleoid valve was bad
C/M: Put new valve on
recur: Possibly in time What: No air at the spray unit
Why: Broken wire in box
C/M: Re terminated the wire What: No air blow at trim press
Why: Solenoid no good
C/M: Replaced valve What: No air blow for sleeve
Why: Solenoid valve
Root cause: Air blow solenoid valve for sleeve stopped working
Counter measure: Replaced valve
R/C: Yes Life
Cycle time: Unchanged What: No air blow on spray cartridge.
Why: Missing keeper allowed coil to coil to separate from solenoid valve stem.
C?M: Re-install coil on valve repalce missing keeper with zip tie. What: No good part conveyor not working
Why: Tabs from water passage got in between belt and rollers
Counter measure: Removed tabs
R/C: Yes time
Cycle time: Unchanged What: No green light for start
Why: Ladle not metering due to bearings going bad
Counter measure: Replaced lower unit
R/C: Yes
Cycle time: Unchanged What: No home light on ingot loader.
why: What: No plunger lube
Why: 1st hole in lube line 2nd electric plug fell came off of solenoid valve for lube.
Counter measure: Put plug back on and fixed lube line
R/C:
Cycle time: Unchanged What: No response squeeze master #4
Why: Hydraulic line on die was not fully connected`
C/M: Connected line properly and fixed hyd. leak on fixed side What: No spray from spray cartage
Why: Die release pump stopped
Counter measure: Replaced pump
R/C: No
Cycle time: Unchanged What: No start light
Why: Bad bulb
Counter measure: Replaced bulb What: No water to die
R/C: small bottom water lines to die had buildup in lines not allowing water to pass thru
C/M: Removed lines going to bottom of die. Removed piping and cleaned. Reinstalled and v What: Noisy hydraulic pump
Why: Busted shaft on pump
C/M: Replaced Pump
Recur: Yes, in time What: Not breaking
Why: Leaving tab on part. Punch not hitting tab
Counter measure: Retaught robot at punch P48 What: Not breaking tree off
Why: Not close enough to vibrator
Counter measure: Re taught robot What: Not cutting scrap at trim press
Why: Positions off
Countermeasure: Touch up scrap press positions
Reoccur: Possible What: Not dumping ingots
Why: Lid open limit switch staying on
Counter measure: Adjusted limit switch arm and operated 10 times not problem What: Not firing for melting crucible. (Low aluminum)
Why: Upper limit was on. Due to probe stuck to aluminum on filter
Counter measure: Broke probe loose from aluminum
R/C: Yes
cycle time: Unchang What: Not getting cycle start
Why: Relay for press NG
Countermeasure: Replace relay
Reoccur: Possible What: Not getting home light. (Green light)
Why: Shot home position was 3.1mm not 0.0
Counter measure: Reset 0 position and ran in and out multiple times to see if it was going to come off 0. What: Not getting ladle start light
Why: Lower ladle bearing froze up
C/M: Replaced lower ladle unit with rebuilt
Recur: Possibly in time What: Not getting plunger lube.
Why: lube pump failure, attrition.
Countermeasure: Replace plunger lube pump.
Re-occurrence: Eventually, attrition. What: Not holding vacuum in tank. (System)
Why: Bad solenoid valve for tank
Counter measure: Replaced valve
R/C: No
Cycle time: Unchanged What: Not loading aluminum into melting crucible.
Why: Keyence sensors Upper and lower limit set too close.
Countermeasure: Set sensor with and without an ingot filled half way. What: Not loading ingots
Why: Open sensor bad on lid
Counter measure: Replaced sensor for open What: Not melting right
What: Upper the thermo coupler
Counter measure: Moved thermo coupler out What: Not melting right
Why: Losing sensor on door
Counter measure: Adjusted sensor
R/C:
Cycle time: unchanged What: Not picking shot off die. (RPY one rocker)
Root cause: Teaching at sprue
Countermeasure: Touched up points P5,P6,PR8,P11,P23,P24,P25,P26,P27,P49,P50
Reoccurrence: No
Cycle time: Unchanged What: Not putting out much plunger lube.
Why: Plunger lube tip clogged.
Countermeasure: Unclogged plunger lube tip.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Not running
Why: Gear Box key is slipping
CM: Fix Gearbox What: Not setting in trim press
Why: Needs taught
Counter measure: Taught P23 p24 p25 What: Not trimming right
Why: Robot off at punch for top of part
Counter measure: Retaught positions What: Nothing moving in machine. SS not in neutral alarm
Why: Wire came off on ladle key switch. Due to Operator trying to fix loose switch
Counter measure: Re-terminated wire
R/C: No
Cycle time: Unch What: Nothing moving in manual
Why: Bad 4 way switch
Counter measure: Replaced switch and had to tear apart new switch to reconfigure it
R/C: Yes time
Cycle time: Unchanged What: Noticed ingot loader motor terminal box cover was damaged.
Why: Ingot fell.
Countermeasure: Replaced damaged wire and repair terminal box cover.
Will Problem Reoccur?: Possible.
Cycle Time: No What: OA told me and showed me prosity in parts
Why: Lube setting to much
Counter measure: Adjusted in
R/C: Unknown
Cycle time: Unchanged What: OA wanted tip changed
Why: OA wanted it changed
Counter measure: Replaced tip (Water passage) What: OB slide core leaking water
Why: Cracked slide core
C/M: Replaced with new What: OK Conveyor jam initially, then no power to the safety PLC
Why: Loose chain and OK tray jam at unload, PLC control panel terminal strip had 2 loose wires, 16123 and 5.Q3
C/M: Tightened/checked e What: OK Conveyor wont go all the way up
Why: Slides getting bound up in rails
Countermeasure: greased slides and rails What: OK bucket conveyor sticking at top
Why: Chain to tight putting on bind
C/M: Loosened and skipped a link on sprocket to line up evenly
Recur: Possibly in time. What: OK bucket getting stuck and going up and sitting after dumping parts
Why: Sensor for up end not made and moved causing the jam
C/M: Tightened anchor for floor bracket and adjusted sensor What: OK carrier getting stuck
Why: Tension on chains tight
C/M: Loosened all bolts, adjusted tension and tightened down bolts to get tension even across both chains What: OK carrier not advancing
Why: Rollers on carrier, one fell off and the other missing snap ring
C/M: Installed rollers with new snap rings What: OK carrier not moving
Why: Key was out of the key-way and the keyway was damaged beyond use
C/M: Replaced gearbox and key. Had to adjust the chain tensioner
Reoccur: Yes timing What: OK carrier not moving
Why: Part jammed between carrier and chute
C/M: Got part out causing the jam What: OK carrier not moving
Why: Root cause unknown, gearbox/motor bound up
C/M: Separated motor from gearbox, turning okay. Placed back in gearbox and operating properly What: OK carrier stopped moving
Why: Key came out of gearbox shaft
C/M: Put key back in place and reassembled motor/gearbox What: OK carrier won't come up
Why: Got shoved too far back
C/M: Pulled conveyor out What: OK conv. catching on frame at top of travel.
Why: Chain Slack on opposite sides of sprockets.
C/M: Slack and skip chain. What: OK conveyor bucket not returning down
Why: Bad motor
C/M: replaced with new
Recur: Possibly in time What: OK conveyor bucket would not get a return light.
Why: sensor flag was bent and hitting.
C/M: straightened the flag What: OK conveyor getting "stuck" at top
Why: Bad sensor
C/M: Replaced sensor What: OK conveyor jam
Why: Conveyor jammed halfway up
C/M: Cleaned track with WD-40, What: OK conveyor jammed
Why: Tray jamming on far side at the top
C/M: Adjusted sprocket position on motor shaft to straighten out the tray
Recur: Possible in time What: OK conveyor mesh belt torn up
Why: Worn and a part got jammed in conveyor
C/M: Replaced mesh belt on OK conveyor What: OK conveyor not moving
Why: set screws on clutch pack loose
c/m: tightened all set screws on clutch pack and gear box side
will it reoccur: timing/wear
cycle tiem: unchanged What: OK conveyor not operating
R/C: Conveyor jamming not allowing smooth operation, chain tensioner on left side broke
C/M: Replaced ok conveyor with repaired ok conveyor
Will it reoccur: Timing
C/T: What: OK conveyor sticking at the advance position.
R/C: There is to much movement for conveyor at the top and the chaions were loose.
C/M: Adjusted rails to allow for little movement also tightened t What: OK conveyor will not move.
Why: Keyway was not in correct position
C/M: Put keyway back in position
Recur: In time due to wear on gear box shaft What: OK table 2 not turning
Why: Sprocket on table shaft not compressed, spinning on shaft
C/M: Took apart, and reseated everything, tightened up so it wouldn't spin freely What: OP slide core not returning, MovCore2 fault
Why: Die temperature
C/M: Heat up shot in order to move slide core 2 out of shot What: OP top slide core leaking water. Why: Cracked slide core. CM: replaced slide core. What: OPerator side door plexiglass window broken. (cracked and couldnt see through)
C/M: Replaced with new piece of plexiglass What: Occasional parts out of spec, Cav 4
Why: Aluminum stuck to cutter
C/M: Cleaned all cutters, parts in spec... Problem came back, Replaced cav 4 outside cutter What: Oil Leak from directional valve in back of injection unit
Why: Valve is original and seals leaking
C/M: Replaced valve and checked back plate to make sure no ware What: Oil in water dip tank
Why: hose busted off valve to scrap air blow. Blowing air across to the trim press valve stack blowing oil into cooling dip tank
C/M: Replaced air line and cleaned up oil o What: Oil leak What: Oil leak
Why: Hydraulic line leaking
Countermeasure: Instructed DH to change hose What: Oil leak
Why: Bad O rings in stack for DG33 DCV
Counter measure: Replaced 10 O rings in stack
R/C: No
Cycle time: Unchanged What: Oil leak Trim Press Pump
Why: Pump and seals no good
C/M: Replaced pump
Recur: Possibly in time What: Oil leak at Accumulator tank
Why: O-rings in bottom are no good and found 1 broke
C/M: Shibaura come in and replaced
Recur: Possibly in time What: Oil leak in back of die
Why: Line had a hole in it
Countermeasure: Replaced line
Reoccur: Time wear of line
Cycle time: No change What: Oil leak machine lubrication line
Why: Line had hole in it
C/M: Replaced line
Recur: Possibly in time What: Oil leak squeeze master
Why: Hose leaking and inlet filter choking alarm
Counter measure: Replaced hose and cleaned up. Plus replaced all filters
R/C: No
Cycle time: Unchanged What: Oil leak trim press
Why: Back pipe leak at stack block. Aluminum block cracked What: Oil leak. Way lube
Why: Rubber line leaking
Counter measure: Replaced rubber line What: Oil leaking from ACC directional valve
Why: O-rings no good in valve and valve stack
C/M: Replaced all O-rings on valve and valve stack
Recur: Possible in time What: Oil line leaking to auto oil
Why: Hose failed
Counter measure: Replaced line
R/C: Yes time
Cycle time: Unchanged What: Oil mist filter replacement
Why: Out of spec
C/M: Replace with 2 new filters
Recur: In time What: Ok Conveyor
Why: Guide wheel fell off due to retainer clip
Counter measure: Put back on
R/C: Yes time
Cycle time: Unchanged What: Ok Conveyor
Why: Slow down sensor went bad
Countermeasure: Replaced sensor
R/C: No
Cycle time: Unchanged What: Ok Conveyor wont move.
Why: Key had fallen out of gear box shaft due to it not being fully seated after last rebuild and set screw was ran into shaft instead of the key way.
C/M: Installed key w What: Ok bucket carrier not going up all the way
Why: tension on inner carrier had to much slack causing it to go to top crooked causing it to stop before reaching the top
C/M: Loosened motor to get s What: Ok bucket flipper 4 missing bottom plate What: Ok bucket getting jammed at top of carrier
Why: Chain to tight on the right side
C/M: Jumped link on left to straighten bucket up What: Ok bucket getting stuck at top of carrier
Why: Center guard for part separation was to long ok bucket hitting it and jamming up
C/M: Cut some length off so it will not hit now What: Ok bucket getting stuck halfway up track.
Why: left side chain was getting bound up, uneven.
C/M: Slipped chain to even up and remove tension. Confirmed ok bucket smoothly goes all the way up an What: Ok bucket hitting side rail
Why: Alignment off
C/M: Slipped a tooth on sprocket
Recur: Possibly in time What: Ok bucket not advancing
Why: Gear box keyway sprung not holding keyway
C/M: Replaced gearbox What: Ok bucket not moving
Why: Set screw loose allowing shaft spin and keyway
C/M: Put set screw in and tightened down and put keyway back in
Recur: Possibly in time What: Ok bucket wont go up
Why: Gear head had 4 teeth on drive gear sheared internaly
C/M: Re-placed gear box
Recur: Possible in time What: Ok carrier door reset request won't reset.
Cause: x82 door close switch bad.
Fix: Replaced switch
Reoccurence: No What: Ok conveyor
Why: Bolts broke on rail
Counter measure: Replaced bolts
R/C: Yes need linear rails instead of steal on steal rails that bend
Cycle time: Unchanged What: Ok conveyor alarming out
Why: Sensor bar came loose off bucket and hit stop sensor and broke it.
Counter measure: Welded bar on and replaced stop sensor
R/C: Yes time
Cycle time: Unchanged What: Ok conveyor alarming out
Why: Slow down Sensor staying on
Counter measure: Replaced sensor
R/C: Yes time
Cycle time: Unchanged What: Ok conveyor chain belt bad
Why: Unknown
Counter measure: Replaced chain belt. Guide rollers
R/C: No
Cycle time: Unchanged What: Ok conveyor crooked
Why: Guide bearing missing
Counter measure: Replaced with spare What: Ok conveyor fault
Why: guide wheel fell off
Counter measure: Replaced with spare What: Ok conveyor getting stuck at the top
Root cause: spacing on the rails were off a little at the top
Countermeasure: corrected spacing between the rails at the top
Reoccurrence problem: no. What: Ok conveyor getting stuck mid travel
Why: Play in tub during travel
Countermeasure: Adjust guide plate
Reoccur: Timing What: Ok conveyor idler and drive shafts were worn bad
Why: Shafts bad
Counter measure: Replaced shafts and bearings. What: Ok conveyor is getting stuck when trying to return from advance position.
Why: Left wheel missing retaining clip allowing it to almost fall out of conveyor.
C/M: Installed retainer clip.
R/O: NO What: Ok conveyor jammed
Why:Guide bolts for blue ok tub fell out and the guide came off track
Root cause: Guide bolts had not been tightened properly during rebuild
Countermeasure: Put new bolts in g What: Ok conveyor jammed at top position
Why: Sensor bar broke off bottom of bucket
Counter measure: Fixed bar
R/C:
Cycle time: Unchanged What: Ok conveyor jammed in the forward position.
Why: Chain slipped off of the bottom left sprocket.
R/C: no pm schedule for chip conveyor
C/M: Reinstalled chain on sprocket.
R/O: Yes, as the chain What: Ok conveyor jamming
Why: Chains out of alignment (wear), not coming to slow speed
c/m: removed bucket and adjusted chains to get bucket to adv/ret strait. Bucket not slowing down at advance posi What: Ok conveyor not moving
Why: Key way fell out
Counter measure: Replaced key way What: Ok conveyor not moving
Why: Key way fell out of motor
Counter measure: Put key back in and set screw
R/C: Yes Time
Cycle time: Unchanged What: Ok conveyor not moving
Why: Keyway not in position shaft no good
C/M: Tack welded sprocket to shaft
Recur: Possible in time What: Ok conveyor not moving
Why: Motor no good
C/M: Replaced the motor
Recur: Possibly in time What: Ok conveyor not moving
Why: To much chain slack and ok bucket bouncing at top, and didnt have enough power to travel to top
C/M: Took out 1 link on each side of chain replace 2 broken bolts on r What: Ok conveyor sticking at top
Why: Top slide rail out of adjustment
C/M: Put spacers to open up space
Recur. Possibly in time What: Ok conveyor stopping at top
Why: Chain too tight
Root cause: Chain too tight on advance.
Countermeasure: Loosened chain and skipped 2 links on sprocket to even chain out.
Reoccurrence: Yes if ch What: Ok conveyor stopping in cycle causing robot issue
Why: Possible conveyor chain but not sure
C/M: Tried new motor and gear box What: Ok conveyor was bouncing and stopped
Root cause: Side guides wore out on blue tub
Countermeasure: Replaced guides
Reoccurrence: Yes wear on guides
Cycle time: Unchanged What: Ok conveyor will not go home
Why: Cover for ok conveyor came loose and was jamming the conveyor
Countermeasure: Repaired the cover, tested OK What: Ok mesh conveyor belt broke
Why: Part got stuck in mesh
Counter measure: Replaced belt
R/C: Yes time
Cycle time: Unchanged What: Ok table operation
why: clutch slipping
c/m: Adjusted clutch tension for table
will it reoccur; timing
cycle time: unchanged What: Ok turn table 1 wont rotate
Why: Bearing locked up for table rotate
Countermeasure: Replaced bearing What: Ok turn table not working
Why: Blown fuse in panel
C/M: Replaced the fuse
Recur: Possibly in time What: Ok unload conveyor chain mesh bad
Why: Part got stuck under mesh
Count measure: Replaced with rebuilt one
R/C: No
Cycle time: Unchanged What: Okay Conveyor cycle timing over.
Root cause: Bucket hitting on advance sensor.
Countermeasure: Adjusted sensor down.
Will Problem Reoccur?: No. What: Okay Conveyor jamming.
Why: Left side (inside) missing wheel and worn wing.
Countermeasure: Replaced wheel, wings and rails, adjusted the chains.
Will Problem Reoccur?: Timing.
Cycle Time: No What: Okay Conveyor not advancing all the way.
Why: Chain slipped.
Countermeasure: Adjusted chain, cleaned out parts.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Okay Conveyor not moving.
Why: Key worn.
Countermeasure: Replaced key and gear box. What: Okay Conveyor not moving.
Why: Key came out of key way.
Countermeasure: Key and key ways both good, set screw was not in. Replaced set screws.
Will Problem Reoccur?: No.
Cycle Time: No Change. What: Okay conveyer jammed at advance end.
Why: Chain jumped tooth.
Countermeasure: Adjusted chain on both sides.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Okay conveyor jammed.
Why/Countermeasure: Worked back and forth - did not jam for us. Could not recreate issue. What: Okay parts conveyor jammed.
Why: Conveyor worn.
Countermeasure: Replaced conveyor.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: On going ladle bouncing and dunking
Why: Bad connection on wiring terminal to metering bulb in ladle green electrical box
Counter measure: Replaced terminal strip and re- terminated all connect What: One Tappet pin stuck out (die 5A2 #15 S-3)
Why: Tappet bent
Counter measure: Replaced tappet and slide core because tappet was so bent it was stuck in bushing in slide core. I had to cut slide c What: One of the bottom nozzles on spray cartridge movable side not getting water/die release when spraying die
Why: Bad spray valve on spray cartridge
C/M: Verified that line was clear and replaced v What: Op slide core damage
Why: Area leaving heavy soldering
Countermeasure: Replace slide core
Reoccur: Yes What: Operator asked for assistance with detection sensor on melting tower
Why: Allowing charging machine to dumb when tower is too full
C/M: Adjusted lower end so it detects aluminum scrap. Needs mon What: Operator asked for ladle
Why: Broken ladle cup
C/M: Got replacement ladle cup for operator What: Operator asked me to make a new plunger lube line
Why: Old one clogged and bent up
C/M: Made a new piece of tubing for the plunger lube, worked with DH to adjust spray What: Operator called because ladle cup would not return to start position
Why: Ladle electrode alarm
C/M: Cleaned ladle bar and explained to new operator what causes ladle electrode fault What: Operator called for leak underneath moveable side
Why: Could not source leak, looks to be coming from lube lines for joints. just drips during cycle What: Operator called for side wall in furnace pulling apart
why: wear/ jack hammer clean out
c/m: Removed chucks of furnace wall that were in question and falling off. small Outer layer of furnace r What: Operator can't get trim press to home, press start position light flashing on sub operation stand
Why: Down sensor on scrap press stuck on, broken wire in sensor
C/M: Replace sensor for scrap pr What: Operator couldnt get outside helper door to shut all the way.
Why: Bracket the door lock is on got bent back and key couldnt go into lock.
C/M: Adjusted lock bracket and tighted down bolts, oper What: Operator doing checks found that die release was out of spec. (To High)
Why: To much die release in tank mixture
Counter measure: Showed operator how to drain and get mixture right What: Operator door Blue reset door light keeps coming on with door closed and latched.
Why: Switch not latching in
Countermeasure: Replace switch
Why: Suspect bad door safety switched. Replaced door What: Operator door Gate switch no good
Why: Lock mechanisum broke
C/M: Replaced with new What: Operator door alarm
Why: X236 stuck on
Counter measure: Replaced relay 0736FGR1. In upper safety panel. Located in front of die cast machine What: Operator door lock housing broke
Why: Wear
Counter measure: Replaced switch
R/C: No
Cycle time: Unchanged What: Operator door on DCM will not lock
Why: Female end of safety mechanism too far away from door
C/M: Loosened bracket and adjusted mechanism closer to door so it latches What: Operator door safety switch not working
Why: Not sure
C/M: Reset safety unit now working What: Operator door safety switch will reset with the door open
Why: Bad door switch
C/M : Replaced switch
Reoccur: Yes timing What: Operator door switch no good
Why: People take stuff apart lost part of inside latch
C/M: Replaced door switch with new What: Operator door switch not making
Why: Male end of door switch was loose and not going into female end
Counter measure: Tightened male end of door switch
R/C: Yes Time
Cycle time: Unchanged What: Operator door would not shut all the way
Why: Safety switch no good
C/M: Replaced the switch What: Operator dropped probe assembly in crucible
Why: It was an accident
Countermeasure: Replaced probe assembly and wires
Will problem reoccur: Possibly
Cycle time: No change What: Operator found air leak on vacuum system
Why: Some one cut holes in clear vacuum hoses from pump to junction in back
Counter measure: Replaced clear hoses. Added air blow to blocks and used air What: Operator found bent plate, operator hit his knee on plate when entering machine
Why: Plate going up scrap conveyor was damage with a rough edge pointing outward
C/M: Took side cover off and flat What: Operator found bolts in scrape out pan under die. (Die 5BA M #6)
Why: Two bolts fell out of bottom slide cores
Counter measure: Replaced two blots and tightened remaining 2
R/C:
Cycle time: Unch What: Operator found damaged connector on operator side reed switch
Why: Smashed collar, can't turn to tighten
C/M: Took reed switch off Die 11 for 6B2 water passage and put on Die 9 What: Operator lost 2 ejector pin washers
Gave them 2 new ones What: Operator magnetic latch broke.
Why: Head worn out
C/M: Replaced new head with old latch
Recur: In time What: Operator noticed cover for solenoid valve loose
Why: Missing 3 bolts
C/M: Replaced all 4 bolts and added washers and lock washers to them What: Operator reported a noise while die was opening and closing
Why: Noise is audible but unable to pinpoint at this time, possible cover hitting with movement
Countermeasure: Searched for the sourc What: Operator reported trim damage on cavity 1 (breaking inward)
Why: This cavity has been polished too much and is causing excess material build up on runner causing it to always break inward *See a What: Operator reports all cavities mounting hole parallelness NG
Why: Excessive build up on die
Countermeasure: Cleaned die
Will problem reoccur: Possibly
Cycle time: No change What: Operator reports chip in die, requested it to be polished
Why: Weld repair fell out of the die
Countermeasure: Polished die What: Operator reports parts showing residue
Why: Die wasn't being cleaned correctly
Countermeasure: Adjust spray points to better clean die
Reoccur: Possible What: Operator reports soldering
Why: Aluminum was building up on die
Countermeasure: Cleaned die What: Operator reports soldering
Why: Coating wore off in this spot and build up keeps coming back
Countermeasure: Polished die What: Operator reports trim press issues
Why: The problem did not occur
Countermeasure: Had to pull off for higher priority calls What: Operator requested help to align product detect sensor
Why: Operator changed over, had never verified product detect on this model before.
Countermeasure: I verified the positions were correct, What: Operator requested new ladle
C/M: Gave operator a ladle What: Operator requested new ladle
Why: Old ladle broken
C/M: Changed out ladle cup What: Operator said sparks came out of the Forward/Reverse control on side of conveyor.
Why: Possible because on the aluminum on the wire.
Countermeasure: Cleaned out aluminum. Could not recreate.
W What: Operator side cooling joints for top slide core leaking
Why: Bad/damaged O-rings on cooling joints and pieces of O-rings in slide core housing preventing good seat of cooling joints
C/M: Repla What: Operator side door alarm and tie bar alarm
Why: terminal strip come off inside operator pane
C/M: Inside operator panel one terminal strip was off board pushed back in to correct position allowi What: Operator side door safety latch not responding properly
Why: Switch damaged, blue button stays on when it locks
C/M: Replace switch, verified operation What: Operator side door safety switch key bent
Why: Loose and ran into lock
C/M: Straighten out key and put back on door What: Operator side door safety switch needs replaced
Why: Taken off for higher priority machine
C/M: Replaced safety switch with new unit What: Operator side vacuum block stuck in die
Why: Aluminum wedging block in the die after blowout
C/M: Got vacuum block out What: Operator stated that robot was just leaving shot in trim press
Why: Possibly flipper not returning and causing it to wait for home position
C/M: None, issue did not reoccur while watching machin What: Out of furnace chart paper
Why: Life
counter measure: Operator replaced paper What: Outer signal temperature alarm (Q-82F).
C/M: Changed filters. What: Over flow vibrator no good
Why: Solenoid hooked up before the oiler
C/M: Put new overflow vibrator and hooked solenoid up after oiler
Recur: Possible if oiler is empty What: Over pour What: Over pour at sleeve
Why: 90 was off
Counter measure: Adjusted 90 What: Over pour at sleeve
Why: Ladle pour position was off
Counter measure: Adjusted ladle forward limit for 145.5 to 145.0
R/C: Yes time
Cycle time: Unchanged What: Over pour at sleeve. Plugged sleeve
Why: 90 off on ladle
Counter measure: Reset 90 and cleaned sleeve out and checked plunger lube line
R/C:
Cycle time: Unchanged What: Over pour on sleeve and behind sleeve
Why: Ladle pour spout was half plugged
Counter measure: Cleaned out and checked pour
R/C: Yes time
Cycle time: Unchanged What: Overflow in holding crucible
Why: Halfpipe got clogged, unplugged and overflowed down to metal leak door
C/M: DH and operator working on getting it cleaned up and get machine running What: Overflow in holding furnace
Why: Root cause unknown, overflow door damaged, needs patched and new probes made
C/M: Air hammered old patch work out, filled with new patch and waiting to dry. New What: Overflow pin cylinder not knocking off overflow runner
Why: Not enough air pressure if the pin hits 2 x and it doesnt break it puts on scrap conveyor
C/M: turned air up/down had to fig out when What: Overflow tabs not being knocked off by punch cylinder
Why: Position too far, just pushing shot through chuck claws
C/M: Touched up overflow tab positions What: P -1 slide core cracked
Why: Time
Counter measure: Replaced P-1 slide core What: P parts getting stuck in trim die
Root cause: 2 upper guide bars fell off and plate. Were missing.
Counter measure: Replaced both upper guide bars for (Cav #2 P). Borrowed from tore down trim di What: P-1 RPY die #4 Slide core out of spec in roller groove. Soldering
Why: Coating wore off. MM
Counter measure: Replaced slide core with mm
R/C
Cycle time: Unchanged What: P-1 slide core chipped (5ba)
Why: possible bad coating
c/m: replaced P1 slide core on 5BA P&S die F-13 What: P1 & P2 crack out of spec
Why:
C/M: Replaced both slide cores
Recur: In time What: P1 NG
Why: Plug gauge not going in completely
C/M: Replaced P1 slide core What: P1 Quality issue
Why: Soldering on back side of slide core
C/M: Changed P1 (OT) slide core What: P1 cavity slide core NG (Operator Top)
Why: Chunk of material missing
C/M: Replace with TEG slide core. Already changed once today What: P1 out of spec
Why: See work request note
C/M: Replaced slide core What: P1 parts out of spec
Why: Slide core damage
C/M: Replaced slide core. Fixed water leaks, replaced brittle water lines What: P1 slide core
Why: Cracked slide core
C/M: Replaced with new What: P1 slide core change
Why: Crack in groove excessive
C/M: Replace slide core with machine shop slide core What: P1 slide core cracked 12,093 shots
Why: Unknown
C/M: Replaced with new and set pressure on channel 2 to 13.7 from 14.7
Recur: Possible in time. What: P1 slide core cracked and build up
Why: Coating on slide core worn off and wear
C/M: replaced with new Matt Kline made slide core
Recur Possibly in time What: P1 slide core leaking
Why: Top of slide core broke
Countermeasure: Replaced slide core
Will problem reoccur: Possibly
Cycle time: No change What: P1,S1 slide cores just changed but measured out of spec
Why: Slide cores possibly not made to spec
Countermeasure: Replaced both slide cores What: P2 (back left) flipping door putting NG parts in OK carrier every time, no NG parts coming out NG conveyor
Why: Door shaft bracket clamp was loose, shaft moving but door wasn't
C/M: Tightened cl What: P2 cavity trim damage
why: cutter buildup
c/m: Cleaned cutter buildup, reinstalled
will it reoccur; timing
cycle time: unchanged What: P2 out of spec
Why: Cracked slide core
C/M: Replaced HB P2 slide core What: P2 out of spec
Why: Slide core damage
C/M: Replaced slide core HB P2 What: P2 slide core broke off in part
Why: Unknown
Countermeasure: Replaced slide core
Will problem reoccur: Possibly
Cycle time: No change What: P2 slide core chunked out
Why: Root cause unknown
Countermeasure: Replaced with new What: P2 slide core out of spec
Why: Cracked
C/M: Replaced slide core with new What: P2 slide core snapped off
Why: Unknown
C/M: Replaced with new
Recur: Possible in time What: PC Battery Fault on robot system panel
Why: PLC battery needed replaced
C/M: Replaced PLC backup battery What: PC battery alarm on robot panel
Why: PLC battery needed replaced
C/M: Replaced battery What: PLC issues.
Why: PLC failure.
C/M: Replace Relay output PLC and load program. What: PLC link fault
Why: Un-determined
C/M: Reset fault using software. What: PM Vacuum filters What: PM vacuum filters needed What: Paddle bent on the ingot loader
Why: Unknown
Countermeasure: Removed paddle and straightened
Will problem reoccur: Possibly
Cycle time: No change What: Paddles all bent up (16)
Why: Loader crashed
C/M: Replaced with new paddles
Recur:Yes What: Part being chipped
Why Bad slide core 5BA S-2 {12-2}
Countermeasure: Replace slide core
Reoccur: Possible What: Part broke off in die
Why: Shot sensor wire break alarm
Counter measure: Pulled die and replaced shot sensor What: Part detect
Why: Not seeing #4 cav part. Sensor bad
Countermeasure: Replaced sensor
R/C: Yes Time
Cycle time: Unchanged What: Part detect PH X2C not seeing part on shot removed from press.
Why: Bad N24 Jumper connection on control cabinet term. strip.
C/M: Assist Travis P in locating bad connection and re-install orig What: Part detect issue.
Why: Lower west Part detect sensor enclosure contaminated with coolant.
C/M: Clean sensor enclosure, Confirm sensor operation, Re-aim sensor.
Will it Re-occur: No What: Part detect was off
Why: some one hit one of sensors
Counter measure: Adjusted sensor
R/C: No
Cycle time: Unchanged What: Part getting stuck in die
Why: Cavity 2 squeeze pin staying out
C/M: Found lines crossed and pinched, bled squeeze master and issue went away What: Part getting stuck in trim press, not going down chute.
Why: Positioning slightly off.
C/M: Touched up robot positions and confirmed part isnt getting stuck. What: Part had porosity
Why: Casting low
Counter measure: Added nitro. Was 8.0 now 9.2
R/C: Yes time
Cycle time: Unchanged What: Part issues.
Why: Cavity 1 soldering.
C/M: Cleaned the die What: Part left in Die.
Why: Aluminum in cavity 3-3.
Countermeasure: Cleaned cavity 3.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Part missing scrap punch
Why: Mislocated in robot chuck from die
C/M: Touched up robot part pickup position from die, verified production What: Part not coming out of big claw at scrap conveyor
Why: Was pinching on finger guide
Counter measure: Bent arched guide a little
R/C: No
Cycle time: Unchanged What: Part out of spec What: Part out of spec
Why: Soldering on cavity P2, slide core
C/M: Polished cavity P2. Had quality check parts again and was told that P2 needed replaced What: Part out of spec, S1
Why: Can't read "5BA"
C/M: Changed S1 slide core What: Part quality issue (T20)
Why: QA says part bent
Counter measure: Took part from trim die and a part from die to lab What: Part quality issues at trim press.
Why: Robot missing a finger tip.
C/M: Installed new finger tip.
R/O: Yes. What: Part quality slide core crack Die 8 Cavity 1 5BA-S part. What: Part sensor on trim press no good
Why: Wiring in plug twisted and pulled out
C/M: Replaced all pins and put plug back together and checked all sensor to make sure working correctly What: Part sticking in die
Why: Soldering in cavity
Counter measure: Polished die What: Part sticking in die and breaking off of shot
Why: Debris on die and pins
Countermeasure: Cleaned die and pins with WD 40 and scotch brite. What: Part sticking in moving side die
Why: Squeeze pin not returning all the way
C/M: Alclean The squeeze pins waxed them and bled each cavity
Recur: Possibly in time What: Part sticking in trim press
Why: Bent push off pin. Temp to high aluminum plugging holes on part
Counter measure: Replaced pin and adjusted temp for die What: Part sticking in trim press
Why: Guide pin cav #3 bent. (upper side of trim press)
Counter measure: Replaced and cleaned out guide hole
R/C: Yes time
Cycle time: Unchanged What: Part sticking to die, (Breather cover)
Why: Not enough die release on die
Counter measure: During preheat shots we did no air blow off of die release
R/C: Unknown
Cycle time: Unchanged What: Part sticking to fixed side. 59B F1-2
Why: Raised spot in tappet area fixed side of die.
Counter measure: Polished
R/C: Yes time
Cycle time: Unchanged What: Part sticking to top of press cavity 4
Why: Bushing may be going bad on die
C/M: cleaned trim die and pulled off all 4 blocks cleaned out locate holes
Recur: possibly in time What: Part sticking to trim die
Why:
Counter measure: Checked pins. ok What: Part stuck in cavity 4
Why: Squeeze pin not retracting
C/M: Found hydraulic line coupler not completely connected/corroded, changed fitting on manifold What: Part stuck in die
Why: Part in die to long
Counter measure: Heated die to get part pout What: Part stuck in die
Why: Suspect spray points
C/M: Tightened loose spray nozzle and check spray points with plex to set direction of spray. Operator checked die lube concentration What: Part stuck in die
Why: Unknown root cause
Countermeasure: Followed set standard What: Part stuck in die, die maintenance not here to help operator
C/M: Helped operator heat up movable side of die and get part out What: Part stuck in trim die
Why: Hole filled up with aluminum that pin goes in
Counter measure: Drilled out all holes for all pins and replaced cavity 2 pin What: Part stuck in trim press
Why: Debris in press and cylinder was out of alignment
Counter measure; Aligned cylinder and cleaned debris out What: Part stuck in trim press
Why: Pin bent
Counter measure: Replaced pin What: Part stuck on squeeze pin
Why: Build up on pin
Counter measure: Cleaned pin and bled squeeze master and adjusted spray point
R/C: Yes
Cycle time: Unchanged What: Parting line thick on Cavity 4 and and cavity 3. Die 4
Why: Low spots on die around cavitys 3/4
Counter measure: Pulling die What: Parts are getting broken in trim press.
Why: Robot position is off and not setting part down properly in trim press.
C/M: Touched up robot positions. What: Parts bent
Why: Trim press bending parts. Due to stand being to low that part sets on.
Counter measure: Put .600 shim under stand What: Parts bouncing out of bucket
Why: Bucket returning to far leaving gap
C/M: Adjusted sensor up so bucket dont return to far What: Parts chipped out 5BA Die 12 cavity P2 and S2
Why: Slide cores bad
Countermeasure: Replace slide cores
Reoccur: Possible What: Parts damaged by trim press
Why: Trim press has broken cutters and both punches damaged (cavities 3&4)
C/M: Installed trim press #1 What: Parts dropping on to NG conveyor.
Why: Flapper #2 was out of position.
C/M: Readjusted flapper #2 and tightened bolts. Confirmed parts aren't getting through. What: Parts dropping.
Why: Running M parts both bottom slide cores not moving freely.
Countermeasure: What: Parts getting damaged
Why: Trim press not pushing part into position
Counter measure: Adjusted trim press air up on regulator on trim die. From 1.0 to 2.0 What: Parts getting stuck in trim die. ( 5A2 BC)
Why: Part holes are covered with aluminum due to bushings in die
Counter measures: Pulled die sent to die maint
R/C: Yes
Cycle time: Unknown What: Parts getting stuck in trim press. 5A2 breather cover
Why: Trim press broke
Counter measure: Had to fab up spring loaded bushing that we are waiting on
R/C: Yes time
Cycle time: Unchanged What: Parts hanging up in NG conveyor
Why: NG conveyor worn
Countermeasure: Replace NG conveyor
Reoccur: No What: Parts kicking out good when temp bad
Why- plunger returning too fast
c/m- slowed down plunger return
reoccur- no What: Parts not loading on to table
Why: Blue lift bucket bolts fell out of guide rails
Counter measure: Replaced bolts What: Parts not sitting in trim correctly What: Parts out of spec
Why: Cavity 1 measuring negative at parting line, solder
C/M: Polished cavity 1 What: Parts out of spec
Why: Cracked slide core, P2 greater than 10mm
C/M: Installed a new one
Recur: Possible in time What: Parts out of spec
Why: P2 slide core
C/M: Replace P2 (OT) slide core What: Parts out of spec
Why: Porosity
C/M: Checked for leaks, none. Checked concentration & cleaned clogged filter on die lube pump. Checked large air lines for holes. Checked spray points and spray t What: Parts out of spec
Why: Porosity, leaking spray cartridge
C/M: Replace spray cartridge valve, checked die lube concentration- slightly low, added more die lube, quality to check parts again What: Parts out of spec
Why: S1 HT, can't read the 5BA
C/M: Change slide core S1, before starting on slide core noticed the sprue bushing was leaking. Changed cracked slide core What: Parts out of spec
Why: S1 soldering
C/M: Clean slide cores. Ran parts, still NG. Changed S1 (HT) What: Parts out of spec
Why: Slide core P2 OT cracked
C/M: Replaced slide core, repaired leaking water lines What: Parts out of spec
Why: Solder
C/M: Cleaned slide core P1, quality reported slide core is cracked but still in spec. Also fixed a water leak on movable side (sprue bushing). What: Parts out of spec
Why: Solder
C/M: Cleaned the die What: Parts out of spec
Why: Soldering
C/M: Clean/polish die cavities What: Parts out of spec
Why: Trim damage
C/M: Adjust cutters and replaced cutter #4
Reoccur in time w/wear What: Parts out of spec
Why: Trim damage
C/M: Removed and cleaned cutter surface, cleaned cutter pocket and adjusted. Parts in spec. M/C ran production for a couple of hours and parts out of spec agai What: Parts out of spec
Why: Trim damage
C/M: Removed cutters and cleaned cutter cavities (1,2 & 4) and cleaned cutters. What: Parts out of spec
Why: Trim damage, all 4 parts
C/M: Couldn't get movement from cutters to adjust. Removed cutters, cleaned sides of cutters and cutter pockets. Replaced and adjusted, operator t What: Parts out of spec
Why: Trim height P1 cavity
C/M: Attempted to adjust cutter, removed cutter & cleaned out the pocket, no success. Replaced cutter. Ensured parts are in spec What: Parts out of spec
Why: Trim press leaving "gouges" in 3/4 parts
C/M: Adjusted cutters & guides What: Parts out of spec on tappet squeeze and squeeze master squeeze
Why: Casting pressure to low.
Counter measure: Added nito to tank was 4.5 need to be 5.5 max
R/C:
Cycle time: Unchanged What: Parts out of spec, cavity 1
Why: Ejector pin for cavity 1 measuring -0.05
C/M: Removed material from ejector pin. Now measuring +0.01 What: Parts out of spec, cavity 4 trim damage 5BA MID
Why: part breaking off runner in die
C/M: Removed cutter and cleaned base and cuter, attempted adjustment with NG results. Replaced cavity 4 cutte What: Parts out of spec- roller groove
Why: P1 slide core
C/M: Replaced P1 slide core What: Parts smell sweet
Why: Glycol getting in water at exchanger. Has Happened in past
Counter measure:
R/C:
Cycle time: Unchanged What: Parts sticking in trim die
Why: Pins to push parts off bent.
Counter measure: Replaced pin and 2 caps What: Parts sticking in trim press
Why: Bent pin and broken block in top die
Countermeasure: Straightened pin and replaced block What: Parts sticking on die/ RB not catching at part detect
R/C: Part sticking to squeeze pin, RB position not correct at part detect
C/M: DM polished die, line bled machine due to air in cavity 2 at What: Parts sticking on the die
Why: Pins had some soldering on them
C/M: Cleaned off all 4 slide core and checked spray and concentration
Recur: Possible in time. What: Parts sticking to top of trim press
Why: Cavity 3 pin had burr on it and missing plunger pin
C/M: Replaced all with new
Recur: Possibly in time What: Parts sticking to top of trim press. (Breather cover)
Why: Guide pin bent cavity #2
Counter measure: Replaced pin and drilled out hole pin goes in.
R/C: Yes
Cycle time: Unchanged What: Parts sticking to upper trim press
Why: aluminum getting around bushing causing burr
C/M: Pulled block on trim die cleaned out
Recur: Yes Possible bushings need replaced on die What: Parts turntable was not turning
Why: Gear shaft broke
C/M: Replaced turntable shaft and bolts now ok What: Patch side door and back door
Why: Chunk out of side door allowing to glow orange on outside
C/M: Re-patched Side and back door
Recur: Possibly in time What: Piece stuck in fixed side of die. Water passage F-4
Why: Biscuit to small 17.0 should be 20.0 for good casting
Counter measure: Removed piece and cleaned and adjusted biscuit up to 22.0
R/C:
Cy What: Pin not knocking off overflow chill block runner
Why: Once it punches the first time it bends the runner down so it has to extend the pin out further with less hitting preasure
C/M: Re-taught r What: Pin that holds lid to lid open/close cylinder almost falling out
Why: Cotter pin and washer missing from one side
C/M: Found washer and knocked pin back in, ran cylinder rod into bracket more an What: Piping moving on movable side die plate
Why: Bracket missing
Counter measure: Zipped tied up
R/C:
Cycle time: Unchanged What: Piston vibrator no good
Why: Constant running
C/M: Replace with new for Trial Plus added outside oiler
Recur: Possible in time What: Pit filling up.
Why: Spray cartage leaking.
Countermeasure: Taped and tightened leaking pipe (Robot side).
Will Problem Reoccur?: No.
Cycle Time: No Change. What: Plan 120V drop for un-defined motor load. What: Planned down for furnace rebuild, crucible replacment What: Plex glass melted
Why: Heat from crucible
Counter measure: Replaced plex
R/C: Yes time
Cycle time: Unchanged What: Plug gauge mount issues. What: Plugged lube tip
Why: Tip and sleeve worn (Over Life)
Counter measure: Replaced tip and sleeve
R/C: Yes time
Cycle time: Unchanged What: Plugged sleeve
Why: Lube tip was out of adjustment and was too far over sleeve. Aluminum pouring on lube tip
Counter measure: Adjusted lube tip What: Plunder lube line broke
Why: Weld to collar
Counter measure: Made new one What: Plunger Lube not spraying.
Why: Nozzle Plugged.
Countermeasure: Replaced nozzle.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Plunger Lube not working correctly.
Why: Clogged tip and needed adjusted.
Countermeasure: Cleaned tip. Adjusted placement of plunger lube. What: Plunger Lube not working.
Why: Tip had aluminum in it.
Countermeasure: Drilled out aluminum. Repaired leak. Adjusted plungers lube to shoot down sleeve properly. What: Plunger Rod snapped
Why:
C/M: Replaced whole plunger rod shaft and inner cooling rod and Tip and Sleeve
Recur: Possibly in time What: Plunger lube bucket leaking
Why: Seal leaking
Counter measure: Tightened fitting on bucket
R/C:
Cycle time: Unchanged What: Plunger lube issues
Why: Blockage in tip
C/M: Unclogged tip, verified where plunger lube spraying and turned over to production What: Plunger lube leaking
Why: Hole in hose
Counter measure: Replaced hose and fitting What: Plunger lube leaking.
Why: Hole in hose.
Countermeasure: Replaced hose.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Plunger lube line came off sleeve collar
Why: Weld broke
Counter measure: Welded back on
R/C/ NO
Cycle time: Unchanged What: Plunger lube line got plugged
Why: Sleeve turned
Counter measure: Straightened out sleeve and unplugged tip
R/C: Yes time
Cycle time Unchanged What: Plunger lube line leaking at plunger
R/C: Fitting broke off at plunger
C/M: Installed new feral and reinstalled verified not leaking
Will it reoccur: NO What: Plunger lube line plugged
Why: Collar for line moved and aluminum pour on tip
Counter measure: Tip was stuck on had to pull injection tip and collar off to get tip off
R/C: Yes Round collar on r What: Plunger lube line spotted working
Why: Aluminum in tip and line
Counter measure: Replaced line with trial tip and line
R/C: Unknown
Cycle time: Unchanged What: Plunger lube mounting bracket broke
Why: Root cause unknown, operator was told to change tip and sleeve also and needed a sleeve
Countermeasure: Repaired broken bracket, gave operator sleve What: Plunger lube not operating, no lube getting to the sleeve
R/C: Plunger lube line lost prime not allowing lube to get to sleeve
C/M: Replaced black line with clear and quick disconnects to allow What: Plunger lube not spraying adequately
Why: Aluminum build up in tubing running to sleeve
C/M: Cleaned out tube What: Plunger lube not spraying in sleeve
Why: Tip came loose
Counter measure: Tightened and aligned What: Plunger lube not working
Why: Pump went bad
C/M: Replaced with new pump
Recur: Possibly in time What: Plunger lube nozzle spray issue
Why: Holes in plunger lube line running to nozzle
C/M: Replaced hose, tightened up nozzle as it was loose in bracket What: Plunger lube pump leaking
Why: Check valve fitting on pump was cracked
Counter measure: Replaced pump What: Plunger lube pump no good
Why: Stopped working
C/M: Replaced with new
Recur: Possibly in time What: Plunger lube tip plugged
Why: Aluminum in plunger lube tip
Counter measure: Replaced plunger lube tip
R/C: Yes if blow back gets worse
Cycle time: Unchanged What: Plunger lube tip plugged
Why: aluminum plugged it
Counter measure: Had to pull collar off due to tip being striped out
R/C: No
Cycle time: Unchanged What: Plunger rob extension fitting broke off rod end
Why: Root cause unknown
C/M: Replaced sleeve and put together new plunger rod with new tip. Replaced spacer in coupler for plunger rod, excessive What: Plunger rod leaking oil out of bushing
Why: Seals no good
C/M: Replace bushing with all new seals and outer flange with new seal and all new bolt ran in and out no leaks, Cleaned and stoned the What: Plunger rod not return to home position
Why: Blow back covering sensor and bolt that holds sensor bracket broke
C/M: Cleaned out blow back debris from sensor
Recur: Possibly in time What: Plunger rod not returning
Why: Aluminum build up inside around tip
C/M: Replaced both shafts and tip and sleeve
Recur: Possibly in time What: Plunger rod snapped
Why: ?
C/M: Replaced whole plunger rod assembly
Recur: Possibly in time What: Plunger rod sticking in sleeve
Why: Putting in all used tips and sleeves
C/M: none we have no new tips or sleeves have tried 2 used plunger shafts 2 used tips and 2 different used sleeves usual What: Plunger shaft leaking
Why: Bushing NG
Countermeasure: Replaced bushing
Will problem reoccur: Possibly
Cycle time: No change What: Plunger shaft stuck in sprue bushing
Why: Unknown
Countermeasure: Replaced plunger shaft, tip, sprue bushing and sleeve, retaped and connected all water lines
Will problem reoccur: Possibly
Cycl What: Plunger tip melted to sleeve
R/C: Plunger lube discharge nozzle broke off end of sleeve causing tip and sleeve to not receive any lube
C/M: Replaced broken holder on sleeve to allow tip to recei What: Plunger tip stuck in sleeve
Why: Big spot of aluminum stuck in sleeve and no water
C/M: Put water line correctly and made sure lube line and air not plugged
Recur: Possible in time What: Plunger tip stuck in sleeve
Why: Root cause unknown
C/M: Worked with DH to pull die and free plunger tip What: Plunger water leak
Why: Bad o-ring inside female coupler on plunger
C/M: Replaced fitting
Recur: In time with wear What: Plunger wouldn't move in sleeve
Why: Aluminum build up in sleeve
C/M: Replaced tip and sleeve
Recur: In time What: Porisity
Why:
C/M: Checked for water & hydraulic leaks - none found. Checked spray/air points with laser, normal. Operator running test parts for quality What: Porosity
Why: Air blow end missing on spray cartage
Counter measure: Replaced air end
R/C: No
Cycle time: Unchanged What: Porosity
Why: Leaking sprue bushing
Counter measure: Replaced sprue bushing
R/C: Yes
Cycle time: Unchanged What: Porosity
Why: Possible Sprue Bushing leak
C/M: Replace Sprue Bushing
Recur: In time
"SPRUE DID NOT RESOLVE POROSITY ISSUE" What: Porosity
Why: Spray cartage leaking
Counter measure: 4 spray valves leaking
R/C: Yes
Cycle time: Unchanged What: Porosity
Why: Spray cartridge valve leaks
C/M: Replaced faulty valves What: Porosity
Why: Spray valve leaking on spray cartage
Counter measure: Replaced 2 valves
R/C: Yes time
Cycle time: Unchanged What: Porosity
Why: Sprue bushing cracked die 8 water passage
Countermeasure: Replaced sprue bushing and air bowl
Reoccur: Possible What: Porosity
Why: Squeeze master setting wrong
Counter measure: Set to plex settings. Ch 2 and 3 pressures were 13.0 now 14.7. Flow on 2 was 30 now 50
R/C: No
Cycle time: unchanged What: Porosity
Why: Blow timer cant be adjusted on tocast screen. Spray cartage comes down and just goes right back up. So it leaved liquid on die. YA1A stuck on TC32DON card which is keeping x36 in What: Porosity
Why: Spray cartridge leak
C/M: Replaced valve. Also cleaned die What: Porosity #2 and #4
Why: Cavity 2 roller groove leaking and going into cavity 4
Counter measure: Pulled die
R/C: No
cycle time: Unchanged What: Porosity (micro)
Why: squeeze pins not squeezing hard enough
c/m- zeroed squeeze master, set flows on all 4 channels
reoccur- not likely What: Porosity S-1 Rpy
Why: possibly the vacuum not pulling all impurities out
c/m: replaced worn vacuum fitting on the manifold What: Porosity S1 and S2 cavity
Why: Water and or die release being left on die as aluminum being injected in
C/M: Adjusted air blows on those 2 cavities also water and air blow timers
Recur: Possible What: Porosity all day even 1st shift. 5YK
Why: X-Axis Alarms
Counter measure:
R/C:
Cycle time: Unchanged What: Porosity in all cavity's
Why: Clear Vacuum hoses had holes in them and couldn't pull air out of die
Counter measure: Replaced both clear hoses and both vacuum blocks
R/C:
Cycle time: Unchanged What: Porosity in cav S-1 RPY
Why: Squeeze master setting wrong
Counter measure: Reset plex setting in squeeze master What: Porosity in part
Why: Axis 2 problem. Hydraulic leak at top of die
Counter measure: Fixed leak What: Porosity in part
Why: squeeze master flow low
Counter measure: squeeze master flow too low
R/C: no
Cycle time: What: Porosity in parts
Why Leaky spray valves and air blow not blowing in correct position
C/M: Replaced 4 valves and adjusted air blow to each cavity
Recur: Possibly in time What: Porosity in parts
Why: Leaky spray valve
Counter measure: Replaced valve What: Porosity in parts
Why: Spray cartage off center
Counter measure: Centered spray cartage
R/C: No
Cycle time: Unchanged What: Porosity, all cavities
Why: Spray cartridge leaking from center
C/M: Switched out cartridges What: Porosity/Axis issues/ Shot dropping off die
why: spray points and spray concentration off, axis issues due to needing bleed, shot dropping off die and sticking in machine due to sleeve not getti What: Possible dropping parts
Why: Spray cartridge face loose causing to much movement missing bolts
C/M: Replace spray cartridge checked spray point all looks good What: Possible porosity
Why: Cracked sprue bushing
C/M: Replaced with new bushing
Recur: Yes in time What: Power Failure.
Why: Unsure, no other power failure alarms.
Countermeasure: Reset alarm, temps are good. What: Power coming into Melting burner cabinet single phaseing
Why: Middle leg at switchboard panel blowing fuse
Rootcause: 480 volt wiring in conduit below ingot loading door melted and shorted
Count What: Power shut off to die heater
Why: Tripped internal breaker
Counter measure: Reset breaker What: Power shut off to trim press
Why: Breaker tripped (CP4) found sensor for scrap conveyor melted. Due to shot laying on it
Counter measure: Replaced sensor
R/C: No
Cycle time: Unchanged What: Power surge to plant
why: Unknown
counter measure: Recovered machine
R/C: Unknown
cycle time: Unchanged What: Pre heat shot cavity 4 ending up on OK conv.
Why: Diverter for cavity 4 missing.
C/M: Cylinder / diverter need to be removed and diverter repaired / replaced. What: Prep for 15Amp service addition to trim press What: Press up time alarm and low shot speed
Why: Washout in sleeve Shots 122,398 and tip
C/M: Replaced with new
Recur: Possible in time What: Pressure Buildup Time alarms
Why: No readings at all on Cast Pres. and Pres. Up T, only showing "-----"
C/M: Replaced pressure sensor PR5 (Injection,, rod side) What: Pressure build up alarm
Why: Holding temp to high
Counter measure: Waited till it cooled down What: Pressure build up alarms
Why:
Counter measure: What: Pressure build up time jumping
Why: Tip
Counter measure: Replaced tip
R/C: Yes as tip and sleeve wear
cycle time: Unchanged What: Probe wire pulled out of probe
Why: General wear
C/M: Stripped and re-terminated wire What: Product Detect Faults due to product detect 4
Why: Position 11 too far from sensors allowing shadows and light interference to cause false indications
C/M: Retaught Point 11 What: Product detect
Why: Not seeing cavity 2 part
C/M: Cleaned and adjusted sensor. Verified several shots reading properly What: Product detect
Why: Shot sticking to tip, dropping parts
C/M: Checked injection lube, Tip has 81.000+ shots. Replace tip What: Product detect 4 not reading part.
Why: Sensitivity is not strong enough to reach that far to see part.
R/C: Sensor is bad.
C/M: Replaced sensor(xoa2)
R/O: Timing.
Cycle Time: NO Change What: Product detect alarm
Why: Dropping Runner tree Op side
Counter measure: Changed vacuum block and set biscuit thickness to get casting pressure up What: Product detect alarms (Robot)
Why: Cavity #1 part sticking in die
Counter measure: Cleaned die
R/C: No
Cycle time: unchanged What: Product detect fault, scrap faults
R/C: Positioning of product detect sensors, and robot positioning off after changeover
C/M: Retaught r/b position 11 at product detect and adjusted sensor posi What: Product detect fault.
R/C: Bottom left product detect not reading due to it being dirty and misaligned because it was loose.
C/M: Cleaned and adjusted sensor.
R/O: NO
Cycle Time: No change. What: Product detect faults
R/C: Cavities 2 and 3 product detect out of adjustment
C/M: verified sensors working, adjusted product detect to middle of each part and adjusted position of r/b to set lev What: Product detect issue
Why: #2 sensor bad
Counter measure: Replaced sensor What: Product detect issue
Why: Dropping part out of die
Counter measure: Cleaned face of die and slide cores What: Product detect issue
Why: Product detect position off, set points of sensor close to where it was reading when shot was held up for sensors
C/M: Touched up positions for product detect, adjusted What: Product detect issue
Why: Robot teaching at product detect sensors off
Counter measure: Retaught position What: Product detect issues
Why: Product detect sensors out of adjustment
Countermeasure: Realign sensors
Reoccur: Possible if they get bumped when changing vacuum blocks What: Product detect issues
Why: Shot catching on die when robot is going out of die
C/M: Touched up positions after robot chucks shot and starts backing out of die What: Product detect loose
Why: Mounting bolt came loose
Countermeasure: Retighten mounting bolt
Reoccur: Possible What: Product detect not reading
Why: Sensor wasnt reading far enough
C/M: Got book from cage and retaught sensor/ Replaced sensor
Recur: Possibly in time What: Product detect not working
Why: Sensor no good
C/M: Tried adjust sensor and product detect both no good so changed out sensor What: Product detect sensor #2 Not reading correctly.
Why: Pot adjuster for sensitivity is broken and not adjustable for range
Countermeasure: Replace with new
Reoccur: Yes if adjusted improperly What: Product detect sensor no good stuck on
Why: Bad sensor
Counter measure: Replaced 3 sensors
R/C: No
Cycle time: Unchanged What: Product detect sensor no red dot
Why: Not right sensor
Counter measure: Replaced with new model sensor. Still not light with this sensor
R/C: Yes. Got with Otto about it
Cycle time: Unchanged What: Product detect sensor not reading
Why: Sensor was bad
C/M: Replaced sensor now ok
Recur: Possibly in time What: Product detect.
Why: Product detect needed adjusted.
Countermeasure: Adjusted Product detect.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Product sensor detect stuck on
Why: Was loose
Counter measure: Replaced because it didn't admit a light
R/C: NO
Cycle time: Unchanged What: Production leak tag indicating oil leak
Why: After investigating found bad flexible lube line
R/C: Normal and routine wear without a predictable life.
C/M: Replaced bad flex line
Reoccurance: What: Production request modification of Trim press air blow sequence.
Why: Attempting to improve removal of trim from die.
C/M: Bring in air blow sol. o/ps Y6E & Y6F with M113 "Press Cyl. Adv" disabl What: Program 5 problems
Why: Teaching and missing press 1 for 59B one rocker
Counter measure: Put trim press one in and taught all positions What: Program change for additional scrap trim unit. What: Provide electrical service for light
Why:
C/M: This work completed by others. What: Pump on SQM leaking oil
Why: Coupler riding against pump possibly not installed right
C/M: Replaced pump and placed coupler in correct position
Recur: No What: Pump stopped pumping
Why: Set screw come out of sprocket on Vacuum pump motor.
Counter measure: Replaced set screw
R/C:
Cycle time: Unchanged What: Pump wont turn on
Why: Says SS switch not in neutral position
C/M: Loose On Off key switch tightened up.
Recur: No What: Punch not taking proper material off of part
Why: Punch was actuating before part made it into position
C/M: Touched up punch positions, added wait commands to punch positions 4 and 6. Also took What: Push button command die close switch melted
Root cause: Half pipe plugged. Lower crucible over heated and melted buttons. From 1st shift
Counter measure: Replaced push button. Unplugged half pi What: Pusher 1 not returning back
Why: Air line had holes in it
C/M: Replaced line with new
Recur: Possibly in time What: Quality flow line
Why: Hydraulic leak. Male fitting on die
Counter measure: Replaced fitting
R/C: Yes time
Cycle time: Unchanged What: Quality judged cavities 3 and 4 NG for trim damage
Why: R/B position register was saved in NG program which change PR number to be different in NG program vs main program ( always select no when What: Quality judged parts as NG for slide core issues
Why: Getting NG part
Countermeasure: Changed S2 slide core
Will problem reoccur: Possibly
Cycle time: No change What: Quality porosity
Why: Ls for vacuum at 85.0. Plex says 100.0
Counter measure: Set to plex settings. (100.0)
R/C: No
Cycle time: Unchanged What: Quality problem One ejector pin out of spec. should be max 0.500 was 0.924 (Water passage #8)
Why: #3 ejector pin was bent. Put on Ottos desk
Counter measure: Checked all washers thicknesses and What: Quality problem little nub damaged
Why: Aluminum stuck in die hole
Counter measure: Cleaned out nub hole in die. Changed die release settings from .3 to .4
R/C yes
Cycle time: Unchanged What: Quality problem slide core height
Why: Barley in spec
Counter measure: Replaced slide core due to crack
R/C: Unknown
Cycle time: Unchanged What: Quality reported slide core S1 out of spec
Why: Cracked slide core
C/M: Replaced
Recur: possible in time What: Quality said die needed polished
Why: Soldering, mainly cavity 3 but all cavities had it
Countermeasure: Polished all cavities
Will problem reoccur: Possibly
Cycle time: No change What: Quality says die needs cleaned
Why: Soldering/ chunking out
Countermeasure: Polished and all cleaned die
Will problem reoccur: Possibly
Cycle time: No change What: Quality, Discoloration
Why: Flow line, mounting bolt B
C/M: Checked for water/hydraulic leaks. Operator just started m/c running again. check parts again after pre-heat What: Quick connect on water hose, robot side fixed die leaking
Why: Quick connect NG
C/M: Replace quick connect What: R/B (after coming out of warm up) getting collision detect at trim press after parts pressed out of shot.
Why: What: R/B collision detect alarm at trim press.
Why: R/B gripper issues
C/M: Adjust gripper / set screw in, ouch up PR [73,58,59, 60].
Will it Re-occur: Likely, griper set screws are prone to becoming What: R/B crashing out at air blow after water tank or at press 2 that punches parts out
Why: Pickup inside machine off, press 1 set down off
C/M: Touched up pickup position out of die, touched up set What: R/B fault at trimpress
R/C:
C/M:
Will it reoccur: What: R/B faulting out at trimpress and scrap press
R/C: R/B pulling shot of die incorrectly
C/M: Retaught R/B at die positions, trim press ok after that. Touched up r/b at scrap press due to faults
What: R/B faults
R/C: Opposed pair photo eye used to detect part left in trim press mis-aligned.
Countermeasure: Realign part detect photo eye.
Will it Re-occur: No What: R/B faults at trim press.
Why:
C/M:
Will it Re-occur: What: R/B faults at trimpress
R/C: Trim press was not against both stops allowing positioning to be off.
C/M: Repositioned trim press against stops and verified clamps holding trim press. Retaught r/b What: R/B move error excess alarm
R/C:
C/M:
will it reoccur: What: R/B randomly letting go of biscuit before trim press cycle is over, then crashes into leftover tree sitting in press
Why: Issue didn't reoccur What: R/B side helper door will not close
Why: Has fault for DCM on Robot main panel
R/C: Communication error from robot to DCM PLC
C/M: Ran program #8 DOOFF to manually reset communication error.
cyc What: R/B stuck at trim press.
Why: Bolt broken in joint block of gripper.
C/M: Jog R/B out of Trim press, replace Joint block What: R/B will not home
Why: Axis alarms and motion movement on robot
R/C: Unknown
Countermeasure: Run all home prog to return R/B to home pos.
Will it Re-occur: unknown What: R/B would not home
R/C: R/B inbetween labels and would not allow next move
C/M: Manually jogged robot to safe position, used home all to home r/b
will it reoccur: Timing, if robot faults in bet What: RB tappet pin not moving
Why: Aluminum buildup
C/M: Removed slide core assembly and removed aluminum
Recur: Possible What: RPY 13-2 soldering.
Why: Die needed cleaned.
Countermeasure: Cleaned Die. What: RPY P/S F-1 Leaking S1 Slidecore. Why;Cracked at the base.Counter measure: replaced with new one. Will it reoccur: Yes What: RPY trim mark
Why: Upper punch leaving dent in round part pf part
Counter measure: ground on upper punch to stop making mark What: RPY- 1 Rocker trim damage.
cause: Trim press buildup allowing shot to not load correctly.
countermeasure: Found part supports missing on top off trim press, installed new part supports. Adjusted What: RPY-1RKR Die 3 Cavity 3 soldering.
Why: Build up.
Countermeasure: Die Cleaning
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: RPY-1RKR Die 9 cavity 1 needed polished.
Why: Build up.
Countermeasure: Polished.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: RPY-S cav 2 has a crack in slidecore, needs changed
Why: Quality measurement NG
C/M: Changed slidecore to help DH What: Random alarm (Every thing still running)
Why: Scrap press part detect sensor not reflecting off reflector
Counter measure: Put a new reflector on (KEYENCE Grey one) Had a black one don't seem to What: Random trim damage p-2 cav 5BA
Why: Shot not sitting flat all time. The die runner has flashing sometimes around ejector pin and wont let it set flat. that's why it is random.
Counter measure: H What: Randomly going it to pre-heat while running after having a high cycle time.
Why: Pre-heat set screen settings different then plex.
Countermeasure: Matched settings to plex settings.
Will Probl What: Randomly leaving mark
Why: Near vibrator.
Counter measure: Set all counts in robot at vibrator from 10 count to fine
R/C: Unknown
Cycle time: Unchanged What: Rear door refractory damaged.
Why: Damaged during Jackhammering/Cleaning
Countermeasure: Remove all refractory material from damaged areas and replace with new material.
Reoccur: Yes What: Rebuilt 3 Ladle bars units What: Red 3/8" water line dry rotted and snapped
Why: Hose was old
C/M: Replaced water line with new 3/8" hose from diecast cage What: Reed switch issue
Why: Movable core malfunction
Counter measure: Replaced reed switch What: Remove Melkeeper furnace, and shipped for rebuild of refractory.
Why: Refractory Damage, What: Remove old furnace for repair. Reinstall new furnace and Crucible and stand What: Removing Melkeeper Furnace # 601033-2 To be sent out for refractory reinstallation. Including the Doghouse and back door.
Why: Repair damaged refractory. Furnace ,Doghouse and backdoor. What: Removing crucibles to get ready for machine move
C/M: Removed crucibles, put rings and doghouse back in place What: Replace blue ok conveyor with rebuilt one.
Why: Worn guides
Counter measure: Replaced
R/C: Yes time What: Replace fixed side die water line
Why: Operator began operation without opening the Die cooling water valves and melted the water hose.
Countermeasure: Replace Damaged hoses, Request through te What: Replace tip & sleeve
Why: Aluminum build up and wash out
C/M: Replaced with new
Recur: In time What: Replaced servo valve with new one. Not V checking. Accumulator will not refill. (Alarm Shot operation malfunction)
Why: Servo valve needed set to machine
Counter measure: Set servo valve to mach What: Replaced trim press filter What: Reported multiple issues with robot
Why: Root cause most likely just debris build up on trim and scrap presses causing robot faults
Countermeasure: Cleaned presses and verified robot, OK What: Reported vacuum system problems
Why: Op Hose leaking at connection to Vac system.
R/C: Attrition
Will it Re-occur: Yes, Timing What: Retaught robot at cooling tank
Why: Robot coming up out of tank flat holding a lot of water causing air blow to spray water off shot all over floor
C/M: Retaught robot into cooling tank and len What: Rewiring Furnace panel power
Why: At power outages shuts complete power off to furnace
C/M: Ran Power wire from furnace to safety power panel
Recur: No What: Right Scale shows 0015 Error.Switch SW1-1 is unsecured. If the terminal is W&M approved, this switch must be ON before setup can be exited. We turned Sw1-1 "On" which cleared the 0015 error. We What: Right side turn table not turning
Why: Shaft that turn table top bolts down to snapped
C/M: Replaced shaft, replaced some of the bad bearings underneath the table top that help it turn. What: Right side weight scale NG
Why: Not sure had battery fault and red no good light and wont get green ok light
C/M: Changed battery still have red NG light not sure why
Recur: Possibly in time What: Right table top not turning very well.
Why: The top on the table is wavy.
Countermeasure: Replaced top of table.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Robot
Why: At set down mid point and pick up out of trim die
Counter measure: Retaught P42 and P67 and 68. Modified right finger tap
R/C: yes time
cycle time: Unchanged What: Robot
Why: Change over
Counter measure: Taught robot at product detect What: Robot fault
Why: Robot side runner sticking to fixed side
Counter measure: Polished die in runner. Bumped up biscuit What: Robot Alarms
Why: Not sure no alarms on screen
C/M: Run in grease program to see if it would fault and it didn't fault What: Robot Chuck Sensor got caught on die or trim press.
Why: Electrical terminal box for robot chuck sensor fell off
C/M: Reterminated sensor head and lead cable remounted box and tested. Ok
Reocc What: Robot Collision detect. Coming out of trim press
Why: Set screw in finger loose and not holding shot when coming out of press.
Counter measure: Moved set screw in 1 full turn. Had to touch up What: Robot Faulting out over dunk tank.
Why: Shot hit the air blow.
Countermeasure: Cleaned robot fingers, made sure fingers were tight. Issues has not reoccurred while monitoring. What: Robot Faults
Why: Positioning not always the same
C/M: Retaught positions
Recur: In time What: Robot Faults at press
Why: press interlock turning in middle of pressing
C/M: Interlock turning on input needs to stay off till press is completely up What: Robot Issues after changeover
Why: Robot was getting collision detect at trim press.
Countermeasure: What: Robot Malfunction Alarm will not reset at DCM panel
Why: X0AE stuck on from robot system PLC cabinet which is XA42 in DCM PLC and setting Robot Malfunction Alarm
C/M: Got X0AE to drop out allowi What: Robot Malfunction alarm will not clear on DCM
Why: Low temp, holding crucible. Metal leak from overflow, operator didn't restart burner
C/M: Restarted burners, told operator if you get a metal l What: Robot SRVO-014 Fan Motor Abnormal What: Robot Stopping at scrap press.
Why: Sensor on scrap press loose.
Countermeasure: Tightened sensor.
Will Problem Reoccur?: No.
Cycle Time: No Change. What: Robot T1 T2 switch spins
Why: Screw came loose in switch.
Counter measure: Tightened screw
R/C: No
Cycle time: Unchanged What: Robot Trouble in trim press
Why: Robot hitting trim not allowing shot to be put in correct position
C/M: Had to reteach from takeout had to make adjustment at Joint 4 then retaught at trim press What: Robot Trouble jerking at product detect causing a collision detect
Why J6 no good
C/M: Replaced J6 motor zeroed all positions and running What: Robot air leak
Why: Air lines had gotten tangled up in material, melting the lines
C/M: Replaced damaged sections of line What: Robot air leak
Why: Hoses got melted
Counter measure: Replaced hoses and wrap
R/C: No
Cycle time: Unchanged What: Robot alarm
Why: Air not on to robot
Counter measure: Turned air on and cleared alarm What: Robot alarm
Why: Crash at trim press in ng program
Counter measure: Taught line 916 area for set down in press in NG area pf program What: Robot alarm
Why: Ladle not pouring at sleeve which causes machine to cycle out
Counter measure: Checked bearings in arm. They were bad. Replaced arm with rebuilt arm
R/C: Yes time
Cycle time: Un What: Robot alarm
Why: Senor not working
Counter measure: What: Robot alarm
Why: Small chiller alarmed. Shows a robot alarm
Counter measure: Reset alarm on chiller What: Robot alarm (Generic alarm)
Why: Water temp controller alarm out. Water pin point controller. (Line 4 leak error). Due to relay
Counter measure: Replaced relay What: Robot alarm at trim press
Why: Cavity # 3 slide core was sticking
Counter measure: Took off and cleaned slide core
R/C: Yes Time
Cycle time: Unchanged What: Robot alarm at trim press
Why: Positioning cylinder was wedged out on part
Counter measure: Loosened cylinder and aligned to part and slowed out on cylinder
R/C; No
Cycle time: Unchanged What: Robot alarm at trim press
Why: Shot not setting in right
Counter measure: Re taught P24 and P26 What: Robot alarm at trim press (5A2 BC trim press #1)
Why: Cavity #2 plunger for pushing sticking part off top was missing
Counter measure: Replaced parts
R/C:
Cycle time: Unchanged What: Robot alarm coming out of trim press
Why: Air cylinder getting stuck under part
Counter measure: Slow air cylinder down
R/C: Yes time
Cycle time: Unchanged What: Robot alarm.
Why: Biscuit too small.
Countermeasure: replace ladle unit
Will Problem Reoccur?:yes
Cycle Time: What: Robot alarming
Why: Bad chuck sensor
Counter measure: Replaced sensor What: Robot alarming at trimpress
why- r/b got crashed on double pour shot
c/m- touch up r/b at trim press and scrap press
reoccur- no What: Robot alarms
Why: At trim press not picking part out of press straight. Due to bolt being missing that holds part straight
Counter measure: Replaced missing bolt on big claw. And retaught P63 an What: Robot alarms
Why: J6 axis problem only move a little bit and alarm and return to original position. Brake wire cut to j6. Wire is cut behind cover for j5
Counter measure: Removed J6 motor/ assem What: Robot anchor bolt snapped off
Why: Excess movement of base Possibly
C/M: Put bigger anchor bolt in and tightened
Recur: Possibly in time What: Robot area door cannot be operated safely.
Why: Linear bearing supporting top of door completely worn out. Mounting screws for linear bearing supporting bottom door missing / backed out.
C/M: Se What: Robot at mid point crash
Why: Chuck arm shoulder bolt broke
Counter measure: Replaced shoulder bolt and had to teach positions for mid to trim die
R/C: Yes
Cycle time: Unchanged What: Robot at trim press
Why: Not setting in all the way sometimes
Counter measure: Took set down pins out ground one pin to a point and (OA Engineer) Had another pin that shaft was shorter
R/C: Yes What: Robot at trim press alarm
Why: Shot going in crooked
Counter measure: Touched up p73 to p78
R/C: Yes
Cycle time: Unchanged What: Robot at trim press collisions
Why: Change over from chain trenchers to 1 rocker. Have to change fingers for different tip size
Counter measure: Touched up robot P-25 and P-26
R/C: Yes due to ro What: Robot at trim trouble
Why: Shot would not sit in trim press by hand
C/M: Took 2 cutters loose set shot in by hand freely and re-tightened
Recur: Possibly in time What: Robot chuck arm bent
Why: 60 mm Biscuit robot went to grab shot hit biscuit
C/M: Replaced with new arm
Recur: Possibly in time What: Robot chuck fault when robot comes on in auto
Why: Air line for robot unchuck side NG
C/M: Replace air line What: Robot chuck finger extension needed changed due to the model change calling for a different size.
R/C: Different models of parts call for different sized chuck finger extensions.
C/M: Changed c What: Robot chuck not opening
Why: Power cable pulled loose and broke bracket that holds cable. Why: Robot cable hitting door on rotating movements.
C/M: re-taught position away from door and replace What: Robot chuck not opening or closing What: Robot chuck sensor
Why: Wire broke between junction boxes
Counter measure: Used spare wires in cable
R/C: Yes Time
Cycle time: Unchanged What: Robot chuck sensor NG
Why: Worn thru wire insulation showing bare wire
C/M: Replaced with new wire
Recur: Possibly in time What: Robot chuck sensor got rippered out/cut.
Why: Unknown, passed on to 3rd.
C/M: Replaced sensor What: Robot chuck sensor ng
Why: Melted. Why: Shot touched hose
C/M: Replaced wire sensor
Recur: Possibly in time What: Robot chuck sensor not working
Why: Broken wire
C/M: Replaced wire connector
Recur: Possibly in time What: Robot chuck sensor not working
Why: Electric wire from robot terminal box to sensor terminal box bad
Counter measure: Replaced wire
R/C: Yes Time
Cycle time: Unchanged What: Robot chuck sensor not working
Why: One of connecting wires broke from terminal
C/M: Put new terminal connector and hooked back up
Recur: Possible in time What: Robot chuck sensor not working
Why: Sensor bad
C/M: Replaced sensor What: Robot chuck sensor ripped off
Why: Root cause unknown, guessing sensor wire got caught
C/M: Replaced male and female side RSMCK 3 connectors and sensor. What: Robot collision after take out
Why: Not sure
C/M: Fixed switch for T1 did not do anything to robot
Recur: Possibly in time What: Robot collision alarms
Why: Tabs building up, set down position off
C/M: Adjusted air blow and touched up robot set down What: Robot collision at mid point drop
Why: Due to new sensor placement. Tree from shot hit new sensor at mid point drop
Counter measure: Took sensor. Don't seem to be hooked up yet
R/C: No
Cycle tim What: Robot collision at mid point drop
Why: Shot sticking to tip. Due to plunger lube line moved. And robot positions were changed
Counter measure: Adjusted lube line. And touched up at Vibrator and What: Robot collision at take out
Why: Robot not taught correctly
C/M: Retaught from take out to scrap press
Recur: Possibly in time What: Robot collision at trim press
Why: ?
C/M:
Recur: What: Robot collision at trim press. (After die change)
Why: Robot tooling arm got bent. Had to hit something
Counter measure: Replaced tooling arm
R/C: No
Cycle time: unchanged What: Robot collision at trim take out
Why: Shot was not sitting completely on base position
C/M: Retaught Line 25 and 26 Final 2 set positions
Recur: Possibly in time What: Robot collision detect
Why: Not loading at the place to put
C/M: Retaught at place to put and inside trim press, Also had to replace 2 of the air lines the run the air to the chucks
Recur: Maybe What: Robot collision detect
Why: Shot pick up point at die un-level
Counter measure: Touched up P-5,6 21,22,23,24,25
R/C: No
Cycle time: B-26.0 A-26.0 What: Robot collision detect alarm at trim press
Why: Robot tool head bent
Counter measure: Replaced tool end arm. Retaught positions
R/C: No
Cycle time: Unchanged What: Robot collision detect alarms
Why: Shoulder bolts were loose
Countermeasure: Tightened bolts
Will problem reoccur: Possibly
Cycle time: No change What: Robot collision detect at scrap press
Root cause: Coming out of trim die crooked. Due to twice clamp
Countermeasure: Took twice clamp out of program ( Unclamp wait clamp)
Reoccurrence: Yes
Cycl What: Robot collision detect at trim press
Why: Shot is not lined up with trim press
C/M: Adjusted robot position
Reoccur: Yes, timing What: Robot collision detect fault
Why: Found that in previous model had to long a bolt in robot chuck jaw ends. Bolt was holding the shot not the claw ends. This model was taught with that bolt in. W What: Robot collision detect faults
Why: Trim press RPY 1RKR TRIM 1 jerky movement
Countermeasure: Swap trim press out with RPY 1RKR TRIM 2
Reoccur: Possible What: Robot collision detect in trim press
Why: Multiple things
Counter measure: Taught P35 from hitting trim die guide post with tree from shot. Add a holder to right finger to keep shot from tiltin What: Robot collision detect in trim press
Why: Tree on shot sticking in slide. Due to slide
Counter measure: Ran temporary air. Added 2 air lines to press to blow tree off. (See Work request notes)
R What: Robot collision detect. Coming out of trim press
Why: Stuck on pins
Countermeasure: Adjusted air for cylinders that push part over down
R/C: Yes time
Cycle time: Unchanged What: Robot collision faults
R/C: Wrong chuck fingers on robot/Robot positions
C/M: Replaced r/b chuck finger grips with correct size for 60mm tip parts, Retaught all positions from die to scrap pres What: Robot continuous collision detect alarms, Either using the manual controls or using the home program the alarm would occur with very minimal movement
Why:
C/M: I had to power the robot off then What: Robot cover fell off
Why: holes were all stripped out
C/M: re tapped holes and welded some flat stock for new holes
recur: Possibly in time What: Robot crash
Why: Crashed into parts on scrap conveyor
Counter measure: Returned robot and clear parts off scrap conveyor What: Robot crash
Why: Hit big biscuit
Counter measure: Replaced bent tooling arm What: Robot crash
Why: Hit die. Due to not running model Chain tench after J2 axis change months ago
Counter measure: Replaced robot tool head and retaught.
R/C: Yes if there is another model that has What: Robot crash
Why: Part not trimmed. Robot chuck jaws bolt broke. Little square runner getting under part
Counter measure: Replaced bolt and adjust air line to keep little square runner from get u What: Robot crash
Why: Shoulder bolt broke
Counter measure: Replaced shoulder bolt
R/C: No
Cycle time: Unchanged What: Robot crash
Why: Tab being left in trim press
Counter measure: Re taught robot What: Robot crash (Change over)
Why: Robot off at mid point
Counter measure: Retaught robot at mid point What: Robot crash and mid point
Why: Teaching off
Counter measure: Re taught in die and out to set down What: Robot crash at mid point
Why: Was hit pins
Counter measure: Retaught mid point and line 193 sped up from 2.00 wait to .50
R/C Yes
Cycle time: 52.2 now 49.5 What: Robot crash at scrap press
Why: Teaching
Counter measure: Taught
R/C: Yes
Cycle time: Unchanged What: Robot crash at trim press
Why: Big chuck jaws bolt broke again
Counter measure: Welded it again. Waiting on part
R/C: Yes
cycle time: Unchanged What: Robot crash at trim press
Why: Double stacked
Counter measure: Adjusted cross sensor down to see shot when in trim press What: Robot crash at trim press (Water passage)
Why: Claw arm was loose
Counter measure: Tightened claw and re-taught position from pick up to into trim press
R/C:
Cycle time: unchanged What: Robot crash at unload conveyor
Why: Conveyor not moving due to tap from shot getting caught in belt
Counter measure: Removed tab
R/C:
Cycle time: Unchanged What: Robot crash in trim press
Why: Needed re-taught
Counter measure: Re-taught all position form mid point into press. Used level to level tooling end.
R/C:
Cycle time: unchanged What: Robot crash in trim press
Why: Robot jaws loose and trim press damage to ramp
Counter measure: tightened jaws and repaired trim die. Polished die What: Robot crash into biscuit
Why: Biscuit to big
C/M: Replaced aluminum arm cause it was bent
Recur: Possibly in time What: Robot crash mid point
Why: Ejector speed to high.
Counter measure: Ejector speed was 80 went to 60. Slowed down P6 on robot for 100 to 50. For pick up off sprue
R/C: Unknown
cycle time: Unchang What: Robot crash trim press
Why: Big gripper jaws mounting bolt stripped out and let jaw float around
Counter measure: Weleded new bolt with a nut
R/C: Yes
Cycle time: Unchanged What: Robot crashed
Why: Biscuit very large robot hit it on take out
C/M: Replace robot chuck arm
Recur: Possibly in time What: Robot crashed
Why: Crashed into dunk tank. Why: Did not let off controller
C/M: Replaced Robot wiring harness and Axis 3 motor due to encoder cable getting ripped apart
Recur: No What: Robot crashed
Why: Hitting trim press
Counter measure: Taught set position in trim press, P23/ P24/ P25 What: Robot crashed
Why: Unknown bent tooling arm. Taka replaced
Counter measure: Re taught pick up and trim press What: Robot crashed into biscuit bend end of arm tooling
Why: Biscuit was to big
C/M: Put new end of arm on robot and re-taught take out all way back to trim press
Recur: Yes if biscuit is oversized t What: Robot crashed into door while trying to home from trimpress
R/C: Home program does not work correctly Needs positions added for home all program
C/M: Jogged robot manually to position to allow t What: Robot crashed into excessively long biscuit now robot does not pick up properly
Why: Aluminum Armature bent during crash
C/M: Replaced aluminum armature,remounted chuck assembly and tested, and What: Robot crashed into fixed side of die
Why: Moving to much in soft float
Counter measure: Slowed ejector speed from 80% to 60% what plex says
R/C:
Cycle time: Unchanged What: Robot crashed into helper door
R/C: Robot fault at trimpress DH used wrong robot program to try home robot, crashed into door
C/M: Jogged robot to new location and used correct program home all What: Robot crashed into stand
Why: Biscuit sticking to tip
Counter measure: Adjusted lube line and retaught robot at stand What: Robot crashing
Why: Cooler heater Alarm 04. Set point 35. Actual temp was 51.5.
Counter measure: Reset alarm and let cooler return temp to optimal range. Didn't find anything wrong with cooler. What: Robot crashing
Why: Shot moving in chuck jaws
Counter measure: Replaced chuck jaws and taught robot in trim press What: Robot crashing at scrap press
Why: Guide bar broke and holder broke for shot
Counter measure: Replaced guide bar and welded holder back on
R/C: No
Cycle time: Unchange What: Robot crashing in trim press
Why: Chuck finger fell off
Countermeasure: Replaced chuck finger
Will problem reoccur: Possibly
Cycle time: No change What: Robot crashing in trim press
Why: Shot sticking to die a bit, robot needs touched up
C/M: Touched up robot, die release needed adjusted. Concentration was low What: Robot cycle stopping after it goes into run
Why: X0A6 input from furnace on, this is tied into robot cycle stop line in logic
C/M: Reset low temp alarm on furnace What: Robot cycle time over
why: Robot could not travel to next position in program due to lines deleted in program
c/m: After die change machine would not run robot program, Found 2nd shift re added What: Robot cycle timing out (Alarm) (Higher than arc pressure adjustable range)
Why: Ladle stopping at sleeve and not pouring. Low nitro in accumulator
Counter measure: added nitro to accumulator
R/C What: Robot door safety switch
Why: Door safety wiring was pulled out of switch, 2 wires lost connection
C/M: Re terminated wires to the proper connections
Reoccur: What: Robot door won't close to start production
Why: Control terminal strip inside operator control panel vibrated loose on the circuit board...
C/M: Reconnect and locked terminal locking clips
Recur What: Robot door won't open
Why: Bolts from the cylinder into the door fell out
C/M: Installed new bolts after re-tapping one of the two holes What: Robot double stacking
Why: Sensor not seeing shot and press miss aligned
C/M: Adjusted sensor and aligned press and retaught robot
Recur. Possibly in time What: Robot dropping parts
Why: Machine not getting any plunger lube, copper line junction came loose under machine
Countermeasure: Tightened junction
Will problem reoccur: Possibly
Cycle time: No cha What: Robot dropping shot
Why: Blow back making biscuit too small. Tip worn
Counter measure: Replaced tip
R/C: Yes time
Cycle time: Unchanged What: Robot dropping shot
Why: Grabbing to far in on biscuit
C/M: Retaught take out What: Robot dropping shot
Why: Take out no good
C/M: Retaught take out and checked all other positions
Recur: Possible in time What: Robot dropping shot in jaws
Why: Tooling arm bent
Counter measure: Replaced tooling arm. Had to reteach in die and all other positions
R/C:
Cycle time: unchanged What: Robot dropping shot.
Why: Not gripping shot correctly due to shot sticking to tip.
Countermeasure: Adjusted the placement of the plunger lube most have gotten bumped.
Will Problem Reoccur?: Poss What: Robot dropping shot.
Why: sleeve worn
Countermeasure: replaced tip and sleeve What: Robot dropping shots
Why: Cause unknown
C/M: Checked robot chuck fingers for tightness (OK). Found large amounts of blow by built up on vacuum block RB side and hoses had holes in them. Replaced What: Robot dropping shots
Why: Shot sticking to tip
Counter measure: Replaced tip
R/C:
Cycle time: Unchanged What: Robot dropping shots.
Why: Air leak.
Countermeasure: Replaced damaged hose.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Robot dropping sot off in trim press and leaving without it pressing the parts
Why: Part detect sensor not seeing shot
Countermeasure: Blew and wiped off part detect sensors What: Robot end of arm tooling bent
Why: Crashed into biscuit cause biscuit to big
C/M: Replaced end of arm tooling and retaught at trim press What: Robot end of arm tooling bent
Why: Robot hit a large biscuit do to operators not doing preheats correctly
C/M: Replaced end of arm tooling re-taught all positions What: Robot fault
Why: Big chuck jaws bolt broke
Counter measure: Replaced bolt
R/C: NO
Cycle time: Unchanged What: Robot fault
Why: Chuck senor not working due to broke wire in plug
Counter measure: Re terminated wire in plug
R/C:
Cycle time: Unchanged What: Robot fault
Why: Chuck sensor
Counter measure: Replaced sensor
R/C: Yes
Cycle time: Unchanged What: Robot fault
Why: Collision detect at trim press, broken bolt on robot chuck arm & 1 bolt missing
C/M: Replaced broken bolt and installed new bolt where missing. Replaced melted blue and black li What: Robot fault
Why: Product detect
Counter measure: What: Robot fault
Why: Product detect
Counter measure: Taught P10 position What: Robot fault
Why: Robot stopped in die. Had a brake alarm for Axis 1 Spray cartage cylinder drifted off its up sensor.
Counter measure: Adjusted sensor and returned robot What: Robot fault
Why: Runner breaking off robot side
Counter measure: Pulled die What: Robot fault
Why: Shot sticking to tip
Counter measure: Adjusted lube line
Counter measure: What: Robot fault after robot was homed.
Root cause: Robot was not truly home.
Countermeasure: Re-homed robot. What: Robot fault and blow back
Why: Biscuit breaking off in sleeve
Counter measure: Replaced tip
R/C; yes
Cycle time: Unchanged What: Robot fault at air trim press
Why: Teaching off
Counter measure: Retaught P11 P12 P13 What: Robot fault at main DC panel and would not clear
Why: Engineers used same address for temperature panel and also for BC sensor Chuck had found problem
C/M: Albin and Jose gonna put on a separate What: Robot fault at scrap press
R/C: Robot position off at trim press moving shot in chuck allowing fault
C/M: Touched up robot positions at trim press and in scrap press
Will it reoccur: No
Cycle ti What: Robot fault at trim press
Why: Robot was off at pick up out of die
Counter measure: Re taught pick up and trim press What: Robot fault at trim press
Why: Shoulder bolt broke allowed chuck hand to go on outside of trim post
C/M: Replaced both shoulder bolts and chuck finger
Recur: Possibly in time What: Robot fault at trim press
Why: Teaching off
Counter measure: Re taught position 24 What: Robot fault at trim press
Why: Flashing on shot
C/M: Retaught
Recur: Possibly in time What: Robot fault in die (Water passage)
Why: Shot was too big. Robot tooling end hit shot and bent it
Counter measure: Replaced tooling arm
R/C:
Cycle time: Unchanged What: Robot fault, die interlock
why: Die not closing completely during cycle causing machine to instantly stop killing hydraulic pump, all machine.
c/m: Replaced J6 motor/encoder.remaster and calibra What: Robot fault, product detect line 116 in robot program is gone
Why: ?
Countermeasure: Ryan reentered line for work detect in line 116
Reoccur: no What: Robot fault.
Why: Shot staying in the die.
Countermeasure: Cleaned die, adjusted ejection from 21 to 23.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Robot faulted
Why: PSU fan was not spinning
C/M: Remove fan, got it working again and put back in PSU What: Robot faulted in trim press.
Why: Water passage part not sitting correctly.
Countermeasure: Tightened loose pin on fixed jig.
Will Problem Reoccur?: No.
Cycle Time: No Change. What: Robot faulted out at trim press.
Why: Sensor reflector dirty.
Countermeasure: Replaced Reflector with spare.
Will Problem Reoccur?: Timing. What: Robot faulted out mid-cycle
Why: SRVO-0045 HCAL Alarm (Axis 3)
C/M: Cycled power, fault cleared and robot appears to be running OK. This fault indicates a current increase in the power circuit o What: Robot faulting
Why: Sensor wire pulled out of quick connect (robot side)
C/M: Put robot back in quick connect What: Robot faulting and trim height
Why: Chuck claws worn allowing shot to move going into trim press
Countermeasure: Replace chuck claws and touch up P24 and P25
Reoccur: Possible What: Robot faulting at scrap press shot is hitting cutter.
R/C: Not getting sufficient plunger lube, parts sticking to tip and robot not picking up shot consistantly looks bad going into trim press. What: Robot faulting at the overflow press
Why: Set position off
C/M: Re-taught finale set position
Recur: Possibly in time What: Robot faulting at water tank. Dropping shot
Why: Was hitting basket
Counter measure: Taught positions
R/C: Yes time
Cycle time: Unchanged What: Robot faulting in trim press
Why: Press not coming down in auto. Does not move in 1-cycle either. Works fine in inching
C/M: Changed Y0C9 relay, started having issues with trim press sensor What: Robot faulting out at trim press
Why: Robot chuck arm shoulder bolt broke
Countermeasure: Replaced bolt
Will problem reoccur: Possibly
Cycle time: No change What: Robot faulting out at trim press.
Why: Scrap shot (trees, flags) building up on trim press.
Countermeasure: Straightened ramp up on trim press to allow scrap to fall.
Will Problem Reoccur?: Timi What: Robot faulting out at trim-press (running water passage).
Why: Scrap build up (trees, tabs) on trim-press.
Countermeasure: Bent ramps/shoots straight on trim-press to allow scrap to fall.
Will P What: Robot faulting out in trim press
Why: Set down position in trim press too high, causing collision detect when press comes down
C/M: Touch up robot in trim press What: Robot faulting out over conveyor
Why: Chuck sensor flickering, wire broke in quick connect fitting
C/M: Reterminated wire What: Robot faulting out when taking shot out of die
Why: Plunger tip NG
Countermeasure: Adjusted plunger lube spray line and flow, verified robot pick up, replaced plunger tip What: Robot faults
Why: ?
C/M: Retaught take out and jig sitting
Recur: Possibly in time What: Robot faults
Why: Arm bent
Counter measure: Replaced robot tooling arm What: Robot faults
Why: Bad tip
Counter measure: Replaced tip
R/C: Yes time
Cycle time: Unchanged What: Robot faults
Why: Big gripper bolt broke off
Counter measure: Replaced bolt
R/C:
Cycle time: Unchanged What: Robot faults
Why: Biscuit too thin and casting problems alarms. Due to shot sensor counting backward on return. Was dirty
Counter measure: Replaced sensor
R/C:
Cycle time: Unchanged What: Robot faults
Why: Broken wires on chuck sensor
C/M: Replaced
Recur: Possible in time What: Robot faults
Why: Dropping part
Counter measure: Taught P5 and P24 P25 What: Robot faults
Why: Dropping shot when die opened. Shot sticking to tip
Counter measure: Replaced tip
R/C: Yes time
Cycle time: Unchanged What: Robot faults
Why: Due to tool arm bent
Counter measure: Replaced tool arm
R/C: Yes
Cycle time: Unchanged What: Robot faults
Why: Final sit down position was off
C/M: Re-taught final sit position What: Robot faults
Why: Operator was sending robot to home position but would fault out, Pendant showed it was in the grease program.
C/M: Pressed abort all and then successfully sent robot to home p What: Robot faults
Why: Product detect off
Counter measure: Re taught P11 What: Robot faults
Why: Servo alarm HCAL 045
Counter measure: Cycled power What: Robot faults
Why: Shot sticking to tip
Counter measure: Adjusted lube plunger line
R/C: no
Cycle time: Unchanged What: Robot faults
Why: Shoulder bolt holders stripped out
C/M: Replaced both
Recur: Possible in time What: Robot faults
Why: Tip worn. Water was left off
Counter measure: Replaced tip
R/C: Yes time
Cycle time: Unchanged What: Robot faults
Why: Bad air fitting on chucks
Counter measure: Replaced fitting
R/C: No
Cycle time: Unchanged What: Robot faults at cylinder that knocks tabs off, not knocking tabs off parts and causing crashes in trim press
Why: Position at cylinder to knock tabs off, cylinder air fitting damaged. Cylinder n What: Robot faults at press
Why: Rubbing cavity at insert
C/M: Retaught robot finale set position
Recur: Possibly in time What: Robot faults at product detect
Why: Sensor was off on product 1
C/M: Re-taught at product detect What: Robot faults at scrap press
R/C: Robot not gripping part correctly during second clamp at trim press
C/M: Touched up position 26 at trim press to allow regrip of shot
Will it reoccur: No
C/T Be What: Robot faults at scrap press
R/C: robot running shot into scrap press bottom block
C/M: Retaught positions for robot at scrap press
Will it reoccur: NO What: Robot faults at scrap press. (whole shot going into scrap press)
Why: Trim press sensor needed adjustment
Counter measure: Adjusted sensor up
R/C: No
Cycle time: Unchanged What: Robot faults at the trim press
Why: Changeover was the change point
C/M: Retaught in the trim press
Recur: Possibly in time What: Robot faults at trim press
R/C: Plunger lube line plugged
C/M: Removed plunger lube line and removed aluminum debris, reinstalled and verified lube working ok now
Will it reoccur: No
C/T before: What: Robot faults at trim press
Why: 3 out of 4 fingers touching the biscuit
C/M: re-taught from take out and at trim press
Recur: In time What: Robot faults at trim press
Why: Cylinder in trim press jamming part when robot tries to take it out
Counter measure: Retaught p60 position. Set down position
R/C:
Cycle time: unchanged What: Robot faults at trim press
Why: Flashing from die in runner for biscuit. See Pic
Counter measure: Re moved pin from trim die
R/C:
Cycle time: Unchanged What: Robot faults at trim press
Why: Pick up out of trim press crooked
Counter measure: Laid level on arm and set level then set P63 P64
R/C: No
Cycle time: Unchanged What: Robot faults at trim press
Why: Positions all off
C/M: Retaught all positions from place to put to final set position
Recur: In time What: Robot faults at trim press
Why: Robot not sitting into position correctly
C/M: Had to reteach all positions from place to put to take out
Recur: Possibly in time What: Robot faults at trim press
Why: Robot sitting part down at the place to put not smooth transition when picking up
C/M: Retaught at place to put and in trim press What: Robot faults at trim press
Why: Set down point off
Counter measure: Re-taught robot at set down point in trim press
R/C:
Cycle time: unchanged What: Robot faults at trim press after change over
Why: Change over
Counter measure: Adjusted screws for water passage claw
R/C:
Cycle time: Unchanged What: Robot faults at trim press coming out after trim finished (Water passage)
Why: Long pin that part sets on was loose
Counter measure: Took trim press out and tightened pin from bottom. (Bolt goe What: Robot faults at trim press. (New Water passage trim press)
Why: Square runner fell in stamping hole and tilled part
Counter measure: clean out hole and adjusted top air blow
R/C: No
cycle time: What: Robot faults at trim press. When twice clamp robot bouncing
Why: Twice clamp on
Counter measure: Turned twice clamp off switch on trim press What: Robot faults at trim take out
Why: Unknown
C/M: Retaught take out and slowed it down
Recur: Possibly in time What: Robot faults coming out of trim press
Why: Collision detect coming out of trim press
Counter measure: Retaught pick up out of trim press. (Used level to level arm) What: Robot faults in die
Why: Draw bars washer was missing and mismatched with 4mm and 2mm washers for ejector plate. (Ejector Pins)
Counter measure: DH pull die and replaced with 2mm washers on all What: Robot faults.
Why: Not getting any die release.
R/C: Diaphram pump bad.
C/M: Replaced Pump.
R/O: Timing.
Cycle time: NO change What: Robot faults.
Why: Noticed not much lube on biscuit.
Countermeasure: Lube line had hole in it. Replaced line. What: Robot froze putting part in trim press.
Why: Unknown, no obvious trim press issue.
C/M: Recovered robot. What: Robot getting collision detect at trim press
Why: Unable to identify root cause due to many issues throughout the night, production ended up pulling die
Countermeasure: None What: Robot getting collision detect when trying to remove water passage from trim press
Why: Dragging part out causing it to fault
C/M: Adjusted ramp for runner that was bent. Adjusted PR[63] positio What: Robot getting stuck at trim press
Why: Found robot not letting go of shot because ok parts conveyor was getting jammed up
C/M: Adjusted conveyor tension and advance sensors What: Robot go in to get shot off die and come right back out
Why: Solenoid valve for the chuck open and close no good
C/M: Replaced valve What: Robot going in die to get part wiring harness
Why: Harness on wrong side of end of arm tooling
C/M: Put new end of arm on robot that is predrilled for other side bracket mounting and ran new se What: Robot going to home position
Why: Product detect What: Robot hit die
Why: Haven't ran this die type since robot got new axis joint put in (5A2 tensioners).
Counter measure: Retaught all positions
R/C: No
Cycle time: Unchanged What: Robot hits electrical conduct when you cycle stop D/C machine
Why: No Pr16 in program
Counter measure: Added Pr 16 line 367
R/C: No
Cycle time: Unchanged What: Robot hitting auto door.
R/C: DH touched up point for product detect, he taught wrong point.
C/M:taught correct position for PR5
R/O: Yes if wrong point getstouched up again this will occur agai What: Robot hitting helper door
Why: Cushion for the helper door cylinder needed adjustment
Countermeasure: Adjusted cushion What: Robot in trim press issue
Why: Ramp missing on trim press. Letting square runners under part
Counter measure: Replaced ramp off of other trim die What: Robot is going down at trim press then back up and unchucking up off the trim press.
R/C: Position 24 was recorded where position 22 should have been.
C/M: Turned the position 24 back into a 22 What: Robot is stopping after product detect
Why: The robot is stopping out of position for the 7th product detect check
C/M: Re-teach robot position
Reoccur: Timing What: Robot issue
Why:
Counter measure: What: Robot issue
Why: Crashing in trim press. Leaving part in and not pressing it then crashing into with next part
Counter measure: Adjust sensor down to see part in trim press What: Robot issue
Why: Sensor wire junction box on arm fell off
Counter measure: Removed box because we dont use What: Robot issue
Why: Trim press area alarm
Counter measure: Re taught at trim press What: Robot issue
Why; Crashed robot. Bent arm.
Counter measure: Retaught robot What: Robot issue (IMP alarm)
Why: Air shut off to robot
Counter measure: Turned air on What: Robot issue after change over
Why: Robot clamp sensor
Counter measure: Re terminated in plug and zipped tied up What: Robot issue at trim press
Why: teaching in trim press off
Counter measure: Retaught robot in trim press What: Robot issue in trim press
Why: Air blow had hole in hose. Leaving pieces on trim press
Counter measure: Cut line bad spot out of air line What: Robot issue in trim press
Why: Robot off at set down
Counter measure: Retaught 30 and 29 positions What: Robot issue. Not going in die
Why: What: Robot issues
Why: Robot faulting when switching chucks
Countermeasure: Retaught robot position for sitting part down at chuck change point What: Robot issues after changeover to breather cover
Why: DH on 2nd hasn't changed machine over to breather covers before. Didn't know you have to remove overflow tab press
C/M: Removed press What: Robot issues at trim press
Why: Not setting shot down right
C/M: Found all 4 bolts loose on robot chuck, locate pin about to fall out. Pushed pin back in place and tightened bolts What: Robot issues at trim press
Why: Pick up point off of die bad
Counter measure: Retaught all positions What: Robot issues at trim press
Why: Shot being removed before pressing
C/M: Cleaned off sensors
Recur: Possibly in time What: Robot issues in trim press
Why: Set down positions NG, before and after trim press
C/M: Replaced missing part on chuck jaw, touched up position setting down for chuck position change, touched up What: Robot issues.
Why: Had SRVO-069 CRCERR Alarm (Grp:1 Ax:6) it is currently running What: Robot issues.
Why: Sensor cable damaged.
C/M: Replace sensor. What: Robot leaving shot in trim press
Why: Part sticking up and blocking shot sensor in press
C/M: Touched up robot set down position in trim press P(26). Sat shot in trim press and loosened base blo What: Robot leaving shot in trim press after it is trimmed
Why: Twice clamp was off
Counter measure: Turned twice clamp on What: Robot leaving shot in trim press.
Why: No getting Press Complete.
Countermeasure: X34 not made. Turned Twice Clamp from Off to On on trim press.
Will Problem Reoccur?: If it gets turned off.
C What: Robot loading 2 shots into trim press before trim press activates
Why: Found trim press sensor out of adjustment
C/M: Adjusted trim press sensor What: Robot losing grip of shot
Why: Shoulder bolts loose on chuck fingers
C/M: Re-tighten all 4 bolts
Recur: Possibly in time What: Robot malfunction alarm on D/C mach. HMI.
Why: R/B PLC input XA6 "Part left in trim press" Was used in R/B program as Melkeeper Low temp I/P.
C/M: Remove change made regardig XA6. What: Robot malfunction, fence open, emergency stop faults coming from robot panel and trim press
Why: unknown but safety lock at trim press door was wiggled and safety faults cleared
C/M: checked w What: Robot malfunction.
Why: Part detect, dropping bottom operator side.
Countermeasure: Operator bottom slide core was not moving back a fourth. Cleaned up slide core area so that it moved smoothly What: Robot mid position crash
Why: r/b position off
Counter measure: touch up at mid position
R/C: possible
Cycle time: Unchanged What: Robot moves with out pushing start button
Why:
Counter measure: What: Robot not clamping on part
Why: Shoulder bolt broken on part clamp
C/M: Replaced broken bolt after removing old bolt What: Robot not clamping onto parts
Why: Broken bolts
C/M: Replaced shoulder bolts What: Robot not dropping shot on scrap conveyor
Why: P18 off
Counter measure: Re taught P18 What: Robot not going in to get the shot out of die
Why: Robot chuck sensor not reading
C/M: Adjusted sensor now ok What: Robot not going it to pick out shot from die area
Why: Space not clear command. Due to helper door not opening all the way. Regulator was turned down
Counter measure: Turned regulator up to sett What: Robot not going to trim press
Why: Trimpress sensor on top of trim die not working. Bad plug pin
Counter measure: Rigged plug What: Robot not grabbing shot
Why: Hole in airline to robot chuck
C/M: Cut off bad section of airline What: Robot not loading trim die
Why: Rod for sensor not moving well on top of trim die. Due to bad spring stopper cap on Cavity 2
Counter measure: Replaced cavity 2 spring stopper cap What: Robot not picking shot out of die.
Why: Arm bent.
Countermeasure: Replaced arm. What: Robot not picking up part straight at mid point
Why: Mounting bolt in big claw broke
Counter measure: Replaced bolts
R/C: Yes time
Cycle time: Unchanged What: Robot not picking up shot from die.
Countermeasure: Cycled power to robot.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Robot not pulling shot from die
Why: Excessive buildup around robot chuck
C/M: Cleaned off chuck and verified production What: Robot not setting and taking out of trim press
Why: Teaching
Counter measure: Retaught set and pick up points
R/C:
Cycle time: Unchanged What: Robot not setting in trim presses right
Why: Unknown have not ran this Part in while
Counter measure: Re taught from pick up out. All positions 59B 1RKR #5 type What: Robot not sitting in trim press right
Why: A shot would not sit in the press by hand
C/M: Re-taught robot now ok What: Robot not starting
Why: Air line broke off
Counter measure: Replaced air lines What: Robot not starting
Why: Had a broken wire in plug coming out of top of robot
Counter measure: Pulled plug apart and found 3 wires broke. Wire #2 #5 #6. 5 and 6 not in use. Move 3 to 2 in pin are What: Robot not taking part out of trim smoothly
Why: Take out no good
C/M: Retaught take out of press
Recur: Possibly in time What: Robot not unloading (waiting)
Why: Traced back to robot not getting OK signal to come into DCM area in PLC
C/M: Found YA50 (Extraction Start) coming on in program but robot not entering to remov What: Robot overflow punch hitting part leaving dent and trim height
Why: Punch coming down on part
C/M: Retaught punch 4 position taught off onto overflow and moved back towards part to take trim he What: Robot plc not powered up
Why: Found that power supply was bad
C/M: Changed power supply What: Robot positions off at trim press.
C/M: Retaught robot positions. What: Robot problem
Why: Will not reset on toscast screen
Counter measure: Had to cycle machine and robot. Then try to run robot and hit rest alarm to get it to clear What: Robot problem (RPY)
Why: Stop at product detect
Counter measure: Re taught p11 for product detect What: Robot punch position 6 needed touched up
Why: Punch position off since changeover
C/M: Touched up robot positioning What: Robot randomly leaving tree in trim press
Why: Possible timing issue with sensors looking across trim press
C/M: Adjust wear sensors were aiming, issue seems to have stopped What: Robot safety door would not open. (The walk in door next to scrap conveyor).
Why: Wires got pulled out of door switch.
Countermeasure: Terminated wires, replaced broken switch cover.
Will Pro What: Robot sending all parts to scrp after going to punch.
Why: Sensor was not reading anything, bad sensor.
C/M: Replaced sensor. What: Robot sending parts to scrap and main scrap conveyor not working.
Why: Bent flight was causing the conveyor jam sensor to be made.
C/M: Adjusted sensor and removed flight... straightened out and What: Robot sensor not working, injection rod had wrong water fitting on it. Water leak sprue bushing hose had hole in it
Why: Bad connector plug. Water passage arm, Replaced injection rod water fitti What: Robot servo fault after dropping shot in cooling tank, additional IMSTP fault that DH was unable to recover from
Why: Dropped shot
C/M: Disable UOP in system variables and homed What: Robot shuck sensor cable cut
Why: Found during change over
Reoccur: Possible
Reoccur: Possible What: Robot side vacuum block bolt stuck.
Why: Block blown, aluminium got behind block.
Countermeasure: Removed bolts. What: Robot sitting shot in incorrectly at trim press
R/C: Block broken and missing from trim press
C/M: Removed trim press and installed different trim press that has all correct blocks and cutters
W What: Robot snagged backdoor wire pulled out and melted
Why: Cause wire loose hanging out from sensor
C/M: Rewired bump sensor / did not have a spare
Recur: Possibly in time What: Robot soft float alarm
Why: Robot off in trim press
Counter measure: Retaught robot at trim press What: Robot stopped at scrap press
Why: Chuck didn't open. Hole in air line
Counter measure: Put coupler in line
R/C: Yes time
Cycle time: Unchanged What: Robot stopped at scrap press
Why: Crashed into scrap press
Counter measure: Multiple issues: Wrong cutters from change over. Guide rod broke. Senor not seeing shot because sensor couldn't go low What: Robot stopping
Why: #3 product detect not making
Counter measure: Taught position #11 What: Robot stopping
Why: Collision detect above water tank
Counter measure: Tried to teach couldn't fig out why. Ran 5BA trim die on RPY trim die program
R/C: Yes
Cycle time: Unchanged What: Robot stopping
Why: Robot chuck sensor pulled tight
Counter measure: Loosened up sensor wire What: Robot stopping
Why: Sensor connection bad on chuck sensor
Counter measure: Re-terminated plug
R/C:
Cycle time: Unchanged What: Robot stopping
Why: Relay bad for scrap press
Counter measure: Replaced relay What: Robot stopping and going home
Why: Product detect not hitting all parts
Counter measure: Touched up position What: Robot stopping at back door
Why: Door not opening all the way quick enough. Due to one of guide wheels has a flat spot
Counter measure: Replaced guide wheel
R/C: Yes time
Cycle time: Unchanged What: Robot stopping at back door
Why: Stopped at DCM interlock. Robot also said collision detect. Door was hitting robot with bolts for plexy glass
Counter measure: Re taught robot at back door befor What: Robot stopping at back door. Cycle timing out
Why: What: Robot stopping at scrap press
Why: Chuck senor bad on robot
Counter measure: Replaced chuck sensor on robot What: Robot stopping at scrap press
Why: Chuck sensor wire broke on robot was flickering
Counter measure: Replaced sensor
R/C: No
Cycle time: Unchanged What: Robot stopping at trim press
Why: Shot was hitting robot tool after shot was stamped out
Counter measure: Taught P1 at trim press to keep shot up right during press and adjusted trim press air b What: Robot stopping at water tank giving an Axis 6 servo 69 fault CRCERR Alarm
Why: J6 wiring harness NG
Countermeasure: Replaced the J6 wiring harness, retaught the robot positions. What: Robot stopping just outside helper door after getting shot and not moving until door opens again.
Why: Pos. 11 movement was changed from 2000 to 1000.
C/M: Changed number back to original
R/O: Y What: Robot stopping mid cycle
Why: Scrap press work detect sensor always reading parts
Countermeasure: Adjusted sensor
Will problem reoccur: Possibly
Cycle time: No change What: Robot stopping, Running NG program
why: Chuck sensor not operating sending robot into NG program.
C/m:Removed sensor and quick disconnect, sensor wire broke in quick disconnect, reterminated se What: Robot stops at open back door
Why: Back door impact strip had a zip tie holing it on. Which was activating the strip.
Counter measure: Cut zip tie off and fixed strip
R/C: No
Cycle time: Unchan What: Robot stuck in die area
Why: Back helper door cylinder braked broke
Counter measure: Removed backet and welded What: Robot take out switch staying on and robot don't start
Why: ?
c/m: cycled m/c power
reoccur:? What: Robot trouble
Why: Not sitting in press same way from NG to Production
C/M: Retaught take out 2 times ended up changing the position of the arm at take out then checked all other positions and h What: Robot trouble
Why: Place to put was a mess had to pull drawing to make sure all pin height was correct robot go to sit shot down would set all crooked
C/M: So took apart stoned bottom added was What: Robot trouble at the trim press
Why: Not sure
C/M: Retaught place to put and in the press positions were way off at place to put pin was not aligned at all What: Robot trouble at the trim press.
Why: Shot to tight in press.
C/M: Set Retaught robot after adjust press.
Recur: In time. What: Robot trouble at trim press
Why: Die release concentration out of spec very low and filter clogged
C/M: Got die release concentration in spec and cleaned filter and retaught 25,26
Recur: yes in What: Robot trouble at trim press
Why: Final set position no good
C/M: Retaught final set position
Recur: In time What: Robot trouble/ Squeeze master trouble
R/C: Robot: caused by chuck fingers placed in correctly on chuck after changeover, Unsure of proper positioning.
Squeeze master: Stroke needed adjustme What: Robot unloading issues.
C/M: Engineering scheduling to have new modified robot arm installed. Countermeasure for robot crashes trying to unload parts. What: Robot waiting for space to clear
Why: Helper door cylinder coupler broke from door
Counter measure: Replaced coupler
R/C: Yes time
Cycle time: Unchanged What: Robot will not go home
Why: Getting a warning stating that it is waiting for space to clear
C/M: Found helper side door not open all the way What: Robot will not return to home
Why: FWD/BWD was disabled on the teach pendant not allowing movement.
Countermeasure: Turned FWD/BWD disable off and returned robot to home. What: Robot wont leave home position in auto
Why: Chuck sensor not working
Counter measure: trimmed wire at bad spot
R/C:
Cycle time: Unchanged What: Robot wont move
Why: Chuck sensor not made
Counter measure: senor plug wire came off reatached What: Robot wont move in auto
Why: Sensor wire broke
Counter measure: Terminated wire
R/C: No
cycle time: unchanged What: Robot would not home from home position.
Why: Was taken home with X,Y,Z and robot arm was 180 deg out.
Countermeasure: Got robot to a position in grease program and homed form there. What: Robot would not home using home program.
Why: Not sure why but ended up using the trim to home program to get it home.
Countermeasure: Recovered robot, got robot home. What: Robot would not home.
Why: Chain faults.
Countermeasure: Reset faults. Homed robot. What: Robot would not move in the JGFRM mode properly.
Why: J-2 Axis wasn't zeroed correctly.
Countermeasure: Re-zeroed robot J-1 thru J-6. All position re-taught.
Recurrence: No. What: Robot would not run past door gives a SRVO fault 24
Why: Robot cable no good
C/M: Cleaned up robot get ready for 2nd shift to install new cable
Recur: Possibly in time What: Robots chucks
Why: Bolts come loose
Counter measure: Put lock tight on threads What: Run conduit for signal cable Melkeeper to Fanuc R/B cabinet. Provide pull wire in conduit and heat shield where necessary. What: Running 5BA-PS. Tap pin broke off inside of part.
Why: 5BA-P 11-1 broke tap pin.
Countermeasure: Replaced tap pin. What: Running 6A0-P die slamming.
Why: Speed % was higher then what is in plex.
Countermeasure: Adjusted Speed % so that it matched plex.
Will Problem Reoccur?: Yes if it gets changed.
Cycle Time: No What: Running RPY cavity 2 getting crushed.
Why: Cutter on trim damaged.
Countermeasure: Swapped out trim press 1 for trim press 2. Parts are good. What: S-1 has a crack and chip in it
Why: Wear
Countermeasure: Replaced slide core
Will problem reoccur: Possibly
Cycle time: No change What: S-2 Slide core cracked
Counter: replace S-2 slide core What: S-2 slide core cracked at top of roller grove
Why: Unknown
Counter measure: Replaced S-2 slide core
R/C: Yes
Cycle time:Unchanged What: S1 (HT) slide core out of spec
Why: Slide core cracked
C/M: Replaced HT, S1
Reoccur: yes timing What: S1 P1 soldering
Why: Aluminum buildup on backside of slide cores
C/M: Cleaned all slide cores What: S1 parts have a high spot
Why: HT slide core has a "chunk" missing
C/M: Replace slide core S1 What: S1 slide core cooling joint leaking
Why: Damaged O-rings
C/M: Removed cooling joint and installed new O-rings
Reoccur: Yes timing What: S1 slide core cracked + 10mm
Why: Unknown
C/M: Replaced with new
Recur: Possibly in time What: S1 slide core leaking
Why: 2 out of 3 orings broke on cooling joint
Countermeasure: Replaced o rings What: S1 slide core out of spec
Why: Cracked
C/M Replaced slide core
Recur: Timing What: S2 (BO) part of spec- slide core issue
Why: Chip in slide core S2 (BO)
C/M: Replaced slide core and tested. OK What: S2 cavity slide core NG
Why: Wear/life
Countermeasure: Replaced with new slide core
Will problem reoccur: Yes this is a wear item
Cycle time: NA operator had to shut down to sort parts What: S2 slide core build up leaving drag mark inside roller groove
Why: Burr on backside of slide core
C/M: Replaced slide core
Recur: In time What: S2 slide core crack
C/M: Replaced OB slide core
Recur: In time What: S2 slide core out of spec
Why: Cracked
C/M: Replaced OB S2 slide core What: SQM filter clogged
Why: Not been changed Long time plugged up
C/M: Replaced all 3 SQM filters
Recur: Possibly in time What: SQM making noise at pump and motor
Why: Coupler at pump to motor the spider gear in between them was worn to much play
C/M: Replaced spider gear What: SQM trouble
Why: Axis 1 to high
C/M: I re bled SQM and started back up What: SRVO-045 HCAL Alarm (Group: 1 Axis: 3)
Why: Root cause unknown, robot was at OK conveyor
C/M: Cycled power to clear alarm, recovered robot to home. Issue did not reoccur What: Safety Switch not working. What: Safety circuit not resetting
Why: Safety switch in front of furnace not locking/unlocking per blue and black buttons
C/M: Pulled bottom off of switch and found wires pulled out of terminal strip What: Safety circuit not resetting at ingot loading
Why: Safety switches not making good contact on ingot loader
C/M: Adjusted switches so the key was going into lock better. got fault cleared What: Safety contactor
Why: Went bad
Countermeasure: Replaced contactor but had to put in relay for that contactor to work
R/C: No
Cycle time: Unchanged What: Safety cyl. faults
Why: Sensor on cylinder not seeing Cyl. Ret.
C/M: Adjust sensor pos. and secure. What: Safety door alarm
Why: Wire came off at crucible door to no where
Counter measure: Hooked up wire What: Safety door bracket fell off. For robot cage
Why: Bolts came loose
Counter measure: Reattached and put new bolts in
R/C: Yes time.
Cycle time: Unchanged What: Safety door for ingot elevator moved
Why: Switch moved
Counter measure: Re aligned safety switch What: Safety door handle broke on ingot loader
Why: Wear
Countermeasure: Replaced handle and latch
Will problem reoccur: Possibly
Cycle time: No change What: Safety door handle for upper crucible fell off
Why: Bolts came out
Counter measure: Replaced bolts
R/C: Yes time
Cycle time: Unchanged What: Safety door linear bolts broke. On entry door to robot
Why: Bad design. Door linear bolts too small and break off due to door tilting
Counter measure: Cut plate off and drilled out. Replace bolt What: Safety door not closing.
Why: Safety door switch bad.
Countermeasure: Replaced front safety door switch.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Safety door switch broke
Why: Ingot cart caught door on way up to dump ingots in crucible and kicked door open
Counter measure: Replaced door switch
R/C: Yes
Cycle time: Unchanged What: Safety door switch broke for upper stairs
Why: Door got shut with handle sticking out
Counter measure: Replaced handle
R/C:
Cycle time: Unchanged What: Safety door switch for ingot elevator broke
Why: Operator didn't get cart always in and popped door open
Counter measure: Replaced door switch
R/C: No
Cycle time: Unchanged What: Safety door to bottom crucible was loose.
Why: Bolts to locking mechanism were loose.
Countermeasure: Tightened bolts, and replaced bolts that needed replaced.
Will Problem Reoccur?: Timing.
Cy What: Safety equipment, emergency stop fault, safety system wont reset
why: Die cast enable 2 relay contact defective.
c/m: Replace G7SA-5A1B safety system relay
will it reoccur:No
cycle time: Not aff What: Safety handle
Why: Handle broke on ingot loading
Counter measure: Replaced handle What: Safety handle for ingot loader broke
Why:
Counter measure:
R/C:
Cycle time: What: Safety hook malfunction
Why: Gummed up
Counter measure: Un jammed hook What: Safety hook not pulling back
Why: Valve stuck, continuously blowing air out of exhaust on solenoid
C/M: Replaced solenoid valve on safety hook cylinder What: Safety latch on back ingot loader door NG
Why: Inside latch broke
C/M: got the lever to insert for now
Recur: In time What: Safety lights on trim door and ok bucket conveyor door
Why: Scrap conv 2 motor enable contactor did not physically drop out. E stop circuit in Trim press cabinet open between N2 and N3/N4. 1715F What: Safety lock alarm for die open
Why: Safety hook lock at top of machine (back side by pump)was sticking
Counter measure: Lubed up
R/C: No
Cycle time: Unchanged What: Safety lock handle broken for charging loader
Why: Broke when staffing associate tried to load in scrap hopper
C/M: Replaced handle What: Safety switch come on in auto operation
Why: Disingauging from lock
C/M: Straightend key out What: Safety valve on mold heater leaking
why: plunger sticking open allowing water to bypass
c/m: took safety valve apart, cleaned and reassembled
reoccur: possibly What: Saftey door repair.
C/M: Bottled hinges back to extrusion. Also replaced broken saftey door handle. What: Scale control being replaced by toledo.
Why: Original control failed.
C/M: Support contractor attempting to connect and program control with out documentation. What: Scale getting Error 0005.
Why: Broken wire.
Countermeasure: Used excess wire in panel.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Scale not working (Left side) 0009 and 0011 alarm
Why: Cable got cut
Counter measure: Cut bad wire off and pulled excess threw and terminated
Cycle time: Unchanged What: Scheduled Hood Repair
why: Damaged hood
c/m: Hood removed for repair What: Scheduled Hydraulic Filter Change What: Scheduled complete rebuild of the J5 axis
Why: Visible jerkiness in axis
C/M: Complete rebuild of J5 axis. All gears and bearings for J5 replaced backlash set and checked. Backlash after repa What: Scrap C/V 2 NG, rails breaking off where they are welded, chain dragging on
itself and rails eaten through.
C/M: 1st shift welded and repaired track, replaced necessary rods, rollers and cotter What: Scrap Conveyor 1 overload
Why: Small conveyor that goes to main scrap conveyor jammed, will not move
C/M: Had to pull out conveyor, pull motor off and get it moving freely. Re-tensioned conveyor What: Scrap Conveyor Jamming
Why: Links missing and rods pulling out Why: Worn
C/M: Went through put links in and replaced lots of cotter pins
Recur: Possibly in time What: Scrap Press bearings came apart.
Why: Wear.
Countermeasure: Replaced both linear bearings. What: Scrap Sticking to the cutters
Why: Cutter pressing to far
C/M: Adjusted bottom sensor
Recur: Timing What: Scrap aluminum getting jammed up in conveyor
Why: Scrap shot not going thru scrap press
C/M: Re-taught in scrap press maybe ok
Recur: Possibly in time What: Scrap balling up
Why: Cause shots keep tangling up due to that machine does not use the small scrap press
C/M: Operator has to keep eye on scrap and scrap conveyor has guards on it What: Scrap bucket not going in to dump.
Why: Material ful sensor was flashing not doing anything.
C/M: Unscrewed cannon plug and reset sensor, confirmed okey and will dump. What: Scrap building up on scrap press/Robot fault
R/C: Positioning of shot at scrap press off allowing pieces to build up
C/M: Retaught r/b positioning at scrap press to allow shot to be cut in corre What: Scrap chute flipper broke
Why: Wear
Countermeasure: Rewelded flipper to shaft
Will problem reoccur: Possibly
Cycle time: No change What: Scrap conv jammed up.
Why: Links not secured, cotter pins missing.
C/M: Break free, jog conv and replace 8 missing cotter pins.
Thank you Darrel C. What: Scrap conv worn needs replaced
Why: worn
C/M: Replaced scrap conv belt What: Scrap conveyor
Why: Jammed
Counter measure: Blew out and un jammed What: Scrap conveyor #1 motor overload
Why: Jammed up
Counter measure: Unjammed
R/C: Yes
Cycle time: Unchanged What: Scrap conveyor #1 motor overload
Why: Overflow stuck in conveyor jamming it up
C/M: Unjammed conveyor
Recur: Possibly in time What: Scrap conveyor #1 run and stop
Why: Flites bent and tension on chain loose
C/M: Straiten flites and tighten tension
Recur: Possibly in time What: Scrap conveyor 1 jam What: Scrap conveyor 1 not turning
Why: Mounting flange had 3 loose bolts and a piece of the flange broke off where the other bolt goes
C/M: Straightened up motor, tightened the 3 remaining bolts. Wor What: Scrap conveyor 1 overload
Why: Jammed with overflow tabs
C/M: Turned conveyor by hand and freed it up What: Scrap conveyor 1 overloads
What: Excessive flashing and scrap buildup on conveyor
C/M: Had to pull motor chain from conveyor and worked the belt free What: Scrap conveyor 1 tripping overload
Why: Aluminum pieces in chain and chain excessively loose
Countermeasure: Pulled conveyor unit out, cleaned and adjusted tension on chain
Will problem reoccur: What: Scrap conveyor 1 would not rotate
Why: Conveyor jammed up with aluminum
Countermeasure: Removed motor, freed up conveyor cleaned out aluminum
Will problem reoccur: Possibly
Cycle time: No change What: Scrap conveyor 2 broken link
Why: Worn and lots of overflows inside
C/M: Replaced 2 rods and cotter pins What: Scrap conveyor 2 faults
Why: Stretch in chain, Slack in conveyor chain tripping x09F sensor, No adjustment left in adjusting bolts
R/C: No PM schedule to check conveyor system
C/M: Disconnected What: Scrap conveyor 2 jammed
Why: Loose material bound up underneath belt
C/M: There is no reverse function on the conveyor itself so I had to swap the phases of the motor to get it to turn backwards What: Scrap conveyor 2 jammed
Why: Scrap got wedged in conveyor and broke chain
C/M: Replace chain with new now ok What: Scrap conveyor 2 jammed (small conveyor that feeds into large scrap conveyor)
Why: Scrap got jammed beside belt
C/M: Turned conveyor by hand in reverse until I could clear jam What: Scrap conveyor 2 over load
Why: Guarding jamming up
Counter measure: Bent guarding What: Scrap conveyor 2 overload
Why: Motor over load
Counter measure: Re set over load What: Scrap conveyor 2 overload
Why: A part got swept under the conveyor
C/M: Worked conveyor back and forth by reversing motor leads What: Scrap conveyor 2 overload faults
Why: Excessive flashing buildup underneath scrap conveyor
C/M: Cleaned out underneath conveyor What: Scrap conveyor 2 overloads.
Why: Pieces jammed up underneath the conveyor.
C/M: Had to reverse motor to run backwards and break free what was stuck. Got free and confirmed ok. What: Scrap conveyor alarming out
Why: One of the flights to carry scrap was broke on one end and hanging down in sensor
C/M: Cut it off due to it being welded
Recur: Possibly in time What: Scrap conveyor alarming out
Why: Slack in conveyor drooping down to sensor
Counter measure: Tightened chain
R/C Yes time
Cycle time: Unchanged What: Scrap conveyor belt replacement
Why: Missing Pins and bent paddles 16 spots
C/M: Replaced Conveyor belt
Recur: Possibly in time What: Scrap conveyor divider not working
Why: Weld on shaft broke
Counter measure: Welded shaft back on
R/C: No
Cycle time: Unchanged What: Scrap conveyor guard broke
Why: Scrap build up at base of conveyor
C/M: Welded guard back on to conveyor it was bolted and also made bracket to cover side hole
Recur. No What: Scrap conveyor guard fell off
Why: 1 RKR scrap hanging up
C/M: Remounted guard and added angle iron on corner
Recur: Possibly in time What: Scrap conveyor issue
Why: Cotter keys missing
Counter measure: Replaced rods and links and cotter keys What: Scrap conveyor issue
Why: Over load
Counter measure: Reset over load and un jammed conveyor What: Scrap conveyor jam
Why: Conveyor jammed with excess scrap
C/M: Cleared blockage What: Scrap conveyor jam up
Why: Bent rods and guides
Countermeasure: Replace rods and guides
Reoccur: Possible What: Scrap conveyor jam/ fixed side temp. alarms
why: scrap conveyor scrap buildup in track, temp alarms water main pressure low
c/m: pulled scrap conveyor and unjammed and cleaned out, switched wate What: Scrap conveyor jammed
Why: Many flights bent and cotter keys NG/missing
C/M: Replaced missing cotter pins and flight pins
Recur: Yes in time What: Scrap conveyor jammed
Why: Scrap caught in conveyor
Countermeasure: Remove jammed scrap
Reoccur: Possible What: Scrap conveyor jammed
Why: Scrap got pulled back into conveyor due to someone removing sensors to detect this. They bolted them together so they wouldn't alarm out
Counter measure: Put sensors b What: Scrap conveyor jammed up
Why: Cotter pins and links missing but also some aluminum chunks under conveyor chain
C/M: Replaced pin ,links and cotter pins. What: Scrap conveyor jammed. (Big)
Why: Missing rollers and 5 bent rods on belt
Counter measure: Replaced conveyor belt and end rollers What: Scrap conveyor jamming
Why: Damaged links and rods, missing cotter pins
C/M: Replaced 6 damaged rods and 2 damaged links, replace roughly 20 cotter pins on trim press side of chain What: Scrap conveyor jamming
Why: Missing rollers and damaged links in conveyor
C/M: Replaced around 20 cotter pins that were missing, and fixed what we could of damaged rollers. Note left for Darrell What: Scrap conveyor jamming up
Why: Many bent rods , rollers no good , and missing links and cotter pins
C/M: Replaced rods, cotter pins and links , rollers What: Scrap conveyor jamming up
Why: Scrap shots sticking in open slot causing it to build up and jam
C/M: Pushed conveyor closer and have operator keep an eye on it till i can get a piece ordered to What: Scrap conveyor motor OL faults
Why: Connecting Links bent on conveyor where cotter pins were broken/gone
C/M: Removed and straightened, re-installed and replaced cotter pins What: Scrap conveyor not running.
Why: Conveyor jammed.
C/M: Cleared scrap and debris. What: Scrap conveyor overload
Why: Conveyor jammed
C/M: Reversed motor wires to get conveyor to move backwards, cleared jam What: Scrap conveyor overload
Why: Root cause unknown, operator asked for assistance
C/M: Reset conveyor and recovered unload robot for operator What: Scrap conveyor replacement. What: Scrap conveyor sensor bad
Why: Got hit with shot
Counter measure: Replaced sensor
R/C: Yes time
Cycle time: Unchanged What: Scrap conveyor slide replacement
Why: Old one was bad What: Scrap conveyor snagging
Why: Bent pin, missing cotter pins
C/M: Replaced rod and replaced multiple cotter pins What: Scrap conveyor stopped
Why: Chain broke
Counter measure: Re placed master link What: Scrap conveyor stopped
Why: Jammed
Counter measure: Un jammed What: Scrap conveyor train wreck.
Why: Guard from West side of incline torn from mount riding up the conveyor where it lodged between the OK conveyor guarding and the inboard face of the conveyor.
C/M What: Scrap conveyor tripping overload
Why: Aluminum stuck in conveyor
C/M: Removed aluminum and slightly tightened conveyor What: Scrap conveyor was not moving, tripping out the motor.
Why: Coveyor was jammed.
C/M: In order to clear the debris the motor was pulled , and the conveyor pulled out of machine. Clear aluminum What: Scrap conveyor2 jammed
Why: unknown
Countermeasure: Removed conveyor from DC5. Removed motor/gearbox. Turned conveyor shaft and Found 1 bent rod, replaced it and 7 cotter pins (missing). Re-inst What: Scrap cutter cutting wrong
Why: Bearings failed
Counter measure: Replaced bearings and Guide rod
R/C: Yes time
Cycle time: Unchanged What: Scrap detect sensor
Why: Broken wire
Countermeasure: Replace sensor
Reoccur: Timing What: Scrap elevator door stuck and wont open
Why: Door hinge bent from prior crash
C/M: Unbolted and bent back into position What: Scrap elevator safety door not latching
Why: Latch mechanism in safety switch overturned
C/M: Reset mechanism, tested locking and unlocking several times What: Scrap falling onto floor
Why: Main scrap conveyor moving
Countermeasure: Fabricate bracket to secure conveyor
Reoccur: No What: Scrap press
Why: Bearings in guide fell out due to change over to chain tech. No one checked if cutters were hitting each other. Which puts bearings on bind
Counter measure: Replaced bearings an What: Scrap press
Why: Cylinder bolt fell out guide polls dropped
C/M: Replaced with new bolt
Recur: Possibly in time What: Scrap press (Runners stacking up)
Why: Air blow needed adjusted
Countermeasure: Adjusted air blow
R/C: yes time
Cycle time: Unchanged What: Scrap press Malfunction
Why: Up and Down Relay no good
C/M: Replaced both Relays
Recur: Possibly in time What: Scrap press alarm
Why: Sensor stuck off. Shot got caught in upper cutter and double stacked and hit sensor wire and melted wire. Due to bar being missing to keep shot from sticking in upper cutt What: Scrap press build up
Why: No air blow
Counter measure: Replaced valve
R/C Yes time
Cycle time: Unchanged What: Scrap press cylinder pole snapped off threaded stud
Why: Wear and bushing failure causing to much play.
C/M: Replaced both shafts and bushings.
Recur: Timing What: Scrap press faulted out.
Why: Detect sensor Error.
Countermeasure: Replaced sensor.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Scrap press guide bars broke
Root cause: Sensor was to low and cutters overlapped and broke bars
Countermeasures: Adjusted sensor so cutters don't touch. (Put scale between)
Reoccurrence: NO
Cyc What: Scrap press guide for scrap and air blow off not working
Why: Replaced guides with new ones and replaced air blow valve What: Scrap press issue
Why: Guide bearing bad
Counter measure: Replaced bearings What: Scrap press issue
Why: Robot hitting it
Counter measure: Retaught set down in scrap press What: Scrap press issues.
Why: Scrap building up.
Countermeasure: Polished shoot.
Countermeasure: What: Scrap press jamming up
Why: Cutters no good and sitting out of position
C/m: Replaced cutters and retaught robot into scrap press
Recur: possibly in time What: Scrap press leaving runners press
Why: Solenoid valve stuck closed for air blow off. For scrap press
Counter measure: Put some oil in valve. and worked back and forth
R/C: No
Cycle time Unchan What: Scrap press missing coupler
Why: Old one had stripped out bolt
C/M: Had Brock make some New ones and replaced
Recur: Possibly in time What: Scrap press not pressing out shot
Why: Clogged Filters
C/M: Replaced both filters on trim press tank
Recur: Possibly in time What: Scrap press not returning home causing robot to wait and fault
Why: Relay in cabinet NG, also blew fuse on input/output card on PLC
C/M: Replace relay and PLC I/O card What: Scrap press not stamping out every time
Why:
Counter measure: What: Scrap press not stopping in same spot
Why: Cylinder going too fast down and passing x097 advance sensor.
Counter measure: Adjusted speed on DCV stack. Middle stack Knob closest to water tank What: Scrap press part detect sensor melted
Why: Part of the shot grazed the wire
Countermeasure: temporary PLC ladder change. temporary R/B program change
Will problem reoccur: yes sensors and wires What: Scrap press reflector fell off and ingot in tower sensor was not set right
Why: Weld broke on reflector and tower sensor bracket was bent
Counter measure: Re-welded and bent tower bracket back
R What: Scrap press sensor NG.
Why: Sensor got hit by full shot.
Countermeasure: Replaced sensor, adjusted sensor at trim press.
Will Problem Reoccur?: No.
Cycle Time: No Change. What: Scrap press sensor abnormal
Why: After shot breaks it isn't falling out and building up
C/M: Adjusted ramp up so after it presses it falls down to the scrap conveyor. Had to cut sides of ramp ou What: Scrap press sensor not functional
Why: Scrap press broken sensor wire
C/M: Replace sensor
Recur: Yes timing What: Scrap press sensor not working
Why: Broken (cracked casing)
C/M: Replaced sensor What: Scrap press sensor. (Part detect sensor)
Why: sensor went bad
Counter measure: Replaced sensor
R/C: yes time
Cycle time: Unchanged What: Scrap press stopped down
Why: Bad relay
Counter measure: Replaced relay
R/C: Yes time
Cycle time: Unchanged What: Scrap press stopped down
Why: Down relay bad
Counter measure: Replaced relay
R/C: No
Cycle time: Unchanged What: Scrap press stopping down
Why: Relays burnt
Counter measure: Replaced both relays
R/C: Yes time
Cycle time: Unchanged What: Scrap press stuck down and robot leaving whole shot in trim press
Why: Relay bad in external box on side of main panel over water tank
Counter measure: Replaced Bad relay
R/C: No
Cycle time: Unc What: Scrap sensor bad
Why: Broken
C/M: Replaced with new
Recur: Possibly in time What: Scrape cavity 1
Why: Cutter had a mark in it
Counter measure: Adjusted cutter in to part What: Scrape on front of part. cavity 4
Why: Block pushed forward
C/M: Adjusted blocks in trim press for cavity 4, no shim was added or removed What: Scrape on part near mounting
Why: Robot chuck finger left side guide came loose. So it couldn't pick part up square from mid point and set in trim die square
Counter measure: Tightened guide
R/ What: Scrape on part near mounting hole
Why: Air cylinder not hooked up for cylinder on trim press
Counter measure: Hooked up air cylinder hose on trim press
R/C:
Cycle time: Unchanged What: Scraping Tappet on cavity 3
Why: Guides had rough build up at parting line
C/M: Replaced both guides
Recur: Possibly in time What: Scraping on cavity 4 on slipper of part
Why: Buildup on block, block too close to part causing it to scrape
C/M: Replaced cutter (K-079-01-024-R/CUTTER 24R) What: Scratches on part
Why: Scraping coming out of die
Countermeasure: Polished burs in die
R/C: Yes time
Cycle time: Unchanged What: Seal around back door fell out
Why: ?
C/M: Replaced liner
Recur: Possibly in time What: Secondary air pressure drop on melting furnace
Why: Relay for main gas valve not seated all way in
C/M: Pulled out and pushed all way in. What: Sending all #4 parts to scrap
Why: Part stuck in flipping door
C/M: Manually moved #4 several times, sensor not making. Removed trim press and found AL scrap stuck in door What: Sending all parts to scrap at trim press.
Why: Sensor on trim punch was still seeing the punch, constantly NG the parts thinking excess trim is still there.
C/M: Adjusted sensor and confirmed wo What: Sensor X17 on ok bucket bad
Why: Staying on
C/M: Replaced sensor
Recur: Possibly in time What: Sensor abnormal alarm
Why: Top trim press sensor staying on all the time. (Bad)
Counter measure: Replaced sensor
R/C: Yes time
Cycle time: Unchanged What: Sensor abnormal on trim press
Why: Trim press start pos. sensor (X20) staying on when press traveled down and made (X21) down pos
Countermeasure: Removed sensor and cleaned oil and flashing from What: Sensor at scrap press that detects shot is bad.
R/C: Unknown as to way it was broken
C/M: Replaced sensor.
Reoccurrence: Timing.
Cycle Time: No change What: Sensor failed on Tie Bar clamp cylinder
Why: Sensor failed, Very dirty with debris on sensors
Countermeasure: Replace both clamp cylinder sensors, X234, X245. Very dirty inaccessible area.
Re What: Sensor for tower not allowing scrap to dump in
Why: Apparently sensor may have been misadjusted somehow. Unclear on why
C/M: Tried adjusting to proper setting range What: Sensor issue
Why: Plug bad
Counter measure: Replaced plug What: Sensor issue on safety hook
Why: Return senor on cylinder stuck on
C/M: Got sensor off and checked for repeatability, did not reoccur What: Sensor on trim not reading part
Why: Wire in plug pulled out
C/M: Took plug apart and re-terminated Wire
Recur: Possibly in time What: Sensors for Trim die protective circuit ripped out during Die change. What: Sensors for Trim press damaged when removing die.
Why:
C/M: Assist Craig R. with wiring replacement plug. What: Servo amp fault
Why not sure
C/M: Shut power off for 5 min now ok will need to monitor What: Servo-251 DB Relay Abnormal.
Why: During initial start up.
Countermeasure: Cycled power. What: Set down position in trim press NG
Why: Shot turned not allowing a smooth set down
C/M: Touch up robot in trim press What: Shaft galling on return
Why: Water to plunger shaft was off
C/M: Turned valve on and removed handle
Recur: No What: Shaft sticking to shots
Why: Worn tip
C/M: Replaced tip What: Shoots for scrap conveyor jamming up
Why: Shots too big for shoots
Counter measure: Replaced with new bigger one
R/C: No
Cycle time: Unchanged What: Shot Position Sensor alarm.
Why: Shot sensor dirty.
Countermeasure: Cleaned sensor. What: Shot being pulled of die
Why: Tip and extension not tight
C/M: Put new tip and taped up both and reinserted
Recur: possibly in time What: Shot breaking after warm up cycle completes
Why: Settings wrong in program
Countermeasure: Reset settings per plex for 5A2 S (350 T)
Reoccur: Possible What: Shot breaking apart when ejecting
Why: Die release concentrate too high plunger tip lube collar broke
Countermeasure: Adjust die release concentrate back into spec and weld plunger tip lube coll What: Shot breaking at spru
Why: Tip worn
C/M: Replaced tip
Recur: Possibly in time What: Shot detect sensor
Why: Big scratches on sensor bottom
C/M: Replaced with new
Recur: Possibly in time What: Shot detect sensor NG
Why: Sensor had big scratch on sensing end wouldnt allow it to read
C/M: Replace sensor with new
Recur: yes possibly in time What: Shot detect sensor broken wire fault
Why: Debris on sensor not allowing sensor to read correctly
Countermeasure: Clean debris away from sensor
Reoccur: Possible What: Shot detect sensor not reading correctly
Why: Sensor scratched and a dent on face
C/M: Replaced with new What: Shot falling apart
Why: 2 Ejector pins broke
Counter measure: Pulled die
R/C:
Cycle time: Unchanged What: Shot falling apart in die when being removed by the robot
Why: Operator was trying to run the line while the plunger lube had run out
C/M: Told operator to refill lube, verified unloading afterw What: Shot falling out of chuck
Why: Chuck finger worn and not grabbing shot on 4 points
C/M: Replaced finger and retaught take out
Recur: possibly in time What: Shot getting dropped.
Why: Coming out of die.
Countermeasure: Checked chuck claws - good. Checked for air leak. Did not reoccur while monitoring. What: Shot getting stuck in scrap press
Why: Not sure cause its not all time so hard to pin point problem
C/M: retaught many times but no good result or fix sprayed WD-40 on cutters and seemed to help What: Shot getting stuck in unload scrap conveyor chute
R/C: Scrap shot not getting cut at scrap press
C/M: Touched up robot positioning at scrap press to allow parts to set down soft and not fall off What: Shot getting stuck, happened twice in 15 minutes
Why: Root cause unknown
C/M: Operator cleaned out die release filter, DH checked spray points. What: Shot is not returned fault.
Why: Ejection rod not returned.
Countermeasure: Returned. Did V-check. Adjusted plunger lube. Ran ejection rod in and out with plunger lube multiple times. What: Shot moving in jaws
Why: Hunk of aluminum in Jaws and teaching bad at sprue
Counter measure: Retaught at sprue and trim press What: Shot not sitting in press
Why: 1 piece blocks to tight
C/M: Loosened all blocks Re-positioned blocks
Recur: Possibly in time What: Shot position errors
Why: Counting negative on return stroke, shot sensor NG
C/M: Replace shot sensor What: Shot position sensor alarm
Why: Suspected oily sensor, removed, cleaned and reinstalled. Alarm still present
C/M: Replaced sensor What: Shot position sensor break alarm.
Why: Sensor dirty.
Countermeasure: Cleaned sensor. What: Shot position sensor fault
Why: Shot sensor was coated with black film
C/M: Removed and cleaned sensor, inspected and reinstalled. What: Shot position sensor issues.
Why: Dirty Sensor.
Countermeasure: Cleaned and zeroed sensor. What: Shot position sensor reading bad
Why: Dirty and oily
C/M: Removed sensor cleaned inside and out where sensor sits
Recur: In time What: Shot position sensor wire break (Alarm)
Why: Shot sensor went bad. Look like it got hot on end that ride shaft
Counter measure: Replaced sensor
R/C: Yes time
Cycle time: Unchanged What: Shot position sensor/wiring broken alarm
Why: Sensor oily
C/M: Removed sensor, cleaned and reinstalled, no alarms
Reoccur: timing What: Shot position sensor/wiring broken alarm.
Why: shot Sensor face coated with oil.
C/M: Remove and clean sensor.
Will it Re-occur: Soucre of oil not yet determined. What: Shot positioning sensor wire break
Why: Shot sensor went bad
Counter measure: Replaced shot sensor
R/C: Yes time
Cycle time B-49.3 A-49.3 What: Shot scrap getting stuck on conveyor
Why: Guard missing
Counter measure: Put guard on conveyor
R/C: No
Cycle time: Unchanged What: Shot senor alarm / clamping safety device action alarm
Why: sensor dirty
Counter measure: cleaned shot sensor/ found broken wire at (plc terminal rs485 Aplus wire that goes to remote i/o termin What: Shot senor wire break
Why: Shot sensor dirty
Counter measure; Cleaned sensor
R/C: Yes time Blow back
Cycle time: Unchanged What: Shot sensor
Why: Not going to 0 and adding number
Root cause: Collar for injection was loose.
Counter measure: Tightened collar and rotated injection rod out of D/C machine 1/3 turn
R/C: Yes
Cy What: Shot sensor
Why: Oil and Debris
C/M: Replaced sensor
Recur: Timing What: Shot sensor alarm
Why: Bad cable wire
Counter measure: Replaced cable wire. Shot sensor was changed on other work order What: Shot sensor alarm
Why: Dirty
Counter measure: Cleaned What: Shot sensor alarm
Why: Hydraulic leak out of rod seal for injection What: Shot sensor alarm
Why: Shot sensor not reading always
Counter measure: Pulled out shot sensor and cleaned What: Shot sensor break alarm
Why: Shot sensor floating around and losing count
Countermeasure: Up dated with holder we use for 350 ton shot sensor. Cleaned hole out too
R/C: No
Cycle time: B-25.5 A-2 What: Shot sensor broken wire malfunction.
Why:
C/M:
R/O: What: Shot sensor error
Why: Dirty/oily sensor
C/M: Removed, cleaned and reinstalled sensor
Reoccur: Yes, timing What: Shot sensor losing zero position
Why: Injection rod has bad spot on it and it tends to drift to that spot
Counter measure: Put zip tie from injection collar to in injection shaft to prevent it f What: Shot sensor no good
Why: Carbon spacer worn and debris in sensor hole
C/M: Replaced sensor and spacer and blew out and cleaned
Recur: Possibly in time What: Shot sensor not counting right
Why: injection bushing seals NG
c/m: replace seals
reoccur- in time What: Shot sensor not reading and or returning
Why: someone took apart and didnt put together right cross threaded bolt for shot sensor
C/M: Replaced Sensor bushing and o rings What: Shot sensor not reading home (counting right)
Why: Bad shot sensor
Counter measure: Replaced shot sensor
R/C:
Cycle time: Unchanged What: Shot sensor reading climbing
Why: Shot sensor bolts were too tight.
Counter measure: Took sensor out and rotated fiber spacer and tightened. ( Bracket is to hold from turning. Shot sensor float What: Shot sensor was replaced on 3rd
Why: Not reading correctly
C/M: They replaced but didnt put in correctly cause they never done it so i went in and reinstalled it and replaced bottom bracket caus What: Shot sensor wire break
Why: Dirty shot sensor
Counter measure: Cleaned sensor
R/C: Maybe
Cycle time: Unchanged What: Shot sensor wire break
Why: Sensor dirty
Counter measure: Pulled sensor and cleaned blow back out of hole
R/C; Yes time
Cycle time: Unchanged What: Shot sensor wire break alarm
Why: Shot senor dirty
Counter measure: Cleaned shot sensor and replaced one shoulder bolt and one spring that holds shot sensor in.
R/C:
Cycle time: Unchanged What: Shot sensor wire break alarm
Why: Shot sensor
Root cause: Blow back around and in hole sensor sets in
Counter measure: Took sensor out and cleaned around sensor
R/C: Yes if Blow back gets around What: Shot sensor wire break alarm
Why: Shot sensor dirty
Counter measure: Pulled sensor and cleaned
R/C: Yes time
Cycle time: Unchanged What: Shot sensor wire break alarm
Why: Shot sensor dirty
Counter measure: Took out and cleaned
R/C: Yes time
cycle time: Unchanged What: Shot sensor wire break alarms
Why: Found shot sensor wire barely screwed onto sensor
C/M: Tightened sensor, worked with DH to zero out injection and monitor in auto What: Shot slipping out of robot
Why: 2 pawls were replaced. Should have replaced all 4
Counter measure: Replaced the other 2
Retaught robot from pick and on What: Shot speed alarm
Why: Oily sensor
C/M: Cleaned sensor and cavity it goes in. Inspected for any damage to the sensor
Reoccur: What: Shot speed alarms
Why: Aluminum build up on plunger lube spray tip, injector spray tip bracket loose and lube hitting side of sleeve
C/M: Cleaned injector lube spray tip, adjusted and tightened What: Shot speed sensor malfunction
Why: Every part of the sensor was loose even the bracket
Countermeasure: Retightened everything and ensured operation
Will problem reoccur: Possibly
Cycle time: No What: Shot sticking in die
Why: Roller groove on cavity 1 sticking in die
C/M: Cleaned die, did not help (excessive buildup), found robot side vacuum hose blown off and air line to block melted. Repla What: Shot sticking to die. (Robot collision in die)
Root cause: 2 spray valves quit working on spray cartage
Countermeasure: Replace spray valves
Reoccurrence: Time
Cycle time: Unchanged What: Shot sticking to slide cores
Why: Solder buildup on the slide cores
C/M: Polished and used all clean on slide cores What: Shot sticking to the tip
Why: Tip worn
C/M: Adjust plunger lube to spray on tip
Recur: In time at sleeve change. What: Shot sticking to tip
Why: Bad tip
Counter measure: Replaced tip and sleeve due to using over sized tip and not having over sized tip What: Shot sticking to tip
Why: Bad tip and sleeve
Counter measure: Replaced tip and sleeve What: Shot sticking to tip
Why: Galling on end of tip Why: No lube spray on tip
C/M: Replaced tip and adjusted lube tip
Recur: Possibly in time What: Shot sticking to tip
Why: No lube. Tip plugged
Counter measure: Un plugged tip and adjusted lube spray What: Shot sticking to tip
Why: worn had 89,500 shots
C/M: Replaced tip make sure getting lube
Recur in time. What: Shot sticking to tip
Why: Tip no good due to running without water couple times
C/M: replaced with new
Recur: yes in time What: Shot stroke
Why: Injection cylinder not reading on return to home position
C/M: Loosen back coupler and turn cylinder
Recur: In time What: Shot stuck in die
Why: Robot side slide core shaft broke, no longer being moved by cylinder
C/M: Advised DH to swap dies and pull the current die out separated since a part is stuck in it What: Shot stuck in die
Why: Slide core stuck in robot side
Countermeasure: Remove slide core from shot clean die
Reoccur: Possible What: Shot stuck on movable side of die
Why: Unknown (did not get a PC malfunction)
Countermeasure: Followed part removal procedure, removed part from die successfully with no damage
Will problem reoc What: Shot unloading table motor over load: Back by robot panel
Why: Motor bad
Counter measure: Replaced motor
R/C: No
Cycle time: Unchanged What: Shroud was completely covered and blocked
Why: A long time with out any cleaning caused major build up.
C:M/ removed shroud and cleaned it thoroughly. What: Shroud was completely covered and blocked
Why: A long time with out any cleaning caused major build up.
C:M/ removed shroud and cleaned it thoroughly. What: Shut down to confirm trim press component parts to print
Why: Some component parts not to print What: Side door damage
Why: Excessive jackhammering
C/M: Re-patched inside and out
recur: In time What: Side door needs re-patched
Why: Refractory damaged during Jackhammering/Cleaning
C/M: Re-patched side door
Recur: Yes What: Side door on furnace chunk fell out
why-?
c/m- patch
reoccur- yes What: Side door patch fell out
Why: Come loose while jackhammering
C/M: Re- patch side door
Recur: Yes in time What: Slamming noise coming from machine while running
Why: Manifold for slide cores bolts broken, not mounted to movable side
C/M: Replaced missing bolts, unable to locate proper bolts to hold stack What: Sleeve
Why: Bad Washout
C/M: Replaced sleeve and Tip
Recur: Yes What: Sleeve Worn
Why: Possibly no lube or water could have been off.
recur: Possibly What: Sleeve air blow
Why: Bracket turned
C/M: Adjusted bracket
Recur: In time What: Sleeve at over 200K shots, Tip at over 100k shots.
R/C: normal wear.
Countermeasure: Replace tip and sleeve.
Will it Re-occur : Timing What: Sleeve caught fire and contaminated ladle
Why: Plunger lube caught fire
Counter measure: Cleaned around sleeve. Replaced ladle
R/C: Yes time
Cycle time: Unchanged What: Sleeve cooling joint
Why: Leaking
Counter measure: Replaced cooling joint
R/C: Yes time
Cycle time: Unchanged What: Sleeve cooling joint broke
Why: Flashing hit cooling joint and cracked it at threads
Counter measure: Replaced
R/C: Unknown
Cycle time: Unchanged What: Sleeve cooling joint broke
Why: Operator hit it when he pulled out debris
Counter measure: Replaced and talked with operator
R/C: Yes
Cycle time: Unchanged What: Sleeve cooling joint broke
Why: Unknown
C/M: Replaced with new
Recur: In Time What: Sleeve cooling joint broke
Why: Unknown
C/M: Replaced with new
Recur: Possibly in time What: Sleeve cooling joint leaking
Why: Broke off at sleeve due to rings on rod from pour
Countermeasure: Replaced joint and adjusted pouring time from 0.3 to 0.4
R/C: Yes Time
Cycle time: Unchanged What: Sleeve cooling joint leaking
Why: Broke off. Due to pouring leaving rings on rod
Counter measure: Shot delay time was too low. On work order 24019 moved shot delay from 0.3 to 0.4. 0.4 was still What: Sleeve cooling joint leaking
Why: Inlet fitting was loose
Counter measure; Tightened fitting
R/C: Yes time
Cycle time: Unchanged What: Sleeve cooling joint water leak
Why: Broken cooling joint
C/M: Replaced cooling joint
Reoccur: Yes, timing What: Sleeve covered in aluminum
Why: Unknown
Countermeasure: Removed aluminum and verified ladle and plunger lube operation
Will problem reoccur: Possibly
Cycle time: No change What: Sleeve full of aluminum
Why: Root cause unknown. Sleeve filled, running out of the die and thick pile of aluminum on top of sleeve where it dumps in
C/M: Air chiseled aluminum off of sleeve so f What: Sleeve got filled with aluminum
Why: Operator double poured shot after fault recovery (new operator)
Countermeasure: Removed aluminum log from sleeve What: Sleeve keeps turning on operator
Why: Sleeve bushing worn
C/M: Pulled fixed side of die and replaced sleeve bushing with Jason B. What: Sleeve plugged up
Why: Plunger lube line collar was loose and let it cover poor hole
Counter measure: Un plugged and tightened collar
R/C:
cycle time: Unchanged What: Sleeve plugged with aluminum
Why: 90 off on ladle. Aluminum pouring out when it had robot alarm
Counter measure: Replaced sleeve and reset ladle 90 What: Sleeve rotating abnormally.
Why: Sprue Bushing face wear
Countermeasure Replace Sprue bushing What: Sleeve sweeper not blowing
Why: Tube clogged
C/M: Made new tube for plunger lube and sleeve sweeper What: Sleeve turned.
Root Cause: Possible the sleeve holder was not tight enough.
Countermeasure: Tightened sleeve holder after cleaning aluminum out of the way.
Will Problem Reoccur?: No. What: Slide Core Crack > 10mm, P2 operator side
Why:
C/M: Replaced Slide core
Recur: In Time What: Slide Core Malfunction. What: Slide Core Stuck.
Countermeasure: Heated die to get parts out.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Slide Core crack.
Why: Wear.
Countermeasure: Replaced 5BA-S1 HT slide core on 5BA P/S Die 9.
Will Problem Reoccur?: Yes, wear part.
Cycle Time: No Change. What: Slide Core needed replaced.
Why: Wear.
Countermeasure: Replaced Die 14 Operator top P-1 slide core. What: Slide Core out of Spec. 5BA-P/S Die 9 Cavity P-1
Why: Wear.
Countermeasure: Replaced slide core.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Slide core 2 water leak
Why: OT Slide core cracked
C/M: Replace with new
Reoccur: Possible in time What: Slide core 4
Why: M4 out of spec
C/M: Replace slide core What: Slide core 5A2-P Cavity 2 cracked.
Countermeasure: Replacing 5A2-P Cavity 2 slide core with Matt Cline's Trial slide core worked with Die Maintenance.
Will Problem Reoccur?: Not any sooner then What: Slide core 5BA S op bottom chunking out part
Why: Damaged slide core
Countermeasure: Replace slide core What: Slide core Hydraulic cylinder leak
Why: Seals blown out
C/M: Replaced cylinder
Recur: Possibly in time What: Slide core Hydraulic steel line brackets loose
Why: Bolts broke off on machine bracket
C/M: got out and replaced and tightened down What: Slide core Move 2 move faults.
Countermeasure: Worked back and forth - Good. What: Slide core P1 & S1 out of spec, cracked
C/M: Replaced both
Recur: Yes, in time What: Slide core P1 (OT)
Why: Cracked beyond allowable spec
C/M: Replaced slide core
Reoccur: Yes, timing What: Slide core P1 leaking water
Why: Slide core broke off
C/M: Replaced slide core & fixed 3 water leaks
Recur: Possible in time What: Slide core Quality
Why: Out of spec. (New slide cores) MM radius out per Quality. Any questions please see Amy Davidson
Counter measure: Replaced all 4 slide cores per direction of Ryan Traicof What: Slide core S1 & S2 out of spec
Why: Cracked
C/M: Installed new slide cores: S1 (HT) & S2 (OB)
Reoccur: Yes, timing What: Slide core S1 (HT) out of spec
Why: Cracked/chipped
C/M: Installed new slide core
Reoccur: Yes, timing What: Slide core S2 out of spec
Why: Chipped slide core 5BA PS 7
C/M: Replaced slide core operator bottom What: Slide core S2 out of spec
Why: Cracked
C/M: Replaced
Recur: yes What: Slide core broke
Why: Un known
Counter measure: Replaced slide core What: Slide core broke
Why: Unknown
Counter measure: Pulled die What: Slide core broke (5BA M Die 8) Cavity 4
Why: Flashing (Bottom most slide core). Holder too hit from flashing
Counter measure: sent to die maintenance for repair What: Slide core broke (RPY M #5 die) #3 cavity
Why: Unknown
Counter measure: Replaced slide core
R/C: Yes time
Cycle time: Unchanged What: Slide core broke 6A0 M
Why: Blow out on die
Counter measure: Replaced slide core
R/C: Yes
Cycle time: Unchanged What: Slide core broke on cav P-1
Why: I believe a part got left in die during preheat
Counter measure: Replaced slide core P-1
R/C: Yes Time
Cycle time : Unchanged What: Slide core broke. (5BA M 9-2 cavity)
Why: Unknown
Counter measure: What: Slide core broke. Water leak (OB)
Why: Flashing from blow out
Counter measure: Replaced slide core (OB)
R/C: Yes time
Cycle time: Unchanged What: Slide core chipped S-2 5BA
Why: Unknown. Coating might be bad coating
Counter measure: Replaced S-2 slide core
R/C: Yes
Cycle time: Unchanged What: Slide core chunking out part 5BA s-1 die 12
Why: Bad slide core
Countermeasure: Replace slide core
Reoccur: Possible What: Slide core crack P1 (OT)
C/M: Replaced
Recur: In time What: Slide core crack, P1 & P2
Why: Possible die crash?
C/M: Replaced both
Recur: In time What: Slide core cracked
Why: Time s-1
Counter measure: Replaced s-1 slide core 5ba What: Slide core cracked (P1)
Why: Wear and age
Countermeasure: Replaced slide core What: Slide core cracked S-1 RPY
Why: Time
Counter measure: Replaced slide core
R/C: Yes time
Cycle time: Unchanged What: Slide core cracked out of spec, die maintenance has vacation
R/C: unknown of root cause for slide core cracking
C/M: Removed cracked slidecore P2 op side, and installed new, also installed new c What: Slide core cracked to 10.77 mm
Why: Excessive pressure in cavity
Root cause: In house slide cores suspect for defect
Countermeasure: Replaced slide core with one from D1
Cycle time before: 26.5
What: Slide core damaged
Why: Die crash
C/M Replaced slide core & cooling joint
Recur: yes What: Slide core deformed
Why: Unknown Matt cline in house slide core (P)
Counter measure: Replaced slide core with matt cline
R/C: Unknown
Cycle time: Unchanged What: Slide core hydraulic line had pin holes in it
Why: Old need new
C/M: Had josh weld it 3 different times to close other holes created by previous welds What: Slide core leaking
Why: Broken base on slide core
C/M: Replaced P2 OT slide core What: Slide core leaking
Why: Slide core broke
Counter measure: Replaced slide core What: Slide core leaking Bottom one (Die #2 cavity #4 6A0 M)
Why: O-Ring on slide core broke
Counter measure: Replaced O-Ring
R/C: Yes time
Cycle time: Unchanged What: Slide core leaking water (P4)
Why: Slide core cracked
Countermeasure: Replaced slide core
Will problem reoccur: Possibly
Cycle time: No change What: Slide core leaving burr on part
Why: Slide core NG
Countermeasure: Replace slide core What: Slide core out crack, out of spec. 5BA-P Cavity 2.
Why: Wear.
Root Cause: Wear.
Countermeasure: Replaced Slide core.
Will Problem Reoccur?: Yes, timing.
Cycle Time: No Change. What: Slide core out of spec
Why: Chip out of S-2 slide core die 11 5BA
Counter measure: Replaced slide core What: Slide core out of spec
Why: Cracked
C/M: Replaced slide core S1, HT
Recur: In time What: Slide core out of spec
Why: P1 Cracked >10mm
C/M: Replaced slide core
Recur: Yes What: Slide core s-1 cracked (Spec issue)
Why: Time
Counter measure: Replaced slide core S-1 What: Slide cores cracked (5BA P/S #3)
Why: Life
Countermeasure: Replaced all 4 slide cores
R/C: Yes time
Cycle time: Unchanged What: Slide cores for S1 and S2 cracked
Why: Wear
Countermeasure: Replaced slide cores
Will problem reoccur: Possibly
Cycle time: No change What: Slide cores out of spec
Why: Cracked
C/M: Replace S1 & 2, P1
Recur: Timing What: Slide cores showing cracks
Why: Water not coming on to movable side. So no water was going thru slide cores to cool them
Counter measure: Adjusted temps so water for moveable would come on every What: Slide cores snapped off in cavities 1 and 2
Why: Root cause unknown, it happened 28 shots into full auto
Countermeasure: Replaced slide cores What: Slide cores sticking in top side of die
Why: Build up on slide cores
Countermeasure: Replace slide cores
Reoccur: Possible What: Small Biscuit
Why: Earlier changed ladle for hard aluminum in ladle
C/M: Shot weight was adjusted too low after ladle change and needed adjusted to get proper shot weight What: Small Ng conveyor no good
Why: Mesh belt has big hole in it
C/M: Replaced with new
Recur: Possibly in time What: Small Scrap Conveyor jammed.
Why: Jammed on part.
Countermeasure: Unjammed.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Small Scrap conveyor jammed up.
Why: Scrap jamming in conveyor.
Countermeasure: Unjammed conveyor.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Small conveyor jammed
Why: Scrap in chain
Counter measure: Un jammed What: Small scrap conveyor overloading
Why: Too much slack, causing it to bind
C/M: Tensioned up belt What: Small scrap conveyor stopped
Why: Jammed
Counter measure: Un jammed conveyor and fixed leaking hydraulic line to trim press clamp
R/C:
Cycle time: Unchanged What: Small scrap conveyor stopped
Why: Jammed with scrap
Counter measure: Pulled conveyor. removed scrap and replaced warn out drive pins
reoccur: yes in time What: Small scrap conveyor.
Why: Scrap jammed it.
Countermeasure: Unjammed conveyor. What: Smashed parts in trim
Why: Heavy Flashing
C/M: Cleaned shot of flashing then set shot in press to make sure it fit without flashing and it did so sent operator to get die maintenance help
Recur: What: Smelting burner does not fire.
Why: I/P X62, Smelting burner over temp control "Over temp" input to PLC true.
C/M: Removed wire from over temp controller, I/P X62 still true. Moved wire to X72 What: Soft float faults on Robot after trimpress
Why: Robot missing pre softfloat operation
c/m: Line 266 P25 added
Line 267 changed to P26
Line 272 Added UTooL-NUM 1
Line 273 added UTool-NUM3
Line 27 What: Solder issue S1 & possible cracked slide core P2
Why: Slide core cracked P2 HB confirmed
C/M: Replaced slide core
Recur: In Time What: Soldering
Why:
Counter measure: Checked spray points and cleaned
R/C:
Cycle time: Unchanged What: Soldering
Why: Aluminum build up
Counter measure: Cleaned die What: Soldering
Why: Aluminum build up
Counter measure: Polished squeeze pin What: Soldering
Why: Aluminum build up on die
Countermeasure: Used all clean and pencil grinder to remove What: Soldering
Why: Aluminum stuck to die
Countermeasure: Clean die What: Soldering
Why: Die dirty
Counter measure: Cleaned die What: Soldering
Why: Die dirty
Counter meaure: Cleaned die What: Soldering
Why: Part of the process
Countermeasure: Buffed away soldering and used acid What: Soldering (Water passage).
Why: Build up.
Countermeasure: Polished area.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Soldering (water passage).
Why: Build up.
Countermeasure: Polished die.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Soldering 5A2 s-3
Why: Aluminum build up. Spray cartage in backward
Counter measure: Cleaned. Put spray cartage in right What: Soldering Die 10 water passage.
Why: Build up.
Countermeasure: Cleaned die. What: Soldering and axis alarms
Why: Axis needed bled. Dirty die
Counter measure: Cleaned die and bled squeeze master What: Soldering build up. Running water passage die 9.
Why: Build up.
Countermeasure: Cleaned up soldering. What: Soldering cav 3 6AO P/S
Why: soldering
Counter measure: All cleaned slide core
R/C: Yes time
Cycle time: Unchanged What: Soldering cavities 1 and 2 RPY 1RK die 7.
Countermeasure: Polished die.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Soldering cavity 4
Why: Build up
Countermeasure: Clean and polish die
Reoccur: Possible What: Soldering in 2 spots
Why: Die needs cleaned
Countermeasure: Cleaned die with allclean and pencil grinder What: Soldering in cavity 3 and 4.
Why: Aluminum build up.
Countermeasure: Cleaned both cavities.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Soldering on all 4 slide cores
Why: Die release mixture wrong
Counter measure: Fixed mixture and cleaned slide cores
R/C: Yes mixture not consistent
Cycle time: Unchanged What: Soldering on cavity 1 59B 1 RKR
Why: Build up over time
Countermeasure: Cleaned die
Will problem reoccur: Possibly
Cycle time: No change What: Soldering on cavity 3 Die 9.
Why: Aluminum build up.
Countermeasure: Cleaned die.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Soldering on cavity 4 (RPY one rocker)
Why: Aluminum build up
Counter measure: Cleaned die
R/C: yes
Cycle time: Unchanged What: Soldering on die
Counter measure: Cleaned die What: Soldering on part. Water passage
Why: Aluminum build up
Counter measure: Polished it off and checked spray points What: Soldering on parts
Why: Die release tank mixture hit or miss
Counter measure: Replaced mixing unit in tank
R/C: Yes time
Cycle time: Unchanged What: Soldering on parts (water passage) Die 10
Why: Wear on the die lets Aluminum build up in certain spots What: Soldering on parts.
Why: Build up on die.
Countermeasure: Polished Die.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Soldering on the parts.
Why: Die has aluminum residue.
C/M: Clean with acid and then used dremmel. What: Soldering on the water passage
Why: Aluminum build up
Countermeasure: Polished die and used all claen
Will problem reoccur: Possibly
Cycle time: No change What: Soldering on water passage
Why: Build up on die
Countermeasure: All cleaned and polished die
Will problem reoccur: Possibly
Cycle time: No change What: Soldering on water passage die F-10.
Why: Build up.
Countermeasure: Cleaned die. What: Soldering roller groove
Why: Aluminum build up
Counter measure: Cleaned die What: Soldering water passage die
Why: Aluminum build up on die
Counter measure: Checked spray points and cleaned die
R/C: Yes
Cycle time: Unchanged What: Solenoid valve for Damper lid melted
Why: Location of valve to close to furnace and tower
C/M: Relocated the valve to an upright position on backside of tower and put new limit switch for home p What: Sometimes shot is staying in scrap press.
Why: Shot staying on bottom cutter.
Countermeasure: Adjusted the down sensor, down. What: Spec issue P1 and S1 cavitys
Why: Cracked slide cores
Countermeasure: Replace slide cores
Reoccur: Possible What: Spec problem
Why: Lab said had plunger lube in parts
Counter measure: Emptied bucket for die release and cleaned tank. Believe it had been cross contaminated with plunged lube
R/C:
Cycle time: What: Spec problem F-3 Breather cover
Why: Dirty pins. Bent cav #4
Counter measure: Cleaned Pins like JR Ottos email said
R/C: Yes
Cycle time: Unchanged What: Spec problem tappets too deep
Why: Tappets always sticking out with Slide cores in(movable core 2 in).
Counter measure: found that lines were hooked up during die change to movable core to hydra What: Spec problem with new slide core I put in. RPY P-1 Die 4(MM slide core)
Why: Made wrong
Counter measure: Replaced with different maker
R/C:
Cycle time: Unchanged What: Speed acc filling malfunction alarm
Why: Too much nitrogen in accumulator
Counter measure: Let some out was 7 MPa now 6.5 MPa to match plex for 250 ton machines
R/C: Unknown
Cycle time: Unchang What: Spoke with Darrell C., decided to change hydraulic pump filter
C/M: Changed filter What: Sporadic biscuit size
Why: Lower unit, tip and sleeve all replaced. Adjusting shot weight and fine spill to dial in biscuit size
C/M: Adjusted fine spill down to 1.0s from 1.6s, adjusted shot we What: Spray Cartage Leak.
Why: Valve leaking by.
Countermeasure: Replaced spray valve.
Will Problem Reoccur: Timing.
Cycle Time: No Change. What: Spray Cartage Leaking.
Why: Leaking at shut off for spray cartage.
Countermeasure: Cleaned it up and Reinstalled.
Will Problem Reoccur?: Possible.
Cycle Time: No Change. What: Spray Cartidge not blowing air
Why: Air blow solenoid not shifting
Countermeasure: Replaced solenoid What: Spray Cartridge not going up
Why: Extendable cavity sprayer sensor not showing its retracted, shorted sensor from water
C/M: Replaced bad sensor
Recur: In time What: Spray atomizer leaking
Why: O-ring not sealing
C/M: Replaced with new
Recur: Yes with time What: Spray cartage coolant hose leaking
Why: Hole
Counter measure: Replaced hose to spray cartage What: Spray cartage fault
Why: Not making return sensor
Counter measure: Move return sensor What: Spray cartage interference alarm
Why: Line 146 coil Y016 not making during change over Due to X034 not coming on
Counter measure: Cameron took X034 out of line. X034 is for water passage cylinde What: Spray cartage issue
Why: Bolts come loose from base mount
Counter measure: Tightened bolts on mount What: Spray cartage issue
Why: Leaking spray valve
Counter measure: Replaced 3 spray valves What: Spray cartage issue
Why: Up down Cylinder bad
Counter measure: Replaced cylinder What: Spray cartage leak and Axis alarms
Why: Spray valves bad. 5 were changed
Counter measure: Replaced valves. Bled squeeze master. Adjusted flow on screen for #4 and #1 to 25 from 30
R/C: Yes time
What: Spray cartage leak.
Why: Valve went bad.
Countermeasure: Replaced valve.
Will Problem Reoccur?: Timing.
Cycle Time: No change. What: Spray cartage leaking
Why: 6 spray valves leaking
Counter measure: Replaced valves
R/C: Yes
Cycle time: Unchanged What: Spray cartage leaking
Why: Bad spray valve
Counter measure: Replaced 2 spray valve
R/C:
Cycle time: unchanged What: Spray cartage leaking
Why: Bad spray valve
Counter measure: Replaced spray valve What: Spray cartage leaking
Why: Bad spray valves
Counter measure: Replaced 2 valves
R/C: Yes time
Cycle time: Unchanged What: Spray cartage leaking
Why: Bad spray valves
Counter measure: Replaced 3
R/C: Yes time
cycle time: Unchanged What: Spray cartage leaking
Why: Bad spray valves
Counter measure: Replaced 4 Valves
R/C: Yes time
Cycle time: Unchanged What: Spray cartage leaking
Why: Bad valve
Counter measure: Replaced valve What: Spray cartage leaking
Why: Die release spray valve leaking
Counter measure: Replaced spray valve
R/C: No
Cycle time: Unchanged What: Spray cartage leaking
Why: Little spray valve bad
Counter measure: Replaced spray valve
R/C: Yes time
Cycle time: Unchanged What: Spray cartage leaking
Why: One of the Spray valves bad
Counter measure: Replaced spray valve
R/C: Yes time
Cycle time: Unchanged What: Spray cartage leaking
Why: Spray valve bad
Counter measure: Replaced spray valve What: Spray cartage leaking
Why: Spray valve bad 2 of them
Counter measure: Replaced 2 valves
R/C: Yes
Cycle time: Uncahnged What: Spray cartage leaking
Why: Spray valves leaking. 8
c/m- rebuild valves
reoccur- yes What: Spray cartage leaking
Why: Valve leaking
Counter measure: Replaced spray valves What: Spray cartage leaking.
Why: Two bad valves.
Countermeasure: Replaced valves.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Spray cartage leaking.
Why: Valve letting water by.
Countermeasure: Replaced valve with rebuild non-inventory valve. What: Spray cartage loosing up light
Why:
Counter measure: Adjusted speed up to keep from bouncing. and sensor What: Spray cartage not moving in auto
Why: Switch broke
Counter measure: Replaced switch
R/C: No
Cycle time: Unchanged What: Spray cartage not spraying
Why: Bad valve
Counter measure: Replaced bad valve. Air valve
R/C:
Cycle time: Unchanged What: Spray cartage not spraying
Why: Bolt hole stripped out for spray cartage
Counter measure: Welded nut on
R/C: Yes time
Cycle time: Unchanged What: Spray cartage not spraying die release
Why: Spray valve went bad
Counter measure: Replaced spray valve. 100V
R/C: Yes time
Cycle time: Unchanged What: Spray cartage not spraying or going up
Why: Sensors on spray cartage cylinder out of adjustment. (Little cylinder in cartage)
Counter measure: Adjusted sensors on cylinder What: Spray cartage not spraying very well.
Why: Hose cracked.
Countermeasure: Repaired. What: Spray cartage problem
Why: Swing bracket broke
Counter measure: Replaced broken bolts What: Spray cartage spray valve
Why: Spray valve bad
Counter measure: Replaced spray valve
R/C: No
Cycle time: Unchanged What: Spray cartage staying on
Why: 10Y staying on from PLC
Counter measure:
R/C:
Cycle time: Unchanged What: Spray cartage stuck down
Why: Solenoid had water in it wouldn't shift
Counter measure: Drained water out of it
R/C: Unknown
Cycle time: Unchanged What: Spray cartage stuck down
Why: Up down solenoid valve had bear wire
Counter measure: Replaced valve
R/C: No
cycle time: Unchanged What: Spray cartage wont stop spraying die release
Why: Solenoid valve went bad
Counter measure: Replaced solenoid valve on spray arm (New style VXD250LZ2B. Old was VXD2150-06-1G)
R/C: No
Cycle time: What: Spray cartridge Pedestal broke
Why: Ware
C/M: Replaced bearings and Swing Shaft
Recur: Possibly in time What: Spray cartridge continuously spraying at up position
Why: Still investigating
Countermeasure: Hook to PLC to investigate problem and problem went away could not get repeatability
Reoccur: Possi What: Spray cartridge cylinder sensors not working
R/C: wiring issues
Countermeasure: Re-connect wiring to enable operation of new spray cartridge.
Will it re-occur: No What: Spray cartridge does not lower.
Why: Wire Y7 ,Spray cartridge Lower O/P. broken off at stacon in Terminal ? Sol. Valve box.
C/M: Re-terminate Y7 What: Spray cartridge does not return to "Up" pos.
Why: Sol. Y6 sticking.
C/M: Replace Sol Y6. What: Spray cartridge extension spray cylinder not getting advanced or return sensor lights
Why: Both sensors bad and plug at junction point packed with aluminum
Counter measure: Replaced both sensor What: Spray cartridge got smashed
Why: Cylinder shaft pulled out of head so sensor was on the up saying die good to close but spray head still in die
C/M: locktite on cylinder shaft and set screw
Recu What: Spray cartridge issues.
Why: Y16, Interlock to DCM from spray cartridge control not True, Y16 not true due to X34 Spray cartridge Home I/P True.
C/M: Cause X34 to be false. What: Spray cartridge leak
Why: Clogged seat on valve
C/M: Disassembled cleaned and rebuilt valve What: Spray cartridge leaking
Why: 2 bad valves
C/M: Replaced valves- no longer leaking What: Spray cartridge leaking
Why: 3 bad valves
C/M: Replace valves for spray cartridge What: Spray cartridge leaking
Why: Bad valves for spray cartridge
C/M: Gave operator valves so he could replace them What: Spray cartridge leaking
Why: Faulty valve
C/M: Replaced valve and turned on the spray to check it and nothing but air flowing out, valve back at the pump was 1/2 closed. After opening valve saw What: Spray cartridge leaking
Why: Spray valves NG
Countermeasure: Replaced leaking spray valves
Will problem reoccur: Possibly
Cycle time: No change What: Spray cartridge leaking.
Why: 1 Die release spray valve was bad.
C/M: Replaced.
R/O: Timing. What: Spray cartridge leaks & 2 not spraying at all
Why: Faulty/dirty valve
C/M: Removed valves, cleaned and reinstalled
Reoccur: Yes, timing What: Spray cartridge manifold had a bad pipe
Why: Hard line for die release broken
c/m: 2nd- replaced die release pipe. 3rd- installed spray cartridge manifold, verified air and water flow. What: Spray cartridge not coming down to spray
Why: Tree breaking off on robot side
Countermeasure: Polish die
Reoccur: Possible What: Spray cartridge not going down
Why: Root cause unknown
C/M: Had DH return everything to home position and machine ran What: Spray cartridge not spraying
Why: Y010 wire for spray valve broke in the terminal box up in the hood
Countermeasure: Reterminated wire
Will problem reoccur: Possibly
Cycle time: No change What: Spray cartridge not spraying in auto
Why: Advance sensor not coming on and broken wire
Countermeasure: Replace sensor and repair broken wire
Reoccur: Possible What: Spray cartridge staying on
Why: Output Y010 (Spray valve on) has voltage even without output signal from PLC
Countermeasure: Problem is occurring intermittently turned control power off and back What: Spray cartridge wouldn't go up and down
Why: Spray cartridge sensor was bad
CM: change Spray cartridge sensor What: Spray cassette leaking
Why: Bad spray valves
Countermeasure: Replaced leaking valves
Will problem reoccur: Possibly
Cycle time: No change What: Spray cassette valve leaking
Why: Valve life
Countermeasure: Replaced spray valve
Will problem reoccur: Possibly
Cycle time: No change What: Spray cylinder (for die release) not coming down and spraying during auto running.
Why: X003 Full auto mode not being made, switch contact base had came loose
Countermeasure: Reseated base on sw What: Spray cylinder not returning after advancing
Why: Broken wire in cable
C/M: Replaced wire sensor plug
Recur: Possibly in time What: Spray equipment faults
Why: Not getting up sensor all time
C/M: Return (up) sensor replaced What: Spray lube pump will not pump
Why: Internal contamination will not allow pump to prime
Root cause: Failed pump
Countermeasure: Replace pump with new
Reoccur: Yes in time What: Spray not spraying
Why: Advance sensor not working
C/M: Replace spray cartridge out need to replace advance sensor on old spray cartridge
Recur: Possibly in time What: Spray robot pressure alarm. Robot was set to alarm out if pressure got above 0.8 MPa, pressure rose to 0.84MPa.
Why: Root cause unknown
C/M: Adjusted spray robot pressure setpoint to 1.0MPa to c What: Spray robot stopped in the middle of spray cycle
Why: Root cause unknown, only alarm displayed was "Fence Open"
C/M: Got robot to recover after manually moving around. Does not respond well to T What: Spray unit bouncing when going to spray
Why: Bearings no good along with broken welds on cylinder
C/M: Replaced spray unit pedestal and shaft bearings now ok What: Spray unit wasnt spraying
Why: Coil to the water solenoid valve wire pulled out
C/M: Stript wiring back and re terminated in the coil What: Spray valves leaking
Why: Wear
Countermeasure: Replaced leaking valves
Will problem reoccur: Possibly
Cycle time: No change What: Spray wand
Why: Handle broke off
Counter measure: Replaced wand
R/C: Yes Time
Cycle time: Unchanged What: Spray wand broke
Why: Handle broke
Counter measure: What: Spray wand for die cleaning leaking
Why: Missing brass knob
Countermeasure: Replace spray wand
Reoccur: Possible What: Spray wand leaking air
Why: Hole in hose
Countermeasure: Replace air hose What: Spray wand quit working
Root cause: Liquid valve locked up
Countermeasure: Replaced spray wand
Reoccurrence: No
Cycle time: Unchanged
"NON INVENTORY" What: Spray wand stopped working
Why: Air valve stuck on. wand broke
Counter measure: Replaced wand
R/C: No
Cycle time: Unchanged What: Spring plunger on right side of trim die (from trim press door) not coming down
Why: Spring broken, could not find issue that would result in breaking spring
C/M: Replace spring, cleaned up plun What: Sprue Bushing 6A0-S1
Why: Unknown Weld cracked
C/M: Replaced
Recur: Possible in time What: Sprue Bushing leaking
Why: Cracked around outside weld
C/M: Replaced Sprue bushing
Recur: Possible in time What: Sprue Bushing leaking.
Why: Cracked.
Countermeasure: Replaced Sprue Die F-15 5BA-PS. Confirmed no leaks What: Sprue bushing Leak
Why: Cracked bushing
Countermeasure: Replace Sprue Bushing
Reoccur: Yes What: Sprue bushing leak
Why: Cracked bushing
C/M: Replaced sprue bushing What: Sprue bushing leak
Why: Cracked sprue bushing
C/M: Replaced bushing What: Sprue bushing leaking
Why: Age and wear
Countermeasure: Replaced sprue bushing
Will problem reoccur: Possibly
Cycle time: No change What: Sprue bushing leaking
Why: Coupler fittings
Counter measure: Replaced couplers What: Sprue bushing leaking
Why: Cracked due to die being ran too hot
Countermeasure: Replaced sprue bushing
Will problem reoccur: Possibly
Cycle time: No change What: Sprue bushing leaking
Why: Wear
Countermeasure: Replaced sprue bushing
Will problem reoccur: Possibly
Cycle time: No change What: Sprue bushing leaking (5BA P/S die 13)
Why: Cracked
Counter measure: Replaced sprue bushing
R/C:
Cycle Time: Unchanged What: Sprue bushing leaking water
Why: Cracked
C/M: Replace sprue bushing What: Sprue bushing leaking water. Why: Cracked sprue bushing. CC: replaced sprue bushing. What: Sprue leaking water
Why: Sprue bushing cracked
Counter measure: Replaced sprue bushing
R/C: No
Cycle time: Uncahnged What: Sq. master won't bleed
Why: Op. didn't have the green light on the squeeze master. Manual operations needed for squeeze master
C/M: Obtained green light on squeeze master using manual operation What: Squeeze Master Leak.
Why: Hydraulic hose had a hole.
Countermeasure: Replaced hose.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Squeeze Master line filter choke alarm
Why: Dirty/clogged filters
C/M: Replaced intake hydraulic filter. Still getting alarm, replaced inline filter. Alarm cleared What: Squeeze Master lost home while running.
Why: Channel 2 on squeeze was the only one not home.
Countermeasure: What: Squeeze Pin depth out
Why: Pressure low on SQM Reading 6.7 should be 13.0
C/M: Had operator bleed SQM and mad inside panel adjustments
Recur: Possibly in time What: Squeeze master
Why: Channel 3 and 4
Counter measure: Adjusted all squeeze master pods
R/C: Unknown
Cycle time: Unchanged What: Squeeze master (Axis #4)
Root cause: Pod out of adjustment.
Countermeasure: Adjusted all pods for all axis.(Flow and Pressure)
Reoccurrence: Yes every model change What: Squeeze master Channel 4 not responding
Why: Solenoid Valve bad?
C/M: Replace Valve still problem, oa noticed that one of the quick connect fitting (female) looked bad channel 3 we changed now m What: Squeeze master cavity 4 not bleeding correctly
why:
c/m:
will it reoccur:
timing What: Squeeze master channel 1 no good
Why: Hole in the hydraulic line on squeeze cylinder
C/M: Replaced hose
Recur: In time What: Squeeze master hose leaking
Why: Hose above pump went bad
Counter measure: Replaced hose
R/C:
Cycle time: Unchanged What: Squeeze master issue
Why: Axis problems
Counter measure: Adjusted flow on touch screen What: Squeeze master issue
Why: Change over from baffle to 1 rocker
Counter measure: Adjusted flow on touch screen. Operator checked parts What: Squeeze master issue
Why: Not data for squeeze on setting
Counter measure: Had taka put data in What: Squeeze master issue
Why: Running breather baffle
Counter measure: Adjusted setting on touch screen. Touched up robot at water tank What: Squeeze master issue channel 1
Why: Root cause unknown
C/M: Bled squeeze master, checked for leaks. What: Squeeze master issues.
Why: Hydraulic hose leaking.
Countermeasure: Replaced hydraulic hose. What: Squeeze master not going home
Why: Axis bleeding off
Counter measure: Bled and looked for leaks
R/C: No
Cycle time: Unchanged What: Squeeze master not operating correctly Channel 4
Why: Axis 4 Bleeding off ( Counting up)
Root cause: Rubber hose from lines to manifold bad
Countermeasure: Replaced hose
R/C: Yes when hoses or c What: Squeeze master not working
Why: Change over not completed
Counter measure: Moved hoses on side of squeeze master What: Squeeze master oil leak
Why: Gauge NG
C/M: Replaced gauge 0-40 MpA What: Squeeze master problem
Why: Not coming on. Due to motor over load tripped
Counter measure: Re set over load What: Squeeze master pump not starting
Why: Motor tripping over load\
Counter measure: Replaced motor What: Squeeze master pump shut off
Why: Circuit breaker tripped
C/M: Reset and started pump, seems ok now, will monitor and check back What: Squeeze master pump would not turn on.
Why: Pump tripped.
Countermeasure: Reset pump. Monitored. Okay. What: Squeeze master settings wrong (5A2 P/M) (Change over)
Why: 250 ton P/M settings were put in
Root cause: Error putting in settings
Counter measure: Input manually settings for P/M 350 ton from p What: Squeeze master spec problem ( Axis # 3 parts almost out of spec.)
Why: Squeeze master
Root cause: Squeeze master pods out of adjustment. On flow and pressure
Countermeasure: Adjusted all squee What: Squeeze master trouble channel 4
Why:?
C/M: Line bled and powered off machine
Recur: Possibly in time What: Squeeze master wont squeeze right
Why: Fittings not right for squeeze master for PM 5A2. Machine end
Counter measure: Changed squeeze master settings to accommodate hoses. Fittings will need ch What: Squeeze pin 1 not retracting
Why: Inspected hydraulic lines for leaks and noticed a water leak
C/M: Operator bleeding the squeeze master. Replaced red water line and fitting What: Squeeze pin channel 4 won't move
Why: Bent pin? Bad cylinder?
C/M: We spoke with Matt & decided to do a die change
Recur: posssible What: Squeeze pin chunking out part
Why: Movable side not getting water
Counter measure: Adjusted temps an both side s of die What: Squeeze pin chunking out part
Why: Root cause unknown
C/M: Cycled power to squeeze master and machine, rebled squeeze master and waxed pins What: Squeeze pin depth out of spec
Why: Hydraulic Lines backwards and settings were wrong
C/M: Hooked up lines correctly and put settings to original
Recur: Possibly in time What: Squeeze pin depth to deep on cavity #2
Why: Squeeze master pods needed adjusted
Counter measure: Adjusted pods
R/C:
Cycle time: Unchanged What: Squeeze pin hole shallow
Why: Squeeze master settings for flow was 70 needed to be 90. For 59b chain tench
Counter measure: Change to match plex
R/C: Yes If they save program and load program
Cy What: Squeeze pin problem
Why: Bad cylinder in die Cavity #1. Blow bye on cylinder internally
Counter measure: Pulled die What: Squeeze pins reading 0 on monitor
Why: Lost parameters
C/M: Reinstalled parameters
Recur: Possibly in time What: Squeeze pins wont return
Why: Die was not open all way
C/M: Opened die and returned pins What: Squeezemaster not bleeding
Why: Contactor overload was tripped
C/M: Reset overload What: Stage 3 filters out of spec
Why: Age and life
Countermeasure: Replaced stage 2 and stage 3 filters What: Steel cable came out of clamps connected to dog house.
Why: Loosened over time.
C/M: Got both clmaps back on and tightened down. Confirmed ok. What: Stops dumping ingots in auto
Why: New load sensor seeing dump bucket when dumping and stopping
Counter measure: Turned sensor at base to just miss bucket What: Stripped bolts in trim press cutter
Why: trim height out of spec, operator tried adjusting cutters did not clean bolts before trying to remove
R/C: Operator training
C/M: Had to remove die and t What: Switch for fixed core #1 broke
Why: Got hit by something
Counter measure: Replaced
R/C: No
Cycle time : Unchanged What: T&S
Why: Washout
C/M: Replaced T&S
Recur: in time What: T/S change
Why: Wash out
C/M: Replaced
Recur: In time What: T1 t2 switch fell apart
Why: Screw came loos in switch
Counter measure: Took switch apart and aligned and tightened What: T20 part being damaged by press
Why: Shim in cutter for biscuit, shim under block to support part for cutter to come down
C/M: Put a 0.400 shim to push cutter away from part where it removes bis What: Taka asked for assistance with robot cycle stopping as soon as machine starts, causes shot to slam into trim press because it goes from water tank to scrap C/V
Why: Found X3F stuck untrue in log What: Taka/Mihara asked for support on trim press
Why: Damaged cylinder and top hat
C/M: Replace cylinder, top hat and nut. Left loose so they can adjust What: Taking precautionary measures for Holding furnace misfires
Why: Cause it turns burners off and aluminum gets hard
C/M: Cleaned complete burner unit took photo eye out cleaned with alcohol and pu What: Tanaka associates asked for filter element on machine to be changed
Why: injection issues
C/M: Replaced Hydac filter on casting machine What: Tappet cylinder leaking
Why: Bad seal
Counter measure: Replaced cylinder
R/C: Yes time
Cycle time: Unchanged What: Tappet depth, squeeze pin depth out of spec to deep all cavities
WHy: sprue bushing leaking water
c/m: replaced sprue bushing
will it reoccur: yes timing
cycle time: What: Tappet hole to deep
Why: see otto
Counter measure: What: Tappet holes shallow. Die 59b one rocker #15
Why: Setting on squeeze master were way off
Counter measure: Adjusted so all squeezed the same. Die cylinders (squeeze pin) are worn will need replac What: Tappet pin broke
Why: Life
Counter measure: Replaced pin What: Tappet pin broke
Why: Tappet pin stuck in part (P part op side)
Countermeasure: Replace tappet pin
Reoccur: Possible What: Tappet pin broke (P #3 cavity Die 5)
Why: Unknown
Counter measure: Replaced P pin What: Tappet pin broke RPY die #1 S-1 cavity
Why: Life
Counter measure: Replaced tappet pin
R/C: Yes time
Cycle time: Unchanged What: Tappet pin broke off in part. ( RPY Die 7 P-2)
Why:
Counter measure: Replaced tappet pin
R/C:
Cycle time: Unchanged What: Tappet pin broke on P1 cavity
Why: Unknown
Countermeasure: Replaced tappet pin
Will problem reoccur: Possibly
Cycle time: No change What: Tappet pin depth on cavities 2 and 4 out of spec. To shallow after changeover to 59B 1rkr part on 2nd.
Why: squeeze master stroke on high end of spec allowing tappet pins to not protrude out int What: Tappet pin too long
Why: Tappet pin bent
Counter measure: Replaced tappet pin What: Temp A high
Why: Die cast machine running to fast to cool die
Counter measure: Upped the mid stop and shot delay
R/C: Yes
Cycle time: 28.5 now 31.1 What: Temp A not reaching limit
Why: Thermocouple bad
C/M: Replaced with new
Recur: Possibly in time What: Temp D outer signal alarm
Why: Settings not matched to PLEX, spray points off
Countermeasure: Adjusted setting to match and spray points What: Temp b alarms
Why: Quality temp too low
Counter measure: Adjusted quality set point from 374 to to 379 What: Temp problem
Why: Chiller water shut off
Counter measure: Opened valve What: Temp problem
Why: Cycle time to slow
Counter measure: Noticed slide core movable side slow. Open valve for slide core.( Aka tappet pin on one rocker)
R/C: No
Cycle time: Unchanged What: Temp reading wrong
Why: fixed side thermo coupler wires got smashed
Counter measure Replaced lower fixed side thermo coupler
R/C:
Cycle time: Unchanged What: Temp trouble channel C
Why: Possible Thermocouple no good
C/M: Having operator shut down and change die
Recur: Possibly in time What: Temperature A not getting hot enough
Why: Thermocouple no good
C/M: Tried to turn Temp up on monitor but did not work so i changed out Thermocouple What: Thermo coupler bad movable side
Why: Time
Counter measure: Pulled die to replace thermo coupler and found that fixed side tappet cylinder leaking. Replaced 2 adj squeeze pins in cav 3. Replaced What: Thermo coupler for lower crucible broke off
Why: Unknown
Counter measure: Replaced thermo coupler
R/C: No
Cycle time: Unchanged What: Thermo coupler not reading movable side
Why: Bad thermo coupler in moveable side of die
counter measure: Pulled die
R/C: yes
Cycle time: Unchanged What: Thermo coupler on bottom of movable side of die. (Bottom) die 5BA #3 P&S
Root cause: Wire was run wrong during die change.
Countermeasure: Replaced thermo coupler and run wire right
Reoccurrence What: Thermocouple Fails to read on Moving side of die.
Why: Possible damage to Thermocouple wire.
Countermeasure: Pull Moving side of die and replace thermocouple
Reoccur: Timing What: Thermocouple fell out of melting crucible lid.
Why: 3/4" nipple connection to lid inner housing separated from threaded port.
C/M: Chase threads on nipple and thread back into port. What: Thermocoupler broken on dunk tank.
Why: Unknown, maybe during clean outs it got bumped and broken.
C/M: Replaced thermo coupler What: Tie Bar back nut clamp not clamping.
Root cause: Cylinder for the back nut was sticking.
Countermeasure: We unstuck cylinder.
Will Problem Reoccur?: Not sure. What: Tie Bar nut wont clamp
Why: oiler line broke to the lock nut
C/M: Replaced with new
Recur: Possibly in time What: Tie bar clamp issue
Why: Cylinder bent
Counter measure: Replaced Cylinder What: Tie bar clamp issues.
C/M: This issue dealt with by others. What: Tie bar draw out limit switch malfunction
Why: Tip and sleeve fire
Counter measure: Found that both sensors were on to tie bar nut. Had debris around it.
R/C: No
Cycle time: Unchanged What: Tie bar issue. (Clamp not operating)
Why: Don't know where tie bar is What: Tie bar mounts broke.
Why:
Counter measure: Having new sets made
Recur: Possibly in time What: Tie bar nut will not unclamp
Why: Unclamp sensor loose, tie bar backed out against nut
C/M: Got tie bar off nut so it would unclamp, tightened unclamp position sensor and got tie bar out so die What: Tie bar out limit switch malfunction and Die height adjust motor over load
Why: Operator error
Counter measure: Had to take tie bar clamp off . Had to turn motor push handle down on motor to rel What: Tie bar sensors melted
Why: Operator reported fire possible cause from plunger lube
Countermeasure: Replace sensors with non inventory sensors
Reoccur: Possible What: Tiebar clamp will not move
Why: Issues with solenoid leaking, clamp bound up trying to return
C/M: Took solenoid off new cylinder, replaced gaskets for solenoid and cleaned up clamp plate and ve What: Tip & Sleeve
Why: Blowback and excessive flashing on biscuit
C/M: Replaced both
Recur: In time What: Tip & Sleeve
Why: Washout
C/M: Replaced Tip & Sleeve
Recur: Possibly in time
SLEEVE was last changed on 6-28-2018 What: Tip & Sleeve Shot 44,563
Why: Pitting , wash out and a big gouge streak
C/M: Replaced Tip & Sleeve checked lube and air
Recur: In time What: Tip & Sleeve Shot count 7,030
Why: Lube and cooling joint
C/M: Replaced Tip & Sleeve
Recur: In time What: Tip & Sleeve change 19,396 shot life
Why: Washout and chunks out of sleeve
C/M: Replaced tip and sleeve
Recur: In time What: Tip & sleeve worn
Why: Change over and tip and sleeve were bad
C/M: Replaced tip & sleeve
Recur: yes, timing What: Tip Change
Why: Shot sticking to tip breaking biscuit off
C/M: Replaced tip
Recur: In time What: Tip almost locked up in sleeve during preheat shots
Why: Tip has heavy scarring all around it, sprue getting aluminum build up. Sleeve looked somewhat okay
C/M: Pulled half die and inspected sle What: Tip and Sleeve
Why: Blowback Lube tip plugged
C/M: Changed out tip and sleeve unplugged lube tip
Recur: In time. What: Tip and Sleeve
Why: No Lube
C/M: Replaced tip and sleeve
Recur: Possibly in time What: Tip and Sleeve
Why: Washout
C/M: Replaced Tip & Sleeve
Recur: Possibly in time What: Tip and Sleeve
Why: Washout
C/M: Replaced with new
Recur: In time What: Tip and Sleeve worn.
Why: 109,00 shots on sleeve
R/C: Normal and routine wear and replacement
C/M: Replaced tip and sleeve.
R/O: Yes in time What: Tip and rod broke
Why: Change over. Tip was in die during die changed and broke
Counter measure: Replaced rod
R/C: No
Cycle time: Unchanged What: Tip and sleeve
Why: Dropping shots and washout
C/M: Replaced tip and sleeve
Recur: In time
SLEEVE SHOT LIFE: 47,000 What: Tip and sleeve
Why: Life
Counter measure: Replaced tip and sleeve
R/C: Yes time
Cycle time: Unchanged What: Tip and sleeve N/G
Why: Sleeve with excessive washout.Tip scarred
Counter: Replace tip and sleeve What: Tip and sleeve bad
Why: Worn
Counter measure: Replaced during change over
R/C: Yes time
Cycle time: Unchanged What: Tip and sleeve change Blow back
Why: Worn tip and sleeve Possibility lube not spraying in correct position
C/M: Replaced both tip and sleeve
Recur: In time What: Tip and sleeve change.
R/C: Machine is changing over which calls for a bigger sleeve and tip.
C/M: Replaced tip and sleeve.
R/O: Yes if machine changes over to a part that calls for a different What: Tip and sleeve making noise
Why: Tip and sleeve NG
C/M: Worked with Mike W., replaced tip and sleeve. Removed all check valves from hoses running to sleeve, sprue and moveable side. Blew out lin What: Tip and sleeve need changed
Why: Hardened aluminum in sleeve, tip was damaged
C/M: Got tip and sleeve for operator What: Tip and sleeve replacement per production. Requested during change over What: Tip and sleeve started making noise on injection
Why: Aluminum buildup in sleeve starting to form
C/M: Cycle stop machine, removed excessive aluminum build up in sleeve and waxed tip. Operator a What: Tip change
Why: Blowback
C/M: Replaced tip and O ring
Recur: In time What: Tip change
Why: Shot sticking to the tip
C/M: Replaced tip and adjusted plunger lube line
Recur: In time What: Tip galling on return
Why: sleeve washed out and possibly no lube at one point
C/M: Replaced tip and sleeve
Recur: Possibly What: Tip lube leak.
Why: Fitting leaking.
Countermeasure: Replaced fitting.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Tip moaning when returning
Why: No water to tip. Because hand valve to tip was off due to aluminum hit valve and shut it off
Counter measure: Turned hand valve under sleeve What: Tip plugging up
Why: Sleeve got turned
Counter measure: Adjusted sleeve
R/C: yes
Cycle time: Unchanged What: Tip stuck forward in sleeve
Why: tip unthreaded/loose
C/M: Replacing tip & sleeve
Recur: In time What: Tip trial. So they needed new sleeve for trial
No trial. But still changed tip and sleeve for life What: Tip& Sleeve
Why: Wash out
C/M: Replaced with new Tip & Sleeve
Recur: In time What: Tonna 68 leak why: line leaking. countermeasure: replace line. recur: time. What: Tonna 68 lube line leaking
Why: Hose had hole in it
Counter measure: Replaced line
R/C: Yes time
Cycle time: Unchanged What: Top cooling joint leak.
Why: Water connector caught on die cyl. block
C/M: Replaced fittings
Recur: Timing What: Top for ok table warped causing parts to get stuck in table
Why: Wear
Countermeasure: Replace top
Reoccur: Possible What: Top of Squeeze Master is full of fluid.
Why: Leaking hydraulic line H-33 / H-34.
Countermeasure: Replace damaged line. What: Top slide cores not coming out of the shot
Why: Suspect heavy solder buildup
C/M: While alclean was working on slide cores I removed the cylinder coupler and checked that the slide cores were mo What: Toscast display not responding What: Toscast screen froze.
C/M replace screen with new What: Toscast screen shattered
Why: Root cause unknown, operator states they were navigating screen and it just shattered
Countermeasure: Machine left down per Corey Evans What: Toscast screen un-responsive.
Why: Un-determined.
C/M: Re-calibrate Toscast screen. What: Toscast touch screen froze
Why: Un-determined.
C/M: Set rotary switch in TCPDCU module,(Upper Right hand corner top rack), to "C". Hold red button in this module till you hear a beep. This shoul What: Touch screen on squeeze master not working. No touch on screen.
Why: Screen had dent in top right of screen.
Counter measure: Replaced HMI screen. Ryan Up loaded screen data to new screen
R/C: What: Tower lid not closing
Why: Valve issue
C/M: Replaced close side needle valve, replaced open side with spare from warehouse What: Tower lid not shutting after dumping in scrap
Why: Not making top rocker switch so it never completes the dump cycle
C/M: Adjust switch What: Tree got stuck in trim press and melted an air line
Why: Preheat shot, misformed part
Countermeasure: Replaced air line What: Tree off of shot is not falling out of trim press, Lt side
Why: Chute for the "tree" was bent
C/M: Straightened the chute and confirmed parts are falling as they should
Reoccur: Possible What: Tried removing trim die coupler off trimpress in 6, unable to remove. Will have to wait replacement unit is put in
WHY: joint came loose from trimpress cylinder damaging threads in joint/nut
c/m What: Trim Alarm with no indication
Why: Scrap press sensor no good
C/M: Replaced sensor
Recur: Yes in time What: Trim Damage
Why: Removed 2 guides
C/M: Put guides back in position
Recur: In time What: Trim Damage
Why: Trim press going down to far
C/M: Set Trim press to correct height 220mm
Recur: Possibly in time What: Trim Damage
Why: Wrong parts
C/M: parts on order
Recur: yes What: Trim Damage
Why: build up on shaft hole cutter
C/M: pulled trim press to drill out bolt hole for adjustment
Recur:probably in time What: Trim Damage Cavity 2.
Why: Blocks not trim press needed adjusted.
Countermeasure: Adjusted cavity 1,2 and 4 blocks.
Will Problem Reoccur?:
Cycle Time: No Change. What: Trim Damage Running 5BA-M (Trim die 5BA/RPY-M File No. 133).
Why: Cavity 5-1 trim damage near the roller hole end.
Countermeasure: Adjusted trim die found 0.40 mm shim behind cutter, removed. Tr What: Trim Damage S2 Tappet End
Why: Cutter loose
C/M: Realigned and tightened
recur: timing What: Trim Damage at Rocker shaft area
Why: ?
C/M: Put Trim press #2 in
Recur: Possibly in time What: Trim Damage on cavity 1.
Why: Blocks on trim press blocks needed adjusted.
Countermeasure: Adjusted blocks.
Will Problem Reoccur?: No.
Cycle Time: No Change. What: Trim Damage.
Why: Placement of blocks in trim press.
Countermeasure: Adjusted Blocks.
Will Problem Reoccur?: Yes.
Cycle Time: No Change. What: Trim Damage. Trim Die 59B 1Rk Trim 2. cav.1
Why: Possible scrap in the way of shot.
Countermeasure: Cleaned trim die. Set block back to where it should be. What: Trim Die RPY 1RKR Trim 2 Block broke bolts.
Why: Wear.
Countermeasure: Replaced broken bolts (back left from O.P.). What: Trim Die part chute bent during installation.
Countermeasure: Remove part chute bend to correct size and reinstall.
Reoccur No What: Trim Height
Why: Bad Design
C/M: Made adjustments
Recur: Yes in time What: Trim Height
Why: Missing component parts
C/M: replaced 3 guides and the 4 tappet cutters still missing spring plunger
Recur: Possibly in time What: Trim Height
Why: Someone added 4 extra shims and just changed out die
C/M: Adjusted 3 out of 4 cavities had a bolt break off replaced and fixed
Recur: Possibly in time What: Trim Height Cav 3-4 RPY
Why: Cutters needed adjusted
Counter measure: adjusted cutters
R/C: Yes
Cycle time: Unchanged What: Trim Height/Damage 5BA P/S
Why: Poor design trim press
C/M: Adjust cutters & guides
Recur: In time What: Trim Height/damage
Why: Needed adjustment to the cutters
C/M: Adjusted
Recur: What: Trim Pres smashing parts
Why: Robot not sitting in press correctly
C/M: Retaught take out due to limit at press not allowing robot to be taught cause of hitting press What: Trim Press cylinder No good drifting down during operation
Why: Cylinder blowing by
C/M: Replaced cylinder
Recur Possibly in time What: Trim Press Alarms
Why: Robot not setting in press correctly
C/M: Retaught take out and took apart press and cleaned and put new shims in
Recur: Possibly in time What: Trim Press Fault flipper # 3 not able to move.
Why: Mountain of parts up it.
Countermeasure: Removed parts and debris from NG conveyor and shot.
Will Problem Reoccur?: No.
Cycle Time: No Change What: Trim Press Faulting Work full.
Why: Sensor on trim press made.
Countermeasure: Tightened Sensor. What: Trim Press Hydraulic temp at tank 134 degrees
Why: Oil cooler fan not working
C/M: Put one on from D9 sub assy but didnt work also/ Found one in the bottom of Die cast line in cage
Recur: Yes in What: Trim Press Problems
Why: overflow chutes broke and not in position
C/M: replaced chutes
Recur: Probably in time What: Trim Press Safety Door would not shut.
Why: Locking mechanism over traveled.
Countermeasure: Turned locking mechanism so that door could look. Working as it should. What: Trim Press air blow no good
Why: Solenoid valve not good
C/M: took valve apart we have none in inventory so put back together just weak air blow What: Trim Press crushing parts
Why: Take out of dc machine no good
C/M: Retaught Takeout and at Trim press What: Trim Press drifting down
Why: Cylinder blowing by
C/M: Replaced Cylinder
Recur: Possibly in time What: Trim Press drifting down
Why: Cylinder blowing by seal
C/M: Replaced cylinder What: Trim Press drifting down
Why: Cylinder no good blowing by seal
C/M: Replaced cylinder with new What: Trim Press faults.
Why: Shot not getting set correctly Cavity cutters not tight
C/M: Tighten cutters to correct position
Recur: In time. What: Trim Press hydraulic pump running hot.Low suction pressure.
Why : Plugged suction filter. Oil cooler cooling fins plugged with debris
Countermeasure: Replace oil suction filter, clean oil coole What: Trim Press leaving marks on parts
Why: New cutters installed sharp edges
C/M: Put chamfer on top pushers
Recur: Possibly in time What: Trim Press making loud noise when running
Why: Suction filter clogged oil no good
C/M: Put new suction filter on now ok. What: Trim Press motor overload
Why: Clutch slipping/loose
C/M: Tightened clutch
Reoccur with wear What: Trim Press not pressing out properly.
Why: Linear bushing gone bad.
Countermeasure: Replaced Left (if looking at from scrap conveyor) linear bushing and linear shaft. What: Trim Press not returning up
Why: top of press moving to far down
C/M: Loosened nut and adjusted top press up
Recur: Possibly in time What: Trim Press not trimming all of cavity 4 and cavity 3 getting stuck to top.
Why: Cavity 3 getting stuck to top of trim press.
Countermeasure: Replaced pins for cavity 3.
Will Problem Reoccur?: P What: Trim Press plate push pin broke
Why: ?
C/M: Replaces with new
Recur: Possibly in time What: Trim Press top Part sensor plug no good
Why: Wires pulled out of plug now wire to short to re-terminate
C/M: Got new female connectors and re-terminated the sensor now ok What: Trim Press would not move up or down in auto or manual
Why: Wire plug to the KC,KB press had wires bare tripping breaker
C/M: Took plug and taped off bare wires till Sergio gets new plug wired What: Trim Problems parts sticking to top
Why: Possible bushing no good different style/ Centering pins possibly bent
C/M: Pulled both centering pins on cavity 1 back was good front was bent
Recur: Po What: Trim Scrape On rocker shaft area
Why: Build up on guide
C/M: Replaced guide
Recur: Possibly in time What: Trim Scrape on cavity 2
Why: R/S cutter worn no coating on any cutters
C/M: Replaced cutter with new
Recur Yes timing What: Trim at tappet area (59B one rocker)
Why: Unknown
Counter measure: 1st ground on upper punch for cavity's #3 and 2 (68.0 to 66.5) on tappet area
R/C: Yes
Cycle time: Unchanged What: Trim at vibrator
Why: Pick up point in die off
Counter measure: Retaught pick up position off die
R/C: No
Cycle time: Unchanged What: Trim bad on cavity #4 5BA
Why: Guide slid on cavity
Counter measure: moved back to shims
R/C:
Cycle time: Unchanged What: Trim breaking in on Cav 2 and 4 F-7 RPY-M
Why: Breaking into part
Counter measure: Adjusted cutters for cavity 4 and 2
R/C:
Cycle time: Unchanged What: Trim breaking into part (P-1) Die 13
Why: Die is coming apart in runner to that cavity: Right where it is trying to break it. Runner is too thick to be consistent
Counter measure: Pulled die What: Trim breaking inward RPY M
Why: Shot already broke coming out of die. Due to squeeze pin bushing worn
Counter measure: Replaced die What: Trim damage
Why Shot is cracked at runner for that part. So part and get stamped out at trim press right
Counter measure: Taught robot. But couldn't fix root cause of shot being broke. I think t What: Trim damage
Why: ?
C/M: Made adjustments
Recur: Possibly in time What: Trim damage
Why: Breaking into parts
Counter measure: change trim press, adjust cutters
reoccur- yes What: Trim damage
Why: Cavity #2 cutter moved
Counter measure: adjusted cutter for cavity #2 What: Trim damage
Why: Cavity #4
Counter measure: Replaced cutter to Vacuum block runner for cavity 4 What: Trim damage
Why: Cavity 4 guide rubbing part
Countermeasure: Adjust guide
Reoccur: Possible What: Trim damage
Why: Combination of flashing and robot positioning at trim die
C/M: Touched up robot trim die position What: Trim damage
Why: Cutter #4 wore out
Counter measure: Replaced cutter #4
R/C: Yes seems to be the cutter on trim press that wears out. 3rd one I have had to put on since trim die has been used
Cy What: Trim damage
Why: Cutter gummed up
Counter measure: Pulled cutter and polished. Cylinder clamp fell apart. put new on
R/C: Yes time
Cycle time: Unchanged What: Trim damage
Why: Cutter had a bur
Counter measure: Ground bur off
R/C: Yes time
Cycle time: Unchanged What: Trim damage
Why: Cutter was gummed up. Looking in back door Left rear
Counter measure: Cleaned cutter
R/C: Yes time
Cycle time: Unchanged What: Trim damage
Why: Cutter worn
Counter measure: Replaced cutter and cleaned other
R/C: Yes time
Cycle time: Unchanged What: Trim damage
Why: Cutters bad
Counter measure: Replaced cutter
R/C: No
Cycle time: Unchanged What: Trim damage
Why: Guides out of adjustment and cutter bad
Countermeasure: Adjusted guides and replaced cutter
R/C: Yes time
Cycle time: Unchanged What: Trim damage
Why: No position to push runner (Tree) down ramp. So part sets in crooked
Counter measure: Taught p-35 and p-50 to push tree down ramp
R/C: Unknown
Cycle time: Unchanged What: Trim damage
Why: Not sure has had alot of positions out and was hitting the press on the approach
C/M: Retaught alot in the approach to the press and final sit down What: Trim damage
Why: Robot chuck jaw finger end was in the wrong spot after change over from chain tench to 1 rocker. Plus one of the fingers were bent too
Counter measure: Put finger end in right l What: Trim damage
Why: Robot teaching
Counter measure: Retaught robot at trim press What: Trim damage
Why: Robot tooling head bent
Counter measure: Replaced tooling head
R/C: No
Cycle time: Unchanged What: Trim damage
Why: Runner for shot cracking
Counter measure: Added nitro
R/C: Yes time
Cycle time: Unchanged What: Trim damage
Why: Scrap piece got imbedded on mounting surface
Counter measure: Cleaned off and polished
R/C: Unknown
Cycle time: Unchanged What: Trim damage
Why: Shot wouldn't set in by hand. Too tight
Counter measure: Pulled shims to side guides and touched up trim position What: Trim damage
Why: Tooling arm bent
Counter measure: Replaced tooling arm and taught pick up to in trim press. (6A0 S parts) What: Trim damage
Why: Top cutter no good someone ground on cutter
C/M: Replaced cutter
Recur: Possibly in time What: Trim damage
Why: Trim die needed adjusted
Countermeasure: Adjusted trim die
Will problem reoccur: Possibly
Cycle time: No change What: Trim damage
Why: Trim press air cylinder came loose
Counter measure: Put longer bolts in cylinder
R/C: No
Cycle time: Unchanged What: Trim damage
Why: Unknown
Countermeasure: Adjusted trim die
Will problem reoccur: Possibly
Cycle time: No change What: Trim damage
Why: Unknown
Countermeasure: Replaced back cutters with old style cutters from die maint, also had to take the air blows from another trim die to put on this one
Will problem reoccur What: Trim damage
Why: Upper cutter gummed up
Counter measure: Cleaned cutter
R/C: Yes parts are hot going into trim press
Cycle time: Unchanged What: Trim damage
Why: When pushers would come out causing part to lift off of jig on right back side
C/M: Took the 300 shims out of center pedestal put 600 took the 400 from the upper cutter and put What: Trim damage
Why: Worn cutter
Countermeasure: Replace cutter
Reoccur: No What: Trim damage
Why: a)Trim accumulating on die. b) Cavity 4 part being damaged by tappet side of part.
C/M: a)Adjust air blow lines serving cavities 1 & 2 to clear trim. b)
Will it Re-occur: Yes. What: Trim damage
Why: trim press
Countermeasure: Changed trim dies, adjusted cutters, adjusted robot positions
reoccur- yes What: Trim damage
Why: Shot sticking to ejector pins
Countermeasure: Clean ejector pins What: Trim damage #2 cavity (59B RYR trim die #2)
Why: R/S cutter bad on cavity #2. (Back cutter KO73-010026-0)
Counter measure: Replaced cutter
R/C:
Cycle time: unchanged What: Trim damage #2, 3 & 4
Why: Worn cutters and needs adjusted
C/M: Removed cutters. Cleaned cutters and cutter cavities. Replaced both cutters for cavity 2 What: Trim damage ( Water Passage)
Why: Ramps bent
Counter measure: Straightened out ramps
R/C: Yes
Cycle time: Unchanged What: Trim damage (#4)damage on cavity 1,2 on part face
Why: punch height cavity 2 ng
C/M: removed cavity 2 punch and modified added a chamfer to get mark to go away put another punch on cavity 2
REO What: Trim damage (59B 1 RYR)
Why: Shot not setting in trim die good
Counter measure: Retaught robot
R/C: yes
cycle time: Unchanged What: Trim damage (59B 1 Rocker)
Why: Tappet cutters bad #2 #4 Cavitys
Counter measure:
R/C: yes
Cycle time: Unchanged What: Trim damage (59B One rocker)
Why: Bad cutters
Counter measure: Replaced all 4 cutters to vacuum block trees
R/C: yes
Cycle time: Unchanged What: Trim damage (59B one rocker) #1
Why: Upper punches bad and cutters
Counter measure: Replaced trim die
R/C: Yes
Cycle time: Unchanged What: Trim damage (5A2 p/m)
Why: Trim press missing cutter for M2
Counter measure: Replaced m2 cutter and p2 cutter
R/C: Yes time
Cycle time: Unchanged What: Trim damage (5BA P/S)
Why: Robot twice clamp position low and not re-grabbing biscuit right. And upper spring tilting shot
Counter measure: Retaught robot in trim press and removed upper spring What: Trim damage (6A0 M)
Why: Shot breaking due to dragging on die
Counter measure: Polished die
R/C: Yes time
Cycle time: Unchanged What: Trim damage (RPY P/S)
Why: Cutters not high enough for main runner on shot. Main runner hits when it is press down and it tilts due to not being flat. It is round
Counter measure: Took plate out What: Trim damage (Water passage)
Why: Position 58 59 and 60 needed taught
Counter measure: Adjusted 58 59 and 60 positions for robot What: Trim damage (Water passage)
Why: Pin coating worn off
Counter measure: Changed trim die
R/C:
Cycle time: Unchanged What: Trim damage (Water passage)
Why: Slide core causing damage.
Counter measure: Cleaned slide core and adjusted spray point
R/C: Unknown
Cycle time: Unchanged What: Trim damage 59B #1 trim die cavity #1
Why: Changed trim die
Counter measure: Changed trim die to #2
R/C:
Cycle time: Unchanged What: Trim damage 59B 1 rocker
Why: Cutters worn
Counter measure: Replaced cutters
R/C: Yes time
Cycle time: Unchanged What: Trim damage 59B 1 rocker
Why: Burrs on back cutter cavity 4
Countermeasure: Pulled die removed cutter filed off burr
Reoccur: Possible What: Trim damage 59B One rocker
Why: Scrap on parts
Counter measure: Adjusted out back part of part cutter for #3 and #4
R/C: No
Cycle time: Unchanged What: Trim damage 59B One rocker
Why: back cutters too high
c/m- replace back cutters with shorter original cutters
reoccur- ? What: Trim damage 59B one rocker
Why:
Counter measure:
R/C:
Cycle time: unchanged What: Trim damage 59B one rocker
Why: Front tappet area damage (scrape) Cavity #1
Counter measure: Adjusted guide out
R/C: yes
Cycle time: Unchanged What: Trim damage 59B one rocker
why- r/b chuck grippers worn allowing shot to move/cutters out of adjustment
c/m- replace chuck grippers and adjusted cutters
reoccur- yes What: Trim damage 59B one rocker Cavity 4
Why: Cavity #4 height too high
Counter measure: Moved cutter in
R/C: No
Cycle time: Unchanged What: Trim damage 59B one rocker Trim die# 2
Why: Upper missing runner blocks (33 and 34) and vacuum runner cutter for cavity 2
Counter measure: pulled all cutters and guides for cavity #2 and stoned. What: Trim damage 59B one rocker and robot crashing
Why: Cavity #1 tappet area damage
Counter measure: Retaught pick up point out of die and set down point in trim press. Adjusted cutter out
R/C: No
C What: Trim damage 5A2 P-2
Why: Shot broke coming out of die. (Cracked around Cavity#2)
Counter measure: Polished die for runners in die coming apart. Too much damage around ejector pin in runner to ke What: Trim damage 5A2 cav P-1
Why: Shot cracking coming out of die
Counter measure: Polished all cavities and bled squeeze master. Swapped out trim press too
R/C: Yes
Cycle time: Unchanged What: Trim damage 5BA M
Why: Cavity #4 Scraping
Counter measure: Adjusted cavity #4
R/C: No
Cycle time: Unchanged What: Trim damage 5BA P/S
Why: P-2 cavity worn
Counter measure: Replaced cutter
R/C: Yes
Cycle time: Unchanged What: Trim damage 5BA P/S #1 trim die
Why: P-2 S-2
Counter measure: Adjusted cutters in
R/C: Yes
Cycle time: What: Trim damage 5BA one rocker trim die #2
Why: Punching too far down and moving cutters
Counter measure: Set gape space and moved Cavity #1 and #2 cutters out
R/C:
cycle time: Unchanged What: Trim damage 6A0 cavity 1
Why: Build up on die
Counter measure: Polished area in cavity What: Trim damage 6A0-S-2
Why: Robot tooling end bent
Counter measure: Replaced tooling arm What: Trim damage Cavity 1
Why: Build up on cutter
C/M: Put new cutter in
Recur: Possibly in time What: Trim damage Cavity 1 and 2
Why: Robot position off
Counter measure: Retaught P24 and P25 What: Trim damage RPY
Why: Leaving mark from top punches
Counter measure: What: Trim damage RPY 1RKR, Cavity 1 and 2 tappet area
Why: suspected issue may stem from missing shims
Counter measure: cleaned burrs from cutters. tried adjusting cutters. tried cleaning die. robot What: Trim damage RPY 5BA P/S
Why: Cutters for S-1 cav need adjustment
Counter measure: Adjusted cutter for cav S-1
R/C: Yes
Cycle time: Unchanged What: Trim damage RPY one rocker
Why: Robot was off
Counter measure: Touched up positions 25 and 26 What: Trim damage Water passage biscuit end. Chunking out
Why: Guide bad
Counter measure: Turned cylinder up to jam it to guide
R/C:
Cycle time: What: Trim damage after (change over) to 59B 1 rocker trim die #3
Why: Changed tooling arm a while back. We have not checked all points for this model.
Counter measure: Touched up point 6 and 23,24,2 What: Trim damage all cavities
Why: Ongoing issue
Countermeasure: Adjusted cutters in bottom trim die, adjusted robot positions 25 and 26
Will problem reoccur: Possibly
Cycle time: No change What: Trim damage all cavities (RPY P/S)
Why: All cutters bad
Counter measure: Replaced all cutters
R/C: Yes time
Cycle time: Unchanged What: Trim damage all parts
Why:
Countermeasure: Adjusted cutters
Reoccur: Possible What: Trim damage and Very heavy flashing
Why: Die not holding temperature with water valves OPEN, 5BA has a bad thermocouple. (per Jeremy)
C/M: Pull die (Per Jeremy) What: Trim damage back of part
Why: Cylinder in press for holding part moving to fast tilting part
Counter measure: Slowed cylinder down What: Trim damage cav #4
Why: Bad cutter
Counter measure: Replaced cutter for tappet area
R/C: Yes time
Cycle time: Unchanged What: Trim damage cav 4 59B One rocker
Why: Guide broke and cutter worn
Counter measure: Replaced both
R/C: No
Cycle time: Unchanged What: Trim damage cav#4 RPY-M
Why: Cav #1 straight cutter in to tight.
Counter measure: Adjusted straight cutter out a bit to keep cav #4 from being to tight at curve cutter
R/C: Yes time
Cycle time What: Trim damage cavity #3
Why: Block got moved forward
Counter measure: Moved block back
R/C:
Cycle time: Unchanged What: Trim damage cavity #3
Why: Cutter worn
Counter measure: Replaced cutter
R/C: yes time
Cycle time: Unchanged What: Trim damage cavity #3 RPY
Why: Cutter was worn
Counter measure: Replaced cutter
R/C: Yes time
Cycle time: Unchanged What: Trim damage cavity #4
Why: Guide had damage and was damaging part
Counter measure: Replaced guide What: Trim damage cavity 1
Why: Tab cutter appeared to have a bigger gap on one side compared to the other.
C/M: Removed tab cutter and cleaned. Reinstalled and tested, parts look normal What: Trim damage cavity 1
Why: Too high on back side
Counter measure: Adjusted cutter What: Trim damage cavity 1
Why: Unknown
Countermeasure: Adjust cutter
Reoccur: Possible What: Trim damage cavity 2
Why: Not sitting in press correctly
C/M: Re-Taught final set position
Recur: Possibly in time What: Trim damage cavity 2 59B 1RKR
Why: Cutter needed adjusted
Countermeasure: Adjust cutter
Reoccur: Possible What: Trim damage cavity 2 59B trim die 2
Why: Build up on cutter
Countermeasure: Clean cutter
Reoccur: Possible What: Trim damage cavity 2 6A0 S
Why: Excessive trim height on Tappet area
Countermeasure: Adjusted trim press What: Trim damage cavity 3 and 4.
Why: Robot position off
Counter measure: Retaught at trim press
R/C: NO
Cycle time: Unchanged What: Trim damage cavity 4
Why: Broken block cavity 4
Countermeasure: Replace broken block cavity 4 1 RKR Trim 2
Reoccur: Possible What: Trim damage cavity 4
Why: Cavity 4 block NG
C/M: replaced with new block
Recur: Possibly in time What: Trim damage cavity 4
Why: Cutter moved
Counter measure: Adjusted cutter 4
R/C:
Cycle time: Unchanged What: Trim damage cavity 4
Why: Trim too tight in cavity 4
Counter measure: Pulled shims in guides to open up cutting on cavity 4 What: Trim damage cavity 4
Why: Unknown
Countermeasure: Adjust cutter to cut cleaner
Reoccur: Possible What: Trim damage cavity 4 (trim die 1 59B one rocker)
Why: Coating worn off of guide. Aluminum sticking to it
Counter measure: Replaced guide right side closet to biscuit What: Trim damage cavity 4 59B 1 RKR
Why: Cutter was all gummed up and out of position
Countermeasure: Removed cutter, cleaned and realigned, did not hold so I replaced the cutter
Will problem reoccur What: Trim damage cavity#1
Why: Shot not constant setting shot in press due to no die release
Counter measure: Opened hand valve by spray cartage
R/C:
Cycle time: Unchanged What: Trim damage high on 5BA P cavity 2
Why: Cutter out of position, part sitting loose in trim press
C/M: Adjusted P cavity 2 blocks to cut trim better What: Trim damage mounting hole
Why: Robot teaching in trim press
Counter measure: Taught set down position What: Trim damage on P-2 cavity
Why: Excessive trim height
Countermeasure: Adjusted cutters on P-2, had to remove soft float from line 271 and soft float end from line 284 in Type 6 program to keep ro What: Trim damage on P1 and S1
Why: Had a trim press die in that did not have new cutters, cannot get parts dialed in with it
Countermeasure: Put in trim press die that had new cutters
Will problem re What: Trim damage on cavity #4
Why: Cutter for #3 was moved out which correlates to other cutters
Counter measure: Adjusted #3 cutter in. Adjusted position #26 and #25 on robot
R/C: No
Cycle time: Unc What: Trim damage on cavity 2
Why: Scraping
Countermeasure: Shimmed big runner cutter up with washers
Will problem reoccur: Possibly
Cycle time: No change What: Trim damage on cavity 2 RPY 1 RKR and cavity 3
Why: Cutter needed adjusted
Countermeasure: Adjust cutters What: Trim damage on cavity 4 on the top of the R/S hole
Why: Unknown
Countermeasure: Adjusted cutter in cavity 4
Will problem reoccur: Possibly
Cycle time: No change What: Trim damage on cavity one
Why: Burr on block on press
C/M: Removed burr from block, hand loaded shots and they came out with no damage What: Trim damage one rocker 59B
Why: Cavity 2 guide worn
Counter measure: Replaced guide
R/C: Yes
Cycle time: Unchanged What: Trim damage side of part. RPY New trim die
Why: Punches leaving dents
Counter measure: Ground and polished all 4 punches
R/C: Yes when new punches get put in
Cycle time: Unchanged What: Trim damage tappet area
Why- Cutter had build up and wear on it. Coating wore off of cutter so the build up keeps coming back
C/M- Changed Vacuum side tappet cutter for cavity #3
Reoccur, timing What: Trim damage, 59B one rocker
Why: Cutter was damaged
Counter measure: Replaced cutter on cav #2 tappet area
R/C: yes time
Cycle time: Unchanged What: Trim damage, cavities 2 and 4 (RPY M) What: Trim damage.
Why: Cavity 1 had inward trim damage.
Countermeasure: Adjusted cutters.
Will Problem Reoccur?: Yes.
Cycle Time: No Change. What: Trim damage. (6A0-M) cavity #4
Why: Soldering in cavity
Counter measure: Polished cavity
R/C: Yes time
Cycle time: Unchanged What: Trim damage. 59B R1R
Why: Cutters worn
Counter measure: Replaced 2 cutters
R/C: yes time
Cycle Time : Unchanged What: Trim damage. RPY-M
Why: Cutter needed adjusted
Counter measure: Had to adjust cutters
Cycle time: Unchanged What: Trim damage. See W.O. 53592 What: Trim damaged on cavity 3.
Why: Trim press blocks.
Countermeasure: Adjusted tappet end blocks.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Trim die clamps not working
Why: Steel line leaking not enough air pressure
C/M: Replaced steel line worked clamps to get air out and pressure back What: Trim die stripped bolt on cutter, trim height out of spec cavity S2
R/C: DH adjusting cutters for trim height P2 cavity stripped bolt
C/M: No extra trim die, pulled die and had to remove strippe What: Trim getting left on part after being punched.
Why: Punch positions need adjusted.
C/M: Touched up punch positions and confirmed trim is getting knocked off of part. What: Trim height
Why: Braking into part
Counter measure: Adjusted trim press What: Trim height
Why: Cutter needed adjusted. bolts broken for cutter could not remove in machine
Counter measure: Changed trim press and put bad one in work area
R/C: Yes time
Cycle time: Unchanged What: Trim height
Why: Cutter worn
Counter measure: Replaced cutters
R/C: No
Cycle time: Unchanged What: Trim height
Why: Robot take out position only gripping 2 spots instead of 4
C/M: Retaught take out and then taught in trim press
Recur: Possibly in time What: Trim height
Why: Scaping part. S1
Counter measure: Adjusted cutter What: Trim height
Why: Shot broke coming out of die
Counter measure: Cleaned die What: Trim height
Why: Trim height too high.
Countermeasure: Adjusted cutters.
Will Problem Reoccur?: Yes.
Cycle time: No Change. What: Trim height
Why: design no good
C/M Pulled press to work on it
Recur: Possibly in time What: Trim height
Why: s-1 and p-1 trim high
Counter measure: adjusted cutters in What: Trim height RPY-M
Why: Guide worn
Counter measure: Replaced guide
R/C: No What: Trim height (5BA P/S)
Why: P-1 S-1 cutters hitting flashing from ejector pins
Counter measure: Ground on cutters so flashing from ejector pins would let shot set flat. Main runner from shot hitt What: Trim height (RPY P/S) #1
Why: Curved edge of cutters need worked on. New style cutters
Counter measure: 1st Shift engineer polished curved ends of cutters
R/C: Yes
Cycle time: Unchanged What: Trim height 5A2 P-1. Die 30
Why: Shot cracked coming out of die
Counter measure: Bled squeeze master and waxed ejector pins. checked concentration adjusted spray points and lowered the die temp. What: Trim height 5BA P-2
Why: P-2 curved cutter needs adjusted
Counter measure: Adjusted in more
R/C: Yes
Cycle time: Unchanged What: Trim height 5BA P/S
Why: Ejector pins bushing flashing
Counter measure: File parts
R/C: Yes
Cycle time: Unchanged What: Trim height P-2 BA
Why: Cutter needed adjusted
Countermeasure: Ground corners of curved P-2 to allow better movement
Reoccur: No What: Trim height RPY M
Why: Upper punch
Counter measure: Upper punch didn't match others. Other were modified to work. So I modified cav 1 punch and I shimmed cav 1 and 2 cutter
R/C: Yes bad designe What: Trim height RPY M
Why: cutter worn
Counter measure: Replaced cutter and modified cutter. Replaced guide
R/C: Yes time
Cycle time: Unchanged What: Trim height RPY M
Why: poorly designed trim press
Counter measure: took shims out from under cutters replaced cavity 1 cutter with non-inventory
R/C: yes
Cycle time: Unchanged What: Trim height RPY M Cav 1
Why: Cutter worn
Counter measure: Replaced cutter
R/C: Yes
Cycle time: Unchanged What: Trim height RPY P-S
Why: Cutting off tappet end of part
Counter measure: Replaced cutters with new
R/C Yes Timing What: Trim height cav 3
Why: Shot broke coming out of die. Due to some one grinding on ejector pins
Counter measure What: Trim height cavity #1 (RPY 5BA trim die 3)
Why: Cutter bad
Counter measure: Replaced cutter
R/C:
Cycle time: Unchanged What: Trim height cavity 2 (6A0 P)
Why: Shot setting crooked
Counter measure: Taught position 25 What: Trim height is bad on cavity 1 and 2 After change over.
R/C: Cutters were out of position on trim press.
C/M: Adjusted cavity 1 and 2 cutters on trim press cavity 2 came in but 1 didn't i swappe What: Trim height issue 5BA P/S
Why: S2 had trim press 'gouges'
C/M: change s2 cutter,Adjust cutters
Recur: possible What: Trim height issues on s part cavity 2.
Why: One of the cutters is floating around.
R/C: Bolts were stripped so you couldn't tighten them down enough.
C/M: Removed bolts and replaced with all new What: Trim height issues s part cavity 2.
Why: Cutter is bad.
R/C: unknown.
C/M: Replaced cutter.
R/O: Yes due to unknown root cause.
Cycle Time: NO Change. What: Trim height on 5-3 (RPY One rocker)
Why: Cutter was lower on one side compared to other
Counter measure: Replaced all 4 cutters. ( took pic to talk with JR Otto about)
R/C: No
Cycle time: Unchan What: Trim height on cav #1
Why: P-! cutter had been ground on
Counter measure: Welded and ground cutter for curve of part
R/C: Yes Time
Cycle time: Unchanged What: Trim height on cavity 3
Why: Cutter out of position
Countermeasure: Adjusted cutter on cavity 3
Will problem reoccur: Possibly
Cycle time: No change What: Trim height on part. Part that gets vibrated off
Why: Teaching of robot at vibrator
Counter measure: Taught at vibrator What: Trim height out of spec cavity 1 P part
Why: squeeze pin sticking allowing shot to stick, cavity 1 P part trim cutters out of adjustment
c/m: rebleed squeeze master to get shot to hold together, What: Trim height problem 5BA PS #1
Why: P1 and S2 high on trim
Counter measure: Replaced shims for curved part of part went from 0.20mm to 0.30mm on both What: Trim height problems.
Why: Flashing.
C/M: Adjusted cutters.
R/O: Yes. What: Trim height to high cavity 1
Why: Shot wasn't setting flat in die causing part to rock
Countermeasure: Adjust to allow shot to sit flat also adjusted cutter in cavity 1
Reoccur: Possible What: Trim height, Cavities 2 and 3 (RPY M)
Why: Trim press cutters just needed adjusted
Countermeasure: Adjusted cutters for cavities 2 and 3 What: Trim height.
Why: What: Trim height. 5BA P/S
Why: P-2 cav neds adjusted
Counter measure: Adjusted cav P-2 and S-2 went out pulled S-2 curved cutter and ground flat edges of cutter for more bolt slop
R/C: Unknown
Cycle What: Trim height/ breaking inward.
Why:
Countermeasure:
Will Problem Reoccur?: Yes.
Cycle Time: No Change. What: Trim high on (5BA S-1 and P-1 Die #3)
Why: Cutters wrong. (Bad design)
Counter measure: Replaced with spare trim press
R/C: Yes time
Cycle time: B-26.1 A-26.1 What: Trim issue
Why: Die flashing 6A0 M
Counter measure: Pulled lower slide cores and cleaned. Ran 10 shots excessive flashing is back. Had them pull die for spotting What: Trim issue
Why: Dent in parts
Counter measure: Adjusted robot What: Trim issue
Why: Die release pump not pumping
Counter measure: Replaced pump What: Trim issue
Why: Part sticking to top of trim press
Counter measure: Replaced both guides pins What: Trim issue
Why: Robot Position
Counter measure: Re taught robot What: Trim issue
Why: Trim height all parts
Counter measure: Shimmed all cavities What: Trim issue
Why: robot set down and push cylinders
Counter measure: Adjusted set down and turned up push cylinder regulator from 1.5 to 3.0 What: Trim issues
Why: Punch not knocking runners off cleanly
C/M: Worked with Sergio, touched up punch positions so shots come out looking better What: Trim issues.
WHY: ejector pins sticking a little maybe bending shot
C/M: cleaned ejector pins and waxed / robot ok adjusted plunger lube tip to spray back towards the tip more now trim ok What: Trim issues.
Why: Cavity 2 and 4 59B chain tensioners getting scraped off. Trim die 1.
Countermeasure: Block that goes around the 20 ID on cavity 4 needed pushed back against the plate. What: Trim issues. 59B 1RKR
Why: Ejector pins sticking a little maybe bending shot
Countermeasure: Cleaned and waxed ejector pins and waxed. Adjusted plunger lube tip to spray back towards the tip mo What: Trim loading trouble
Why: final set position off
C/M: Re-taught final position
Recur: Possibly in time What: Trim on tappet scraping
Why: Coating on cutter worn off
C/M: Replaced with new now ok
Recur: In time What: Trim press
Why: Little scrap conveyor jammed
Counter measure: Un jammed What: Trim press
Why: New cutters were installed
C/M: Had to adjust before start up
Recur: In time What: Trim press (RPY-M)
Why: Trim height out of spec on cav #4 and #1
Root cause: Trim die not made right
Countermeasure: Ground and shimmed on cutters to make shot sit flat on cutters for #1 and What: Trim press (Water passage) ramps are bent bad
Why: The got doubled stacked on. They are made cheap too
Counter measure: Re worked ramps
R/C; Yes
Cycle time; 50 sec What: Trim press Alarm.
R/C: X82, probably one of two abandoned door switches in trim press not made.
Countermeasure:
Will it re-occur: No What: Trim press E=Stop circuit issue after M/C move.
Why: Wire marked A1-A21 from DSC control not terminated on screw for E-Stop relay coil.
C/M: Re-terminate Coil wire. What: Trim press Hydraulic system cleaning.
C/M: Drained oil and confirmed clean inside. Replaced both return and inlet filters as well as cleaning oil cooler. Filled back up and turned on. What: Trim press Hydulic leak
Why: DVC stack base leaking again. Cracked
Counter measure: Replaced Base What: Trim press Pump making noise
Why: Pump no good
C/M: Replaced pump
Recur: Possibly in time What: Trim press Up and down cylinder drifting down while sitting idle
Why: Front seal blown
C/M: Replaced with new
Recur: Possibly in time What: Trim press Work rest full alarm.
Why: Shot detect sensor always on.
Countermeasure: What: Trim press air blow not coming on
Why: Solenoid for air blow was stuck closed
C/M: Got valve unstuck, issue did not reoccur What: Trim press air blow stuck on
Why: Bad relay (N06E)
Counter measure: Replaced relay
R/C:
Cycle time: Unchanged What: Trim press air cylinder missing holder for part
Why: Fell off
Counter measure: Reinstalled
R/C: No
Cycle time: Unchanged What: Trim press alarm
Why: Blue bucket jammed
Counter measure: Loosened chain and skipped tooth What: Trim press alarm
Why: Motor over load on big conveyor
Counter measure: Reset over load What: Trim press alarm
Why: Scrap press sensor bad
Counter measure: Replaced scrap sensor What: Trim press alarm
Why: Shot not setting flat
Counter measure; Taught P1 just after P25 What: Trim press alarm
Why: Shot setting crooked
Counter measure: Shot hitting shot in in water tank What: Trim press alarm
Why: Trim press not going down in auto
Counter measure: Replaced relay Ro64 and DCV relay Y09C
R/C: No
Cycle time: Unchanged What: Trim press alarmed scrap full parts
Why: Cant reset alarm. x427 stuck on
Counter measure: What: Trim press alarming
Why: Blue bucket conveyor not coming back home. Due to chain skipped
Counter measure: Adjusted chain What: Trim press alarming
Why: Flippers #3 #4 were not working. Due to parts jammed in flippers
Counter measure: Un jammed
R/C: Yes never found root cause of jam
Cycle time: Unchanged What: Trim press alarming
Why: Sensor looking across press adjustment issues
C/M: Aligned and adjusted amplifier What: Trim press alarming out
Why: Part of shot stuck in scrap press
C/M: Replaced damaged bottom cutter and top cutter on scrap press. Adjusted down sensor position on cylinder. Taught robot at scrap What: Trim press alarms
Why: Robot off at trim press
Counter measure: Taught robot What: Trim press alarms
Why: Water on sensor
Counter measure: Blew off sensor What: Trim press alarms
Why: Numbers on Amplifier for sensor seeing if shot left in trim die keep going down when water gets on sensor.
Counter measure: Blew water off sensor What: Trim press alarms
Why: Puts shot and alarms. Due to two rang sensors have to go from green to yellow and back to green
Counter measure: adjusted sensors What: Trim press alarms
Why: Scrap press part present sensor
C/M: Tested new sensor with new reflector, OK. Replaced reflector What: Trim press alarms
Why; Blue conveyor not coming back fast enough. Getting stuck at dump position
Counter measure: Re aligned chain and adjusted tightness What: Trim press broke parts, Trim Press Faulting out.
Why:
Countermeasure:
Will Problem Reoccur?:
Cycle Time: No Change. What: Trim press build up. (Breather cover)
Why: One of tab ramps bent bad
Counter measure: Pulled ramp and bent back straight. Bolts were broke off in press. Tack welded ramp in
R/C: Yes junk ramps. What: Trim press chutes jammed full of parts
Why: Part got jammed
Counter measure: Un jammed
R/C: No
Cycle time: Unchanged What: Trim press clamp hydraulic pump making noise
Why: Root cause Unknown
Countermeasure: Took pump apart and cleaned then reassembled OK What: Trim press clamp pump making noise
Why: Loosing prime
Counter measure: Bleeder screw was leaking. Bled system and tightened bleeder screw What: Trim press crashed.
R/C: Cavity 1 left a part behind and double stacked.
C/M: Got parts out and checked trim press ok.
Reoccurrence: NO What: Trim press crushed RPY parts.
Root Cause: Left scrap on trim-press.
Countermeasure: Put Loctite on all the upper blocks bolts. And adjusted air blows.
Will Problem Reoccur?: no What: Trim press cutter broke
Why: Unknown
Counter measure: Replaced cutter
R/C: Unknown
Cycle time: Unchanged What: Trim press cutter broke (RPY 1RKR trim #1)
Why: Aluminum wedged in cutter
Counter measure: Replaced cutter
R/C: Unknown
Cycle time: unchanged What: Trim press cycle timing over
Why: Press not returning after pressing out parts and then alarms with no fault
c/m: changed trim die What: Trim press cylinder boot ready to fall off
Why: Possibly didnt have set screws tight or jam nut
C/M: Readjusted boot and nut and tightened set screws
Recur: Possibly in time What: Trim press cylinder drifting
Why: Cylinder bad
Counter measure: Replaced cylinder What: Trim press cylinder nut stuck for adjustment
Why: Rusted on
Counter measure: Cut nut off and replaced cylinder with spare from die cast #5
R/C: No
Cycle time: Unchanged What: Trim press damage
Why: After pressed out shot overflows being left in press
C/M: Adjusted air blows and removed one due to blowing overflows back up on top
Machine was running while adjustments What: Trim press damage
Why: Flashing- Shot was difficult to manually put in trim press but parts were in specd
C/M: Cleaned die and removed bottom slide cores which weren't moving by hand, cleaned sl What: Trim press damage
Why: Robot point
Countermeasure: Taught P25 and P26
R/C: No
Cycle time: Unchanged What: Trim press damage
R/C:
C/M:
will it reoccur: What: Trim press damage Die 6A0-s
Why: Cutter needed adjustment
Counter measure: Adjusted cutter and taught p25,26,27 on robot
R/C: No
Cycle time: Unchanged What: Trim press damage cav #4, Die 3
Why: Bad cutters
Counter measure: Replaced all main runner cutters for tappets.
R/C: Yes time
Cycle time: Unchanged What: Trim press damage on parts
R/C: build up of scrap on trim press
Countermeasure: follow up on countermeasure installed. Air pressure for #36 adjusted down to middle range. Moved portion of air bl What: Trim press damage to parts 1 & 3
Why: Shot not fitting into press cavities well
C/M: Removed and cleaned necessary parts (for better fit) and readjusted robot position What: Trim press damage, P1 & S2
Why: Poorly designed trim press?
C/M: Adjusted guides & cutters
Recur: What: Trim press damage. 5BA P/S
Why: Ejector pins bushing bad holding shot up in trim press
Counter measure: Changed die
R/C: yes time
Cycle time: Unchanged What: Trim press damaged. See W.O 52970 What: Trim press damaging parts
Why: Chutes on right side of trim press from operator door smashed and mangle causing scrap to pile up
C/M: Removed chutes, straightened as best as possible and tack w What: Trim press deceleration position sensor smashed
Why: Prior crash
C/M: Replaced sensor What: Trim press die (5A2 P-M K068 14010-1)
Why: Part getting stuck in die
Root cause: Shoot under bottom trim bent and holding parts
Countermeasure: Bent back into place
R/C: Yes if it gets bent
Cycl What: Trim press does not run in auto.
Why: Wiring issue related to M/C re-location.
C/M: Identify wiring issue and correct it. What: Trim press double stacking
Why: Back sensor adjusted too close to edge of part, causes robot to release shot and crash back into it
C/M: Adjusted where sensor was aimed What: Trim press drifting
Why: Cylinder leaking by
Counter measure: Replaced trim press cylinder What: Trim press drifting
Why: Root cause undetermined, still drifting after new cylidner and solenoid What: Trim press drifting down
Why: Cylinder seals NG
C/M: Replace cylinder with Ryan B. What: Trim press drifting off of return sensor after about 1 minute of sitting, trim press not returning after pressing parts
Why: Cylinder NG, internally blowing by
C/M: Change trim press cylinder What: Trim press faulting
Why: Sensor looking across press loose, causing reading to change
C/M: Lined up and tightened transmitter side. Adjusted set point What: Trim press faulting every couple cycles
Why: Sensor looking across shot picking up part too much.
C/M: Realigned and adjusted amplifier with Sergio A. What: Trim press faulting for full work
Why: Sensor bracket loose causing number to fluctuate
C/M: Tighten bracket What: Trim press faulting out
Why: Bent paddle blocking sensor underneath conveyor
C/M: Removed bent paddle What: Trim press faulting out
Why: Flashing on shot causing it to not sit well in trim press
C/M: Tried touching up RB position, did not help What: Trim press faulting out almost every cycle
Why: Trim press not getting down position, Top hat threading off cylinder causing stroke to be different and jamming press down
C/M: Ran top hat back u What: Trim press faulting out for left over trim
R/C: trim left on trim press
C/M: adjusted air lines to clean off tree off trim press and reconnected right side air line to release full amount of air What: Trim press faulting out for part detect
Why: Shot hitting on die when coming down to set shot in press
C/M: Touched up position 4 so it was coming in and down rather than coming in at an angle a What: Trim press faulting out.
Why: Small scrap press sensor not reading correctly.
Countermeasure: Replaced sensor reflective plate. What: Trim press faults
Why: Air blow not getting all parts off after pressing
C/M: Adjust air blow What: Trim press faults
Why: Robot not sitting them in press correctly
C/M: Retaught at trim press had to make alot of changes. had line numbers not matching so i changed so when you teach a line it t What: Trim press faults.
Why: Scrap press Jam sensor reflector out of position, (X99).
C/M: Re-align Reflector.
Will it Re-occur: Un-determined. What: Trim press flipper #1 not flipping
Why: Flipper stud broke
Counter measure: Made a stud
R/C: Yes time
Cycle time: Unchanged What: Trim press guide broke
Why: Double stacked part
Counter measure: Replaced guide
R/C: Yes time
Cycle time: Unchanged What: Trim press guide fell off
Why: Bolts broke
Counter measure: Replaced bolts What: Trim press guide fell off
Why: Weld broke
Counter measure: Welded back on
R/C: Yes
cycle time: Unchanged What: Trim press height 5BA
Why: Bad design trim press
Counter measure: Adjusted all 4 cutters to get in spec
R/C Yes
Cycle time: Unchanged What: Trim press height NG
R/C: Trim press missing multiple guides and blocks to cut parts correctly
C/M: Removed trim press and installed a different trim press to correct issue. Tagged old trim pres What: Trim press high
Why: Cutter out of adjustment. I think this trim press had not been in a machine yet (6A0 M #1)
Counter measure: Adjusted cutters
R/C: Yes time
Cycle time: B-25.2 A-25.2 What: Trim press hose leak
Why: Hose had hole in it
Counter measure: Replaced hose
R/C: yes time
Cycle time: Unchanged What: Trim press hydraulic pump noisy
Why: Clogged intake filter
C/M: Disconnected coupler to check for smooth rotation on pump. Changed filter What: Trim press hydraulic pump noisy
Why: Clogged intake filter
C/M: Replaced filter What: Trim press hydraulic suction filter squalling
Why: Oil hasnt been changed and clogged filter
C/M: Changed filter What: Trim press hydraulic system cleaning.
C/M: Drained oil and cleaned out tank. Replaced return filter and replaced inlet filter with old one of DC 1 that I cleaned. Also cleaned oil cooler and fil What: Trim press hydraulic system cleaning.
C/M: Drained out oil and cleaned tank thoroughly. Replaced return filter and cleaned and reused inlet filter due to not having one. Cleaned oil cooler and t What: Trim press in down position, won't go to home position
Why: Hydraulic pump is not running
C/M: Replaced 2 bad relays What: Trim press issue
Why: Biscuit not falling out after trimmed
Counter measure: Removed bolt from cutter that was holding biscuit in place after trim What: Trim press issue
Why: Damaged part
Counter measure: Pulled and replaced. Checked set down ramp in back needed adjusted What: Trim press issue
Why: Flipper 3 broke off
Counter measure: Welded back on What: Trim press issue
Why: Guide pin broke off
Counter measure: Replaced pin What: Trim press issue
Why: Leaving mark on cavity 4
Counter measure: Replaced guide in trim press What: Trim press issue
Why: Robot double stacking shots. Leaving un pressed shot in trim press
Counter measure: Re taught robot and adjusted part detect sensor and changed relay for down What: Trim press issue
Why: Shot not setting right
Counter measure: Re taught set down in trim press What: Trim press issue
Why: Trim height
Counter measure: Adjusted S-2 cavity cutter What: Trim press issue
Why: Upper plunger jammed
Counter measure: Replaced spring in plunger that hold shot What: Trim press issue
Why: Breather cover sticking to top pin
Counter measure: Cleaned pin off What: Trim press issues
Why: Ejector position not changed back after a lot mark change
Countermeasure: Changed program to read correctly What: Trim press issues
Why: Scrap press part detect sensor was not working
Countermeasure: Replaced sensor What: Trim press issues on T20
Why: 2 out of 3 spring pins locked up and not making contact with part properly before pressing. Cylinders that push part into back of press tilting part What: Trim press issues reported by first shift operator. Cavity P1 getting damaged
Why: Trim die was not centered, build up on trim die
Countermeasure: Aligned trim die and cleaned cavity What: Trim press issues.
Why: Amplifier display shows erh, indicating amp cannot communicate with sesnor heads.
C/M: Replace sensor heads, route cables in different fashion, this required placing the What: Trim press keeps alarming
Why: Turn table wasn't turning causing it to alarm
C/M: Got turn table moving again What: Trim press kicking out OK parts
Why: After examining the trim press and robot PLC logic found Y79 out to robot not coming on, this is caused by X5B not being sent out from the trim press. Y79 re What: Trim press leaking
Why: Hydraulic DCV stack leaking. (Block)
Countermeasure: Replaced manifold block and O rings and checked for leaks ok
Will it reoccur: No
cycle time: unchanged What: Trim press leaking off during full auto
Root cause: Trim press cylinder leaking.
Countermeasure: Replaced cylinder
Reoccurrence: No
Cycle time: Before 27.2 after 27.2 What: Trim press leaving mark on part
Why: Cutter to tight
Counter measure: Removed .500 shim and put in a .200 shim What: Trim press leaving part of shot in trim press
Why: Cutter broke, replaced cutter with non inventory part. What: Trim press leaving tree (Water passage)
Why: Robot position
Counter measure: Touched up PR64
R/C: No
Cycle time: Unchanged What: Trim press left start button pressed down and stuck.
Why: Button was unthreaded and loose.
C/M: Tightened down button and it popped right back up into place. What: Trim press letting #2 cavity threw on preheats
Why: Xoc stuck on robot press keeping M202 on
Counter measure: Replaced cube relay CRY93 in robot panel
R/C:
Cycle time: Unchanged What: Trim press loading issue
Why: Found wrong cutter on trim press, robot dragging against wrong cutter
C/M: Replaced with proper cutter What: Trim press locate pin broke
Why: Shot left in press
C/M: made sure sensors working properly
Recur: Possibly in time What: Trim press looses Master.
Why: Undetermined. Trouble indication not evident.
C/M: Replaced Y060 relay in Master On hardwire circuit. What: Trim press loosing master power What: Trim press making noise.
Why: Hydraulic suction filter clogged up.
C/M: Replaced suction filter. What: Trim press missing upper guide #5. (RPY One rocker)
Why: Broke bolts off and is missing.
Counter measure:
R/C: Yes
Cycle time: Unchanged What: Trim press motor OL alarms
Why: Scrap conveyor jammed
C/M: Ran conveyor back and forth several times to clear stuck scrap, removed scrap What: Trim press motor overload
Why: Scrap conveyor 1 jammed
C/M: Manually made conveyor run backwards to clear tab from the sprocket. Tightened some of the slack out of the conveyor. What: Trim press moving slowly
Why: Started only on the return side got worse the more it was moved. Found pump has very little pressure What: Trim press not cutting
Why: Trim comes down but has no force to cut. Due to cylinder bolts broke off
Counter measure: Replaced bolts
R/C: No
Cycle time: Unchanged What: Trim press not cycling in auto
Why: Sensor not seeing shot right
C/M: Realigned sensor and adjusted range What: Trim press not going down in auto
Why: R064 relay for advance bad
Counter measure: Replaced relay
R/C: Yes time
Cycle time: Unchanged What: Trim press not homing
Why:
Counter measure: What: Trim press not homing, light just flashing.
Why: Unknown, didnt have up or down light.
C/M: Manually hit valve to to return cylinder up, homed after hitting valve and got our light. What: Trim press not putting any parts on table
Why: Range sensors were not seeing parts due to bracket being loose
Counter measure: Tightened and aligned sensors
R/C:
Cycle time: Unchanged What: Trim press not return home position
Why: Up sensor not touching cylinder
C/M: Moved sensor bracket to touch cylinder
Recur: Possible in time What: Trim press not returning up
Why: Bad relay
Counter measure: Replaced down relay What: Trim press not seeing part properly.
Why: Sensors in trim press were misaligned.
C/M: Adjusted sensors and confirmed by maunally putting in a part. What: Trim press not separating parts. Operator found metal piece
Why: Weld broke
Counter measure: Welded it back on
R/C: Yes time
Cycle time: Unchanged What: Trim press not working
Why: Bad relay RO64
Counter measure: Replaced Relay RO64 What: Trim press nut came off
Why: Came loose
Counter measure: Put back on What: Trim press only pressing every other part.
Why: Okay conveyor not dumping parts.
Countermeasure: Repaired okay conveyor. What: Trim press operating slow and vibrating. Hydraulic pump front seals leaking bad
Why: Pump went bad
counter measure: Replaced hydraulic pump
R/C:
Cycle time: Unchanged What: Trim press overflow slide damaged
Why: Overflow build up
C/M: Re- welded slide
Recur: Possibly in time What: Trim press panel saying weight scale full
Why: Liquid tight and wiring got burnt and melted due to aluminum slag pan right next to the electrical wiring
C/M: Chuck Winter and I Replaced and re- What: Trim press part detect issues
Why: Sensor alignment and amp adjustments needed
C/M: Aligned sensors to more fully see beam and found that channel 2's settings were off on the amp. Adjusted amp a What: Trim press part detect sensor issues after changeover
Why: Sensors had been adjusted for previous model
C/M: Calibrated amp and adjusted both channels. What: Trim press pressing the part but not returning to home position
Why: There are 2 sensors at the bottom upper one detects the slow down of press and the other is for final press position The slow What: Trim press problem. See W.O 53326 What: Trim press product detect sensor not aligned properly
Why: Transmit side mounting bracket loose causing sensor to go out of alignment
C/M: TIghtened bracket down and realigned sensors What: Trim press pump making noise
Why: Coupler broke
Counter measure: Machined new coupler What: Trim press pump making sound
Why: Suction filter no good
C/M: Replaced filter What: Trim press quality issues cavitoes 2 and 4
Why: Ongoing issue
Countermeasure: Pulled press due to build up in bolt holes, cleaned out all cutters and adjusted cavities 2 and 4
Will problem reocc What: Trim press quality issues on cavities 1 and 3
Why: Ongoing issue
Countermeasure: Adjusted cutters
Will problem reoccur: Possibly
Cycle time: No change What: Trim press randomly not working
Why: Burnt relays & possible bad directional valve
C/M: Replace relays
Recur: In time w/wear What: Trim press scaring part (Cavity #2 part) 59B Die #1
Why: debris stuck in cutter
Counter measure: Cleaned cutter out
R/C: Yes time
Cycle time unchanged What: Trim press scrap conveyor belt is seized.
Why: Shot fragment stuck in conveyor link
Countermeasure:Remove conveyor from trim press and remove debris
Reoccur: Yes What: Trim press sensor abnormal fault
Why: Faulty sensor
Root cause: Sensor shorted internally
Countermeasure: Replaced "UP" Sensor on trim press cylinder
Cycle time before: 25.5
Cycle time after: 25 What: Trim press sensor issues
Why: Flashing building up on shot and blocking trim press part detect sensor
C/M: Had operator clean die and adjusted channel 1 of amp to further allow for more toleranc What: Trim press sensor issues
Why: Robot leaking tree and coming back and crashing into tree
C/M: Tried adjusting back sensor toward scrap conveyor to get FULL WORK if tree is left behind, still happ What: Trim press set down detect sensors not seeing good part properly, robot chuck sensor flickering
Why: Sensor for part detect in trim press loose and moved, settings also got changed. Robot chuck What: Trim press smashing parts
Why: Robot program positions in trim press NG
C/M: Touched up P[23], P[24] and P[25] What: Trim press stopped
Why: CP3 tripping due to relays for scrap press
Countermeasure: Replaced both relays. They were bad
R/C: No
Cycle time: Unchanged What: Trim press stopping
Why: Down relay bad
Counter measure: Replaced Down Relay What: Trim press stopping before press cycle starts
Why: OK carrier jamming before advance end, parts building up on OK conveyor
C/M: Readjust OK conveyor position to stop parts from jamming What: Trim press stopping in the middle of stroke
Why: Root cause unknown, occurs in the middle of preheats What: Trim press stuck down
Why: Up limit switch stuck on due to oil and flashing on it
Countermeasure: Cleaned up limit switch and returned home What: Trim press throwing all parts away
Why: Robot D10 Output to X8E trim press not there ran temp wire. Wrote line 198 in robot program What: Trim press unloader issue
Why: Not clamping on part
Counter measure: Adjusted arm plate to pick up parts. On the up down to vertical cylinder What: Trim press upper plunger spring broke. 5BA Ten #1
Why: Got shot piece stuck in end
Counter measure: Replaced spring
R/C:
Cycle time: Unchanged What: Trim press will not get home position
Why: Part transport cylinder out of cycle
C/M: Manually cycled trim press unload cylinder and got it to home What: Trim press will not return up
Why: Bad relay
C/M: Day shift replaced defective relay What: Trim press won't power on
Why: Melted sensor wire on conveyor
C/M: Replaced sensor and reset breaker What: Trim press wont go down
Why: Down relay bad
Counter measure: Replaced relay (SCY064)
R/C: No
Cycle time: Unchanged What: Trim press wont start.
Why: Sensor x416 was being made thinking a part was there.
C/M: Adjusted sensor and confirmed gets made with part. Also had to adjust the down sensor on press cylinder...( What: Trim press work full.
Why: Sensor loose.
Countermeasure: Adjusted shot detect sensor to see the shot but not when it has no shot. What: Trim press, CP 3 trips.
Why: Wire R100 feeding Scrap press circuit pulling 5 Amps, CP 3 is a 3 Amp breaker.
C/M: After refeeding this circuit with a 10 Amp fuse for troubleshooting purposes, the What: Trim problem
Why: No water in dunk tank. From Pm done today
Counter measure: Filled tank and polished trim die What: Trim problem
Why: Robot needs taught
Counter measure: Taught robot What: Trim problem
Why: Scraping part Cavity 1
Counter measure: Adjusted cutter and guide What: Trim problems
Why: Robot not sitting shot in correctly
C/M: Retaught robot positions 25,26
Recur: Possibly in time What: Trim pump making noise when running
Why: Suction filter no good
C/M: Replaced filter
Recur: Possibly in time What: Trim punches leaving marks on all parts
Why: Wrong top punches didn't match drawing
C/M: Took up to Matt Kline to have him machine them
Recur: NO What: Trim-press damage. See W.O 53425 What: Trim-press lost home while running in auto.
Root cause: Dirty sensor.
Countermeasure: Cleaned shot detect sensor.
Monitored, Okay. What: Trim1 5BA-S cavity 1, 2 and 5BA-P cavity 2 trim issues.
Why: Changed to Trim Die 2
Countermeasure: Change to Trim die 2. What: Trimpress and scales alarming (scale flashing red quickly)
Why: Red flashing quickly indicates scrap conveyor jam sensor
C/M: Had to readjust jam detect sensor on bottom side of scrap conveyor What: Trimpress faulting
Why: Part detect damage in trimpress. Sensors closest to robot
C/M: Replace sensors What: Trimpress motor overload alarm
Why: Small scrap conveyor jammed
C/M: Worked it free manually What: Trouble loading ingots
Why: Ingot loader out of alignment
C/M: Took spud bar moved it in some toward furnace What: Trouble with Seismograph going off for no reason
Why: Location inside cabinet
C/M: Relocate What: Trouble with casting pressure
Why: Nitrogen was low
C/M: Added nitrogen
Recur: Yes in time What: Trouble with flipper that directs scrap to buckets
Why: Hole in soft air line running to valve for flipper
C/M: Replace air line What: Trying to season in melting but wouldnt get up to temp.
Why: Melting burning wasnt actually firing.
C/M: There is a burner reset on the side of panel, did that and was able to get burner to fire What: Turn table 1 not moving
Why: Found cable running from junction box back to cabinet NG, broken wires. When metering betweeen legs voltage ranged from 150V to 210V. Motor would move when jumping b What: Turn table 1 not turning
Why: Bad relay and blown fuses
Countermeasure: Replace relay and fuses
Reoccur: Possible What: Turn table 2 would not turn.
Why: Broke 4 bolts.
Countermeasure: Removed broken bolts. Repaired. Installed and tested - Good. What: Turn table motor shaft broke
Why: Worn
C/M: Replaced shaft and Chain What: Turntable not working/turning
Why: Not sure
C/M: Pulled chain off and Checked make sure shaft wasnt broke installed chain and now ok What: Turntable 1 locked up
Why: Wear and age
Countermeasure: Swapped table out for spare
Will problem reoccur: Yes in time
Cycle time: No change What: Turntable 1 will not rotate
Why: Table was jammed on separator
Countermeasure: Unjammed table
Will problem reoccur: Possibly
Cycle time: No change What: Turntable 2 not rotating
Why: The 4 bolts that hold the table down had broke
Countermeasure: Removed broken bolts and replaced with new
Will problem reoccur: Possibly
Cycle time: No change What: Turntable motor overload
Why: motor locked up
C/M: Kick started motor and had to order new one
Recur: Possibly in time What: Under pour and die cleaning
Why: Sleeve turned and die dirty
Counter measure: Adjusted sleeve and cleaned die.
R/C: No
Cycle time: Unchanged What: Under pour at sleeve
Why: Sleeve turned
Counter measure: Turned sleeve back What: Unload conveyor bad
Why: Belt bad
Counter measure: Replaced mess belt What: Unload conveyor not moving
Why: Conveyor chain ran up over guard
C/M: Pushed conveyor back down under guard/ Also took motor off to make sure it wasn't bad
Recur: Possibly in time but ok now What: Unload conveyor stopped
Why: Piece of runner got stuck in chain
Counter measure: Took piece out
R/C: Yes
Cycle time: Unchanged What: Unload table
Why: Tabs got stuck on edge of table
Counter measure: Took tabs out and cleaned under table
R/C: Yes time
Cycle time: Unchanged What: Unload table motor over load
Why: Table stopping
Counter measure: Swapped table with spare rebuilt
R/C: Yes Time
Cycle time: Unchanged What: Unload table not turning
Why: Broken bolts in turn table
Countermeasure: Remove table top remove broken bolts and replace with new bolts
Reoccur: Possible What: Unload table stopped
Why: Full of flashing
Counter measure: Cut more slots in side of table to be easier to blow out under it
R/C; Yes time
Cycle time: Unchanged What: Unload table stopping
Why: Nut came loose to sprocket
Counter measure: Tightened nut
R/C: Yes time
Cycle time: Unchanged What: Unload table stopping
Why: Top part of chain belt to tight
Counter measure: Skipped belt to put a little slack on top What: Unload table stopping and alarming
Why: Table divider too low
Counter measure: Raised divider
R/C: Yes time
Cycle time: Unchanged What: Unloading arm will not advance to the press
Why: Trim press return light not coming on
C/M: Adjusted sensor out more to read the flag What: Unloading conveyor stopped
Why: Chain mesh bad
Counter measure: Replaced Sprockets and chain What: Unloading robot positioning off at the punch, having trouble getting it to hold position after touchup, sometimes the part will drift too low and miss the punch, other times the part will be bro What: Unloading table alarm
Why: Table not turning
Counter measure: Pulled table top and replaced 4 roller bearing table rides on
R/C:
Cycle time: Unchanged What: Unloading table jamming
Why: Disk bad that parts lay on
Counter measure: Replaced table disk What: Unloading table not turning
why: Bolts broke to table plate, 2 rollers NG under table top
c/m: Replaced worn bearings, Removed in installed new table top bolts
will it reoccur; timing
cycle ti What: Unloading tables stopped
Why: Flashing under turn table.
Counter measure: Cut some openings to blow flashing out
R/C: Yes
Cycle time: Unchanged What: Updated Plug install
why: Safety/Reduce downtime
c/m: Replaced old style upper crucible stack with updated plug style. Ran wiring for locking cylinder countermeasure. What: Upon removing die for oil leak dh found sleeve to be bad.
Why: Water was turned off for cooling joint on sleeve.
R/C: Unknown why water was shut off.
C/M: Replaced tip and sleeve.
R/O: Yes there What: Upper Aluminum probe wires bad
Why: From heat
Counter measure: Replaced with ladle probe wire
R/C: No
cycle time: Unchanged What: Upper Crucible AL01 alarm on temp controller.
Why: Short on wires.
Countermeasure: Replaced wires, metal braided cable and thermocouple (Broken screws could not terminate wires).
Will Problem What: Upper Crucible not heating up.
Why: High Pressure Gas valve not shifting.
Countermeasure: While troubleshooting valve unable to reproduce issue. What: Upper and lower crucible changed
Why: Corundum build up
Root cause: Dog house door not meeting filter causing cool air to run up half pipe and cause corundum to build up from non scraped aluminu What: Upper burner stops with melting metal upper limit disconnection alarm.
Why: wires to the upper limit probes shorted out
Counter measure: replaced wires to probes
R/C:
Cycle time: Unchanged What: Upper crucible
Why: Upper thermo coupler fell out.
Countermeasure: Took out holder and welded it. Thermo couple got damaged when it fell out. Replaced it
R/C: No
Cycle time: B-26.7 A-26.7 What: Upper crucible Failure.
Why: Ingot impact during empty loading caused movement in the crucible. 3 of the wedges became out of position and the crucible rotated out of center with the halfpipe. C What: Upper crucible Metal leak,Hole in the crucible side.
Why: Appears to be impact from an ingot.3 inch hole in the crucible side by the spout.
Countermeasure: Replace Upper crucible and Halfpipe
R What: Upper crucible aluminum not melting correctly
R/C: Temperature for exhaust on melting crucible reading at 932 shutting burner off before aluminum up to correct temp.
C/M: adjusted thermocouple o What: Upper crucible and halfpipe was cracked
Why: Upper was low on aluminum when ingots were dumped
Countermeasure: Replace upper and lower crucibles.
Reoccur Yes What: Upper crucible broke
Why: Ingot was dropped in empty and Cracked Crucible
Counter measure: Replace upper crucible and JR Otto talking with production on counter measure.
R/C: Yes Operator error
What: Upper crucible broke
Why: Operator loaded empty and put ingot thru side of crucible
Counter measure: Replaced upper crucible and stand replaced halfpipe, patched furnace floor. Repaired tower l What: Upper crucible broke
Why: Operator put ingot threw upper crucible
Counter measure: Replaced upper and lower for P/M
R/C: Yes
Cycle time: Unchanged What: Upper crucible broke . 1st shift
Why: Dropped ingot in empty and broke pedestal and knocked wedges out. Cracked spout on crucible
Counter measure: Replace upper crucible
R/C: Yes Operator error
What: Upper crucible broke. 2nd shift
Why: Ingot into empty crucible
Counter measure: Replace crucible
R/C: Yes operator error
Cycle time: Unchanged What: Upper crucible burner not kicking on.
Why: Temp not reading right.
Countermeasure: Thermocouple pulled too far out not getting correct reading. What: Upper crucible cant be loaded
Why: Sensor for How much aluminum in melting pot not detecting
Counter measure: Re-set adjustments
R/C:
Cycle time: Unchanged What: Upper crucible change. What: Upper crucible cracked and leaking.
Why: Unknown
Countermeasure: Replace upper crucible, Lower crucible and halfpipe. What: Upper crucible cracked. ( molten metal leak) Lower crucible filter broke
Why: unknown
Countermeasure: Replace upper and lower and seasoned on 3rd What: Upper crucible flame is big
Why: Air fuel mix was off
Counter measure: Adjusted pilot and main gas to upper
R/C:
Cycle time: Unchanged What: Upper crucible ingot sensor got moved to out side of crucible
Why: Unknown
Counter measure: Moved to see in crucible for ingots and scrap
R/C:
Cycle time: Unchanged What: Upper crucible leaking
Why: Broke half pipe
Counter measure: pulled upper crucible What: Upper crucible lid broke
Why: Center fell out of lid and damaged thermo coupler
Counter measure: Welded lid and replaced thermo coupler
R/C:
Cycle time: Unchanged What: Upper crucible lid falling apart
Why: Welds let go
Counter measure: Re-welded
R/C:
Cycle time: Unchanged What: Upper crucible lid opening slow
Why: Speed control valve broke
Counter measure: Replaced valve
R/C: No
Cycle time: Unchanged What: Upper crucible lid slamming shut
Why: Most air fittings from DCV were very loose. Cylinder blow bye. Check valves leaking too
Counter measure: Re-tapped most of fittings for air and tightened .R What: Upper crucible load sensor not set right
Why: Settings wrong
Counter measure: Set settings. Checked with ingot and with out and with lid closed What: Upper crucible metal leak
Why: 2 Wedges knocked from position, crucible spoutand halfpipe cracked when crucible shifted
Countermeasure: Replace upper and lower crucibles and halfpipe. Repair re What: Upper crucible not firing
Why: Upper limit fault won't reset
C/M: Moved wires in cable clamp and upper limit cleared. Added wool to cable clamp to secure cable in clamp. If further faults occur What: Upper crucible not melting aluminum properly
Why: Melting temperature not getting high enough, exhaust temp reaching upper limit too fast, kicking off melting burner.
C/M: Replaced exhaust temp What: Upper crucible not melting fast enough
Why: Possible gas to air ratio no good
C/M: Set gas and air to what die cast 1&2 are
Recur: Possibly in time unless others keep adjusting What: Upper crucible not melting right. Alarm AL 01
Why: Broken Thermocouple wire
Counter measure: Re terminated wire
R/C: Yes time
Cycle time: B-27.0 now 27.0 What: Upper crucible over heating
Why: Rest mode was on
Counter measure: Turned rest mode off. With rest mode on the lower thermo coupler for upper must not be in use
R/C: Yes if switch is turn on
Cyc What: Upper crucible plug broke
Why: Operator ran plug over
Counter measure: Replaced plug What: Upper crucible sensor not seeing material.
Why: Not receiving a good reflection from the sensor up above the crucible.
C/M: Adjusted the sensor to be aimed more towards the center to get a bette What: Upper crucible showing red on Furnace outer area
Why: corundum build up not letting heat escape due to splash up from loading empty
c/m- replace upper crucible and half pipe
reoccur- yes What: Upper crucible spout plugged
Why: Corundum around spout. Cause by draft from no bounding material on top of filter to dog house door
Counter measure: Replaced upper crucible and added bonding m What: Upper crucible thermo-coupler not reaching temp. Why: Unknown. What: Upper crucible tower stuck
Why: Cant get it to roll due to exhaust piping
Counter measure: What: Upper crucible wool leaking
Why: Upper crucible had excessive corundum build up on top of crucible causing super heating of the aluminum and upper crucible not being able to vent properly.
Coun What: Upper did not know it is all the way forward.
Why: Bracket limit switch hits broke off.
Countermeasure: Welded bracket back on.
Will Problem Reoccur?: No.
Cycle Time: No Change. What: Upper flame not burning right
Why: Too much gas
Counter measure: Adjusted pilot valve What: Upper flame out
Why: Photo eye dirty
Counter measure: Cleaned eye What: Upper furnace lid not operating
why- bad connection in cannon plug for wiring
c/m- unplug and plug back in cannon plug
reoccur- yes What: Upper furnace not firing.
Why: No pilot flame
Counter measure: Pulled burner again and found that igniter rod was touching side. Bent igniter rod so it was more in center of porcelain star end
What: Upper furnace not heating up
Why: Upper limit wire broke at termination
Counter measure: Re terminated wire What: Upper furnace not igniting
Why: Igniter touching side
Counter measure: Pulled burner and cut igniter down so it just sticks out of porcelain end and pointed it.
R/C:
Cycle time: Unchanged What: Upper furnace not melting
Why: Gas solenoid not opening all the way
c/m- replace main burner right solenoid
reoccur- in time What: Upper furnace not turning off
Why: Upper lid termo coupler can apart in side
Counter measure: Replaced bell thermo coupler and fixed upper lid one What: Upper ladle arm bearing fell apart
Why: Worn out
C/M: Replaced all upper arms and lower unit with rebuilt ladle arms What: Upper lid broke
Why: Center fell apart
Counter measure: welded and reattached What: Upper lid drifting off
Why: Bad cylinder
counter measure: Replaced cylinder
R/C; Yes
Cycle time: Unchanged What: Upper lid drifting off when safety door open
Why: Hose and needle valve leaking
Counter measure: Replaced needle valve and hose
R/C: Yes time
Cycle time: Unchanged What: Upper lid drifting off. Safety problem
Why: Upper lid solenoid bad
Counter measure: Could not locate one in inventory. Took apart and moved seals around to make neutral position hold.
R/C Yes te What: Upper lid electoral box caught fire
Why: Flashing in box. Caused short
Counter measure: Replaced terminal strip. Cleaned box and plugged hole in bottom of box What: Upper lid not opening
Why: Bad solenoid valve
Counter measure: Replaced solenoid valve What: Upper lid not opening
Why: Cylinder bracket weld broke
Counter measure: Replaced bracket from spare
R/C:
Cycle time: Unchanged What: Upper lid opens when de-energized. (push button for entry and lid opens)
Why: Manifold for solenoid has crack between ports
Counter measure: Replaced manifold with one out of scrap area
R/C: No
What: Upper lid thermo coupler alarm AL01
Why: Thermo coupler loose and mount for thermo coupler loose
Counter measure: Tightened mount and thermo coupler stopper bolt and terminals
R/C: Unknown
Cycl What: Upper limit alarm
Why: Wires bad
C/M: Replaced the wiring What: Upper limit alarm staying on
Why: Cable bad from main panel to junction box
C/M: Ran temporary cable to see if that was the cause and it was so i ran a new cable in liquid tight and tested to ma What: Upper limit not faulting out on crucible.
Why: Wire broke.
Countermeasure: Replaced wiring for crucible level. What: Upper limit not working
Why: Wire broke
Counter measure: Re-terminated
R/C: Yes time
Cycle time: Unchanged What: Upper limit not working
Why: Wire broke
Counter measure: Re-terminated wire
R/C: Yes Time
Cycle time: Unchanged What: Upper limit probe not alarming out
Why: Wire bad
Counter measure: Replaced wire with ladle probe wire
R/C: No
Cycle time: Unchanged What: Upper limit probe wire broke
Why: Terminal wire broke
Counter measure: Re-terminated wire and replaced detect probe
R/C: No
Cycle time: Unchanged What: Upper limit probe wires broke
Why: Heat
Counter measure: Replaced with better wire What: Upper limit probe wiring bad
Why: Wire coating fell off causing wire to touch fault melting furnace
C/M: Replaced wiring and made new bracket for wires
Recur: Possibly in time What: Upper limit probes to short
Why: erosion and wear
C/M: Replaced with new
Recur: Possibly in time What: Upper limit probes too short
Why: Melted off
Counter measure: Replaced probes and made new holding block for probes
R/C: Yes time
Cycle time: Unchanged What: Upper limit probes too short
Why: Melted off
Counter measure: Replaced upper limit probes and made new holding block for probes
R/C: Yes time
Cycle time: Unchanged What: Upper limit staying on
Why: EC1 relay no good
C/M: Replaced relay with new What: Upper limit switch actuator bent for remelt bucket dump
Why: Arm out too far, bent arm
C/M: Replace arm non-inventory unit What: Upper limit wire break
Why: Wire broke inside line
C/M: Cut wiring back ran into terminal box so easier to change out if needed
Recur: Possibly in time What: Upper limit wires for crucible broke
Why: Coating broke off of wires and were touching each other due to heat
Counter measure: Replaced wire with ladle wire. Because it with stands heat better
R What: Upper metal leak
Why: Leaking aluminum
Counter measure: Ran out of aluminum What: Upper metal leak
Why: No aluminum just aluminum dust made connection
Counter measure: Cleaned out dust
R/C: No
Cycle time: Unchanged What: Upper metal leak
Why: Unknown
Counter measure: Cleaned out bottom. Was only a part size of aluminum across probes What: Upper metal leak
Why: Unknown
Counter measure: Cleaned under crucible. Nothing leaking What: Upper metal leak alarm
Why: Rods were touching
Counter measure: Moved rods so they dont touch What: Upper metal leak. Bad leak
Why: Spout to half pipe leak
Counter measure: Emptied lower and pulled upper crucible out
R/C:
Cycle time: Unchanged What: Upper sensor for loading not letting us load
Why: Distance angle not right
Counter measure: Adjusted sensor angle to see scrap What: Upper spout broke
Why: Time
Counter measure: PM What: Upper stack wiring replacement countermeasure
why: downtime/ plug wiring trouble
c/m: Removed and installed new replacement double braided line and new lockable fittings What: Upper stopped melting
Why: Aluminum was dripped on probes for upper limit in lower. Causing it not to fire upper
Counter measure: Cleaned off probes What: Upper temp alarm wire break
Why: Wire bad
Counter measure: Replaced wire
R/C: No
Cycle time: Unchanged What: Upper thermo couple reading low
Why: Mount broke that holds thermo coupler
Counter measure: Replaced mount
R/C: No
Cycle time: Unchanged What: Upper thermo coupler alarm
Why: Pug to tower had a wire broke
Counter measure: Soldered wire in plug
R/C: Yes This plug gets turned wrong and pulls wires out of plug
Cycle time: B- 27.1 now 27. What: Upper thermo coupler alarm
Why: Thermo coupler bad
Counter measure: Replaced thermo coupler
R/C: Yes time
Cycle time: Unchanged What: Upper thermo coupler bad
Why: Looks like it got hit
Counter measure: Replaced thermo coupler
R/C: No
Cycle time: Unchanged What: Upper thermo coupler not reading right
Why: Bad spot in wire
Counter measure: took bad spot out
R/C:
Cycle time: Unchanged What: Upper thermo low
Why Thermo coupler bad
Counter measure: Replaced thermo coupler
R/C: Yes time
Cycle time: Unchanged What: Upper tower not home
Why: Limit switch broke for home position
Counter measure: Replaced limit switch
R/C: No
Cycle time: Unchanged What: Upper tower open limit switch not working
Why: Switch arm came loose
Counter measure: Adjusted switch
R/C: no
Cycle time: Unchanged What: Using a lot of oil
Why: Oiler pressure switch leaking on taco way lube oil
Counter measure: Replaced pressure switch
R/C:
Cycle time: Unchanged What: Using a lot of oil from auto oiler. (Tonna 68)
Why: Leaking oil to die open and close joints
Root cause: Rubber line to die open and close joints got hole in it
Counter measure: Replaced line
What: Vacumm pump coupler broken.
Cause: Overfull of oil.
Countermeasure: Drain excess oil and replace plastic coupler and steel gear on motor side.
Reoccur: most likely if oil level not checked. What: Vacuum
Why:
Counter measure: What: Vacuum
Why:
Counter measure:
R/C:
Cycle time: Unchanged What: Vacuum
Why:
Counter measure: Replaced 2 blocks. 2nd block in ran machine in low speed till 5 shots after preheats. Wanted to see if the blocks needed to heat up first. What: Vacuum
Why:
Countermeasure: What: Vacuum
Why: "?
Countermeasure: inspect air lines and blow lines (all recently replaced) pull and clean chill blks and their cavities. clean vacuum unit filter (blow out oil) inspect for air and What: Vacuum
Why: #2 tank to pressure limits setting wrong
Counter measure: Set to plex settings. Was P-1 was -71.0 and P-2 was -73.3. Plex is P-1 -50.0 P-2 -85.0
R/C: Yes if some one leans on it
Cycl What: Vacuum
Why: Air bowl was broke on vacuum line
Counter measure: Replaced air bowl
R/C: No
Cycle time: Unchanged What: Vacuum
Why: Aluminum in block
Root cause: Die cast machine setting
Counter measure: Adjusted temps and vacuum LS from 45.0 to 85.0
R/C: Yes
Cycle time: Unchanged What: Vacuum
Why: Aluminum in junction block for clear vacuum hoses. Top of fixed side of die
Counter measure: Cleared out aluminum
R/C: No
Cycle time: Unchanged What: Vacuum
Why: Bad and or worn valve
C/M: Replaced with brand new block
Recur: In time What: Vacuum
Why: Bad chill block
Counter measure: Replaced chill block
R/C: Unknown
Cycle time: Unchanged What: Vacuum
Why: Bad rebuild on blocks. Think blocks new pistons from matt might be problem. Or rebuild
Counter measure: Replaced with used block out of Die cast #6
R/C: Still investigating
Cycle tim What: Vacuum
Why: Black hose had hole in it
Counter measure: Replaced hose and clear hose o-ring broke too
R/C: No
Cycle time: unchanged What: Vacuum
Why: Block clogged up
Counter measure: Used 3 rebuilt blocks. Finally rebuilt new block we took out from cage. Ran fine with that block
R/C: Yes
Cycle time: Unchanged What: Vacuum
Why: Block full of aluminum
Root cause: No plunger lube. Tip was plugged
Counter measure: Cleaned tip
R/C Yes From blow back
Cycle time unchanged What: Vacuum
Why: Blue and black hoses got crossed. Filled junction block and clear hoses full of aluminum
Counter measure: Replaced both operator side clear hoses cleaned out junction box for hoses What: Vacuum
Why: Clear hose had aluminum ball rolling around in it Plugging up valve blow out. From previous blow block
Counter measure: Unclogged hose
R/C: Yes time
Cycle time: Unchanged What: Vacuum
Why: Clear hoses had burn holes in them
Counter measure: Replaced hoses
R/C: Yes time
Cycle time: Unchanged What: Vacuum
Why: Die Release low (Mixture)
Counter measure: Set to 1.75
R/C: Yes time mixture weakens
Cycle time: Unchanged What: Vacuum
Why: Die release
Countermeasure: Added 3 squirts of die release to tank. Was 1.30 made 1.70
R/C: Yes float system not contestant
Cycle time: unchanged What: Vacuum
Why: Die release and spray cartage hose for spray end had hole in and wasn't pulling die release to spray block
Counter measure: Replaced spray valve and spray hose and made die release m What: Vacuum
Why: Die release filter dirty
Counter measure: Cleaned filter
R/C:
Cycle time: Unchanged What: Vacuum
Why: Die release low and water in air separator bowl
Counter measure. 1.50 made 1.75. Drained water out of bowl
R/C: yes
Cycle time: Unchanged What: Vacuum
Why: Die release mix low
Countermeasure: Was 1.20 made 1.70
R/C: Yes Runs off float system
Cycle time: Unchanged What: Vacuum
Why: Die release pressure was at 1.8
Counter measure: Adjusted die release pressure regular from 1.8 to 3.0
R/C: No
Cycle time: Unchanged What: Vacuum
Why: Die release pump had a 6mm hose on die release mixture when it should have 8mm. Which means it cant mix and hold right mixture
Counter measure: Replaced fittings and hose size to 8mm What: Vacuum
Why: Die release pump hose for mixing solenoid valve came off so no die release was in mixing tank
Counter measure: Hooked hose up and mixed die release. Was 0.1 now 2.30
R/C: No
Cycle ti What: Vacuum
Why: Die release week
Counter measure: Got mixture to 1.73
R/C: Yes Cant hold mixture right
Cycle time: Unchanged What: Vacuum
Why: Getting aluminum in blocks
Root cause: Loosing seal around tip and sleeve
Countermeasure: Replaced tip
R/C: Yes time
Cycle time: unchanged What: Vacuum
Why: Hole in clear hose
Counter measure : replaced hose What: Vacuum
Why: Limit switch for vacuum at 100
Counter measure: Changed to 85
R/C: No
Cycle time: Unchanged What: Vacuum
Why: Multiple issues
Counter measure: Replaced Vacuum hose from pump to mid point very dirty: And replace spray valve that was bad
R/C: Unknown
Cycle time: unchanged What: Vacuum
Why: Not creating vacuum quick enough
Counter measure: Replaced both Vacuum creating valves
R/C: Yes time
Cycle time: Unchanged What: Vacuum
Why: Not reaching vacuum lower set point
Counter measure: Replaced smaller round filter on top. (Napa gold filter)
R/C: Yes time
cycle time: Unchanged What: Vacuum
Why: Not recovering vacuum fast enough
Counter measure: Changed lower setting from -86.0 to -87.5. Because vacuum was dropping to 86.9 and then next shot was dropping to 80.0 and it cant What: Vacuum
Why: Not recovering vacuum fast enough after shot is made. Due to Hugh drop in vacuum tank. Die was opening and vacuum was being pulled at that time. Pulling from every where not just die What: Vacuum
Why: One side pulling more vacuum than other
Counter measure: Replaced bowl filters
R/C: Unknown
Cycle time: Unchanged What: Vacuum
Why: Operator side block had aluminum in it
Countermeasure: Changed LS for vacuum from 83.0 to 40.0
R/C: Unknown
Cycle time: Unchanged What: Vacuum
Why: Plugged vacuum block
Counter measure: Nothing. I did trial to see if I could get a good block. It took 5 bad to get it to run
R/C: Yes
Cycle time: Unchanged What: Vacuum
Why: Power down and V check was not done after letting nitto out
Counter measure: Powered down and V check
R/C: Yes time
Cycle time: Unchanged What: Vacuum
Why: Replaced both vacuum blocks and found squeeze master settings were wrong. Some one saved P/M program to P/S program
Counter measure: Changed squeeze master to plex settings
R/C:
Cycl What: Vacuum
Why: Setting was changed for bisket size in program. Checked plex and found it should be 23. Had a revision on it. Program said 23 which is right but the setting were 10 to 20. So u coul What: Vacuum
Why: Shot sensor reading wrong
Counter measure: Replaced sensor
R/C: Unknown
Cycle time: Unchanged What: Vacuum
Why: Spray cartage broke
Counter measure: Replaced cartage
R/C: Yes time. They hit hydraulic lines
Cycle time: Unchanged What: Vacuum
Why: Spray cartage filter dirty
Counter measure: Cleaned filter. Was plugged
R/C: Yes time
Cycle time: Unchanged What: Vacuum
Why: Spray cartage leaking around mounting on robot side
Counter measure: Replaced o ring that was missing
R/C: Yes. O-rings need verified during changeover of spray cartridge
Cycle time: What: Vacuum
Why: Spray cartage not tight and o rings bad
Counter measure: Replaced o rings and tightened spray cartage
R/C: Unknown
Cycle time: Unchanged What: Vacuum
Why: Spray cartridge loose
C/M: tighten up spray cartridge
Recur: possibly in time What: Vacuum
Why: Spray nozzle aimed at cavity not vacuum block
Counter measure: Replaced nozzle and aimed at block. What: Vacuum
Why: Spray point of die release
Counter measure: Adjusted spray points to hit both pistons on vacuum block and adjusted point on chill block. Operator side
R/C: Yes if they move
Cycle tim What: Vacuum
Why: Spray point to vacuum blocks were off center
Counter measure: Adjusted spray points What: Vacuum
Why: Tank was loosing vacuum
Counter measure: Shut valve at floor
R/C: No
Cycle time: Unchanged What: Vacuum
Why: The way operators are starting machine
Counter measure: Had 2nd shift operator start machine in low and wait till temp is made and then put in HI On
R/C: Yes Operator error
Cycle tim What: Vacuum
Why: Tip and sleeve bad
Countermeasure: Replaced tip and sleeve
Sleeve & Tip was changed during "DIE CHANGE"
Having vacuum trouble with 6A0-P, C/O to 6A0-M
Did Die Change & Tip and Sl What: Vacuum
Why: Tip and sleeve worn
Counter measure: Replaced tip and sleeve. (Life 96315)
R/C: Yes Life
Cycle time: B-24.8 A-24.8 What: Vacuum
Why: Unknown
Counter measure: Had operator change both blocks What: Vacuum
Why: Unknown
Counter measure: Pulled die due to Vacuum block stuck operator side. Die took hit under block
R/C: No
Cycle time: Unchanged What: Vacuum
Why: V-Check not performed
Counter measure: Shut down machine and did V-Check
R/C: Yes time
Cycle time :Unchanged What: Vacuum
Why: Vacuum Valve air pressure low ( Low speed casting air) not coming on in low shot speed on vacuum pump. Causing blocks to not be held shut in preheats
Countermeasure: Cleaned valve of What: Vacuum
Why: Vacuum block on robot side
Root cause: Vacuum line at top (Unknown why it worked)
Counter measure: Swapped vacuum lines at top
R/C: Yes
Cycle time: Unchanged What: Vacuum
Why: Vacuum pump not creating vacuum
Counter measure: Replaced vacuum injectors and DCV
R/C: No
Cycle time: Unchanged What: Vacuum
Why: Vacuum pump solenoid valve for low speed casing air was not working. (Black Hose for blocks)
Counter measure: Manually operated solenoid valve
R/C: Yes time
Cycle time: B- 24.1 A- 24 What: Vacuum
Why: Vacuum tanks not making min in allotted time. Clear hose had hole in it and was pulling too much Vacuum and draining tank
Counter measure: Replaced clear hose.
R/C:
Cycle time: Unch What: Vacuum
Why: Volume from spray cartage low
Counter measure: Turned up die release pump
R/C:
Cycle time: Unchanged What: Vacuum
Why: aluminum in blocks
Root cause: Changed tip on Die cast machine and didn't V-Check machine
Countermeasure: V-Checked Die cast machine
R/C: Yes
Cycle time: Unchanged What: Vacuum
Why: clear hose on operator side was plugged up in junction area. (Was making a check valve in junction block)
Counter measure: Cleared out junction area and replaced both clear and black What: Vacuum
Why: hoses full of aluminum
Counter measure: put new vacuum blocks in both sides
R/C: Unknown
Cycle time: Unchanged What: Vacuum
Why: tip and sleeve damaged
Countermeasure: replace tip and sleeve (also added water spot cooling joint to help get more life out of sleeve)
R/C: yes
Cycle time: What: Vacuum
Why: unsure
Countermeasure: change biscuit size to 28
R/C: Replaced operator side ejector.
Cycle time: Unchanged What: Vacuum
Why: water in air lines
c/m- drain water
reoccur- yes What: Vacuum
Why:?
C/M: Replaced all hoses
Recur: In time What: Vacuum
Why; Rebuilt block o-ring for center piston was soft. Like it was saturated with some thing. Might be the spray lube they spray in blocks is breaking down O-rings
Counter measure: Took re What: Vacuum
Why: #2 air blow (Short black hose) had hole in it. Junction for big hose had debris in it
Counter measure: Replaced hose and cleaned out debris
R/C: No
Cycle time: Unchanged What: Vacuum
Why: 1ST shift operator starting in high on for injection after machine has faulted
Counter measure: 2nd shift operator started in slow on for injection
R/C: Yes
Cycle time: Unchanged What: Vacuum
Why: Change over to 6A0-P
Root cause: vacuum L/S setting
c/m: changed to 50mm
reoccur- no What: Vacuum
Why: Tip worn plunger tip got plugged (operator error)
Countermeasure: Replaced tip
R/C: No
Cycle time: Unchanged
SHOT LIFE ON SLEEVE: 15,334 What: Vacuum
Why: vacuum settings incorrect?
Countermeasure: set vacuum settings to plex
recur- possible What: Vacuum (Change over to (6A0-P)
Why: Dry shot St distance
Counter measure: Dry Shot distance was 245.0 which is in plex. But when you die height check and injection check it is 247.5. So I set What: Vacuum ( Both sides)
Why: Die release low and clear hoses
Counter measure: Replaced clear hoses and set die release from 1.20 to 1.75
R/C: Yes Mixture not consistent
Cycle time: Unchanged What: Vacuum (Operator side)
Why: Robot side clear hose missing red o ring. Spray cartage was in back ward
Counter measure: Replaced o ring. Put Spray cartage in right What: Vacuum (Operator side)
Why: Spray point to vacuum block was off.
Counter measure: Aligned spray point to vacuum block piston that is closet to center of die
R/C:
Cycle time: Unchanged What: Vacuum (RB Side)
Why: Die release low mixture. Clear hose had debris in it.
Counter measure: Replaced hose and changed mixture from 1.02 to 1.71
R/C: Yes Die mixture not consistent
Cycle time: U What: Vacuum (RPY PS #7)
Why:
Counter measure:
R/C: Yes
Cycle time: Unchanged What: Vacuum (Robot side)
Why: hoses
Counter measure: replaced hoses
R/C: yes
Cycle time: Unchanged What: Vacuum 5A2 P/M die (Change over)
Why: Spray points not hitting vacuum blocks right
Counter measure: Adjusted spray points
R/C: No
Cycle time: Unchanged What: Vacuum Block Blown.
Why: Die release low.
Countermeasure: Added die release, cleaned filters.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Vacuum Block blown on robot side.
Countermeasure: Cleaned out filters and they replaced hoses. What: Vacuum Block blown.
Why: Dirty filter.
Countermeasure: Cleaned filters and ejectors.
Will Problem Reoccur?:
Cycle Time: No Change. What: Vacuum Faults
Why: Blowing vacuum blocks
Countermeasure: Changed all D/C machine settings back to what PLEX said, adjusted spray points, cleaned all vacuum filters, replaced blocks and hoses.
Wi What: Vacuum Faults
Why: The hose that was giving to the operator was plugged and didnt know it
C/M: Replaced with a new hose
Recur: Possibly in time What: Vacuum Pressure faults
Why: Possible hole in vacuum line
C/M: Had operator and DH change out hoses and block What: Vacuum Problems on operator side.
R/C: Vacuum hoses were bad
C/M: Replaced hoses.
R/O: Timing.
Cycle Time: No change What: Vacuum Problems.
R/C: A bad used tip and sleeve got put in.
C/M: Put new tip and sleeve in.
R/O: Timing.
Cycle Time: NO change. What: Vacuum Robot and Operator side.
Why:
Counter measure:
R/C: Unknown
Cycle time: Unchanged What: Vacuum Trouble
R/C: Not determined, Still investigating due to multiple days with same issue
C/M: Adjusted settings on die in screen to match operating standards via plex.
Will it reoccur: Yes What: Vacuum Trouble
Why: Channel 2 reading Ng but not in use
C/M: Unplugged channel 2
Recur: Possibly in time What: Vacuum Trouble
Why: Low Nitrogen
C/M: Added nitrogen
Recur: In time What: Vacuum Trouble
Why: Nitrogen level was low
C/M: Had DH add nitrogen What: Vacuum Trouble
Why: O ring on hose needed replaced, filters cleaned, hose replacement
R/C: Training, better understanding of vacuum system
C/M: Replaced hose operator side, replaced o ring on r/ What: Vacuum Trouble
Why: Vacuum pressure going to low not building Fast enough time
C/M: Replaced both out hoses to manifold
Recur: Possibly in time What: Vacuum Trouble
Why:?
C/M: Replaced with Brand New Vacuum Blocks #2 and #9
Recur: Possibly in time What: Vacuum Trouble robot side
Why: Not sure could be a lot of variables
C/M: Put new spray cartridge on it adjusted spray put.05mm shims behind both chill blocks adjusted spray timer from .3 to .5 What: Vacuum air blow installation
Why: Improvement Item
Countermeasure: Added air line to blow block piston out for cleaning
R/C: Yes
Cycle time: Unchanged What: Vacuum alarms (Pump not recovering to set point between shots)
Why: Inlet filter plugged up
Counter measure: Replaced inlet filter and exhaust filter
R/C: Yes time
Cycle time: Unchanged What: Vacuum block bolts holes were full of aluminum in die
Why: Bolts were not put in die
Counter measure: Replaced bolts and drilled aluminum out of holes in die
R/C: No
cycle time: Unchanged What: Vacuum block fault Operator side. What: Vacuum block stuck in die
Why: Took hit by block
Counter measure: Removed block and ground out high spots. What: Vacuum block stuck in die
Why: Vacuum block was missing blot in block. Filled hole full of aluminum
Counter measure: Drilled hole to bit limit and still cant get block out What: Vacuum block stuck in die
Why: bolts to vacuum block were loose and let aluminum behind block and in thread holes
Counter measure: Pulled die
R/C: No
Cycle time: Unchanged What: Vacuum blocks blown on Op. side.
Why: Vacuum block blowing shortly after pre-heat shots.
Countermeasure:
Will Problem Reoccur?: Yes.
Cycle Time: No Change. What: Vacuum blocks blown on both sides
Why: Holes in large vacuum lines and noticed hose from vacuum pump to mid-junction was closed in the tip/sleeve door
C/M: Replaced both large vacuum lines going What: Vacuum blocks blown.
Why: Spray point off on block and Vacuum recovery solenoid valve for Tank #1 in back stuck open. Closest to clear hose
Countermeasure: Adjusted spray point and cleaned valve What: Vacuum blown both sides.
Why: Dirty filters and hoses for one side and dirty preheat hose for one side.
Countermeasure: What: Vacuum cabinet tripped main breaker.
Why: Turned back on pump made loud noise.
Countermeasure: Replaced both the Busch exhaust filter and the air filter.
Will Problem Reoccur?: Possible.
Cycle What: Vacuum equip. failure fault
Why: Found blue air/vacuum line R/B side was not connected to vacuum block
C/M: Replaced R/B vacuum block fitting and trimmed the end of vacuum lines, Cleaned (partia What: Vacuum failure
Why: Ejectors dirty
C/M: Replaced with new
Recur: In time What: Vacuum fault
Why: Blown vacuum block, hole in large hose
C/M: Replace large vacuum hose and block, checked all lines, started machine and had product detect, corrected detection, Found oil leak What: Vacuum fault
Why: OP vacuum block & hose blown (after change over)
C/M: Checked: spray points, die lube concentration & filter, vacuum filters, Plex settings What: Vacuum fault
Why: Overload. vacuum pump NG
Countermeasure: replaced pump
Reoccur: What: Vacuum fault
Why: Tank didn't refill due to clear hose hole. (pulled to much vacuum)
Counter measure: Replaced clear vacuum hose What: Vacuum fault.
Why: No Spray from spray cartridge
R/C: Diaphragm pump is bad.
C/M: Replaced pump
R/O: Timing.
Cycle Time: NO Change. What: Vacuum fault.
Why: Blown vacuum block on robot side.
Root Cause: Dirty hose and air pressure setting too high.
Countermeasure: Replaced clear hose from vacuum machine and adjusted the air pr What: Vacuum faults
Root cause: Multiple issues. 1st die lube mixed in die release. 2nd issue vacuum block is blowing out block at same time spray cartage is applying die release. Which means block ai What: Vacuum faults
Why : Sprue bushing leaking
Counter measure: Replaced sprue bushing
R/C: Yes time What: Vacuum faults
Why:
C/M: Replaced all vacuum hoses from vacuum generator to DC M/C. Cleaned/checked all filters and oil level on vac. gen.
Confirmed spray points, found 3 out of position- correc What: Vacuum faults
Why:
C/M: Replaced filters in air bowls on back of vac controller. Changed large vac lines and trimmed the ends of the small. Noticed that the nitrogen level was at 9. What: Vacuum faults
Why: Die release filter plugged
Counter measure: Unclogged filter What: Vacuum faults
Why: Aluminum build up in vacuum blocks
Root cause: Insufficient die release flow, spray timer not set long enough
Countermeasure: Adjusted die release flow and spray timer from 0. What: Vacuum faults
Why: Blown vacuum block RB side
C/M: Checked spray points & RB side spraying high, OP side spraying down & to the side. Corrected spray points. Operator is going to replace RB vacu What: Vacuum faults
Why: Blown vacuum blocks, R/B side
C/M: Checked: die lube concentration & cleaned filter, spray points, confirmed mold heater temp. setting, confirmed m/c settings with plex standa What: Vacuum faults
Why: Hole in vacuum line
C/M: Checked blocks for aluminum, inspected hoses (trimmed ends) found RB side small tubing had hole in it What: Vacuum faults
Why: Motor/pump coupler broken
C/M: Checked that the vacuum pump spun freely. Upon coupler replacement I found the motor shaft pulley set screw was loose and gear was cracked. Repl What: Vacuum faults
Why: Not creating vacuum fast enough
Counter measure: Replaced both filters
R/C: No
Cycle time: Unchanged What: Vacuum faults
Why: Operator and helper side blocks blown and clear hose had debris in it on operator side. Locking up block
Counter measure: Replaced operator side block and hose. Replaced helpe What: Vacuum faults
Why: Operator side alarms. Robot block slow to react
Counter measure: Replaced both blocks What: Vacuum faults
Why: Upper inlet filter plugged
Counter measure: Replaced inlet filter
R/C: Yes time
Cycle time: Unchanged What: Vacuum faults
Why: V1 and V3 faults, pulling aluminum into blocks.
C/M: Changed vacuum blocks, blew hose off. Replaced hose (robot side) What: Vacuum faults
Why: Vacuum filter on back of machine (Air bowl) had a cardboard cylinder in for filter on one of them. Looks like water separator filter print out center
Counter measure: Replaced What: Vacuum faults
Why: Very little spray from spray cartridge when checking spray points. Found die release pump not functioning properly
C/M: Replaced pump What: Vacuum faults
Why: While running the vacuum control panel turns off then back on again
C/M: Found bad relay inside control panel and replaced What: Vacuum faults
Why:Inlet Air Pressure switch went bad
Counter measure: Replaced pressure switch.
R/C: Yes time
Cycle time: Unchanged What: Vacuum faults (op. side)
Why: Program discrepancies
Will it reoccur: No
Cycle time before: 27.9
Cycle time after: 27.9 What: Vacuum faults on robot side (on going problem for several days)
R/C: Believe to be chill block and vacuum block not creating correct seal
C/M: Added a additional 1mm shim behind chill block to a What: Vacuum faults oper. side.
Why: Spray cartage and die release pump
Counter measure: Replaced 5 spray valves on unit. And spray was still weak. Found that liquid pressure regulator went bad in die What: Vacuum faults robot side.
Root Cause: Tank was not making enough vacuum fast enough for tank 2.
Countermeasure: Opened hand valve for middle exhaust.
Will Problem Reoccur?: Unknown. What: Vacuum faults, no blown vacuum blocks per operator
Why:
C/M: Checked vacuum and die release filters, Replaced vacuum air bowl filters. What: Vacuum faults, robot side.
Why: Possible aluminum got in filter.
Countermeasure: Operator replaced vacuum block, cleaned filters. What: Vacuum faults.
Why: Happening during preheat shots mostly.
Countermeasure: Replace filter. Replaced black hoses on both side. What: Vacuum faults. Changing Tip and Sleeve Shots 20,264
Why: Possible clogged lube tip from previous shifts
Counter measure: Replaced tip and sleeve. Adjusted spay points and changed robot side chi What: Vacuum faults/ blown vacuum blocks
Why: RB side: Small hole in large vacuum line half way up hose. Coupler on top of hose was not completely locked on.
C/M: Replaced large vacuum line and made s What: Vacuum issue
Why: Aluminum in junction block
Countermeasure: Remove aluminum from junction block
Reoccur: Possible What: Vacuum issue
Why: Blew block. sucked aluminum into hose (operator side)
C/M: Operator changed both blocks and replaced operator side hose What: Vacuum issue
Why: Blowing robot side
Counter measure: What: Vacuum issue
Why: Channel 1 not pulling vacuum due to bad valve
Counter measure: Replaced valve What: Vacuum issue
Why: Filter manifold plugged. Dirty clear hoses
Counter measure: DH replaced clear hoses and vacuum blocks. Cleaned out manifold What: Vacuum issue
Why: Unknown
Counter measure: Taka and adjusted vacuum pump setting for vacuum 1 channel What: Vacuum issue
Why: casting pressure was low
C/M: Added nitrogen to the speed tank replaced air lines and plunger tip changed tip after failed again What: Vacuum issue operator side What: Vacuum issue.
R/C: Die release filter was dirty and in line vacuum filters were dirty and oil was low on vacuum unit.
C/M: Cleaned filters and filled oil.
Reoccurrence: No What: Vacuum issues
Root cause: FML Reading in plex is 222 running at 230
Countermeasure: Replaced plunger rod, plunger rod coupler and spacer, also tip and sleeve and changed die back to #2
Will prob What: Vacuum issues
Why: Operator requested new fitting for junction block on top of die
Countermeasure: Got them a fitting (non inventory) What: Vacuum issues
Why: Suspect dirty/clogged filters
C/M: Replace filters
Reoccur: Yes timing What: Vacuum issues on both sides.
R/C: Unknown
C/M: Adjusted the one of the low temps down 28 degrees, when we are blowing the blocks the one temp. is up almost to the highest point of the setting t What: Vacuum issues operator side.
R/C: Filters on vacuum unit were dirty and spray point was off.
C/M: Cleaned filters adjusted spray point.
R/O: NO
Cycle Time: NO Change. What: Vacuum issues, blowing blocks on first high speed shot.
Why: FML End setting off and V2 vacuum system malfuctioning
R/C: Someone changed the settings
Countermeasure:Changed the biscuit size to 2 What: Vacuum issues.
Why: Spray points were wrong.
R/C: Machine changed over and spray points were adjusted for the other die.
C/M: Adjusted spray points and checked die release concentrate.
R/O: Yes What: Vacuum issues.
Why: operator side vacuum block bottom bolt has washers on it.
R/C: Operator side vacuum block bolt hole is filled partially with aluminum.
C/M: Removed all washers and just put a What: Vacuum machine not making any vacuum
Why: Coupler broke that connects motor to pump and coupler on motor cracked.Why/; To much oil operators need to check oil level
C/M: replaced plastic coupler What: Vacuum not building vacuum
Why: Vacuum pump shaft sheared internally.
Countermeasure: Replace vacuum pump.
Reoccur: Possibly in time. What: Vacuum not recovering
Why: 3 issues. Clear hose had hole in it. Vacuum occurrence valve sticking and vacuum ejectors were dirty
Counter measure: Replaced vacuum ejectors and clear hose and Vacu What: Vacuum not recovering after shot
Why: 1st shift found that the settings were not right for the vacuum recovery
C/M: 1st shift adjusted settings What: Vacuum not recovering fast enough
Why: Vacuum valve staying open and filter was dirty
Countermeasure: Cleaned vacuum valve and replaced filter
R/C: Yes time
Cycle time: Unchanged What: Vacuum op side
Why: clear vacuum hose dirty
c/m: replaced op side vacuum hose What: Vacuum problem
R/C: Tip/sleeve worn, blow back shot life 30,855
C/M: Removed and installed new tip and sleeve
Will it reoccur:
C/T Before: 25.0
C/T After:25.0 What: Vacuum problem
Why: Aluminum in junction
Counter measure: cleaned out junction What: Vacuum problem
Why: Blown vacuum block
Countermeasure: Replace blocks change vacuum hoses and clean filter
Reoccur: Possible What: Vacuum problem
Why: Dye lube pump quit
C/M: Replace pump
Recur: In time with wear What: Vacuum problem
Why: Low end setting for Vacuum press was to high and pump cant keep up. The longer machine runs the closer it gets to bottom setting
Counter measure: Still investigating
Cycle t What: Vacuum problem
Why: Spray cartage not spraying block due to missing O-rings between spray cartage and base
Counter measure: Replaced O-rings
R/C: no
cycle time: Unchanged What: Vacuum problem
Why: Vacuum block
Counter measure: Replaced vacuum block What: Vacuum problem
Why: Vacuum pump set screw cam out and let coupler disengage
Counter measure: Put new set screw in What: Vacuum problems
Why: Tip and sleeve prematurely failed.
R/C: unknown as to why tip and sleeve failed
C/M: Replaced tip and sleeve.
R/O: Yes due to unknown reason for premature failure.
Cycle Ti What: Vacuum problems on operator side.
R/C: Spray cartridge wasn't in right and was missing o-rings.
C/M: Removed spray cartridge replaced the o-rings and reinstalled correctly.
R/O: NO
Cycle Time: N What: Vacuum problems robot side.
R/C: Exhaust filter was full of oil.
C/M: Changed that filter along with another filter right above it they were changed around the same time previously.
Reoccurrenc What: Vacuum problems robot side.
R/C: Found some settings wrong in the temp monitor screen.
C/M: Set settings back to what plex showed they should be.
Reoccurrence: NO. What: Vacuum problems robot side.
Why: Block getting aluminum in it.
C/M: Changed ls for vaccum from 85.0 to 40.0
R/O: NO.. What: Vacuum problems.
R/C: Quick connect fittings up on block at the top of machine for pre heat hoses are bad.
C/M: Removed fittings and put new ones on.
R/O: NO
Cycle Time: No change. What: Vacuum problems.
Why: Vacuum control valve bad.
R/C: Valve is internally stuck open not allowing vacuum to build up.
C/M: Swapped diecast 6 and 4's valves.
R/O: Timing.
Cycle Time: NO change What: Vacuum pump making grinding noise
Why: Motor drive gear set screw backed out allowing the key way to slip and also broke the coupler
Countermeasure: Replaced drive gear and coupler What: Vacuum pump making noise
Why: Low on oil
Counter measure: Cleaned sight glass and added oil
R/C: No
Cycle time: Unchanged What: Vacuum pump motor overloads
Why: Bolts not tight on the power in and out took the overload relay out and its middle leg was burnt half off
C/M: Went through tightened all connection bolts and pu What: Vacuum pump not creating vacuum
Why: Pump shaft sheared internally
Counter measure: Borrowed pump off D/C #4
R/C: Unknown
Cycle time: Unchanged What: Vacuum pump not operating right
Why: Both clear hoses had holes in
Counter measure: Fixed clear air lines
R/C: Yes Time
Cycle time: Unchanged What: Vacuum pump not recovering
Why: Vacuum pump couldnt get above low set point
Counter measure: Replaced with pump assembly What: Vacuum pump screeching not building vacuum
Why: Coupler sheared
Countermeasure: Replaced coupler (non-inventory) What: Vacuum pump smoking
Why: Exhaust filter full of oil
Counter measure: Replaced exhaust filter (Non Inventory)
R/C: Yes time. It sucks oil out of tank
Cycle time: Unchanged What: Vacuum pump stops pumping
Why: Trips over load
Counter measure: Replaced motor starter contactor. See notes
R/C:
Cycle time: Unchanged What: Vacuum pump tripping breaker
Why: Switch box had a 10 amp and 2 15 amp fuse in it. the 10 was blow
Counter measure: Replaced all with 30 amp because main breaker on vacuum machine is 15 amp
R/C: What: Vacuum robot side
Why: Vacuum block locked up
Counter measure: Adjusted spray cartage and replaced both blocks What: Vacuum smoking
Why: Exhaust filter full of oil
Counter measure: Replaced filter and drained some oil out of pump
R/C: No
Cycle time: unchanged What: Vacuum system not recovering properly after DH did vacuum PM
Why: Left main air off
C/M: Turned air on What: Vacuum trouble
R/C: What: Vacuum trouble
R/C:
C/M:
Will it reoccur:
c/T before: 25.0 c/t after 24.8
C/T after: What: Vacuum trouble
R/C: plugged filter/ dirty filter
C/M: Cleaned inline filter and replaced canister filter due to oil and dirty. Replaced blown line and slow speed air line. Cleaned die release pu What: Vacuum trouble
Why: 3rd shift operator did not turn on water to tip
Root cause: Excessive heat in tip causing issues
Countermeasure: Turned on water to tip, replaced blocks
Will problem reoccur: What: Vacuum trouble
Why: ?
C/M: Cleaned die release filter and inline filters also raised low speed pressure
Recur: Possibly in time What: Vacuum trouble
Why: Aluminum being sucked into block during high speed injection
Root cause: Fix side die temp too low, sprue spray point off
Countermeasure: Made an adjustment on the fix side d What: Vacuum trouble
Why: Bad block possibly worn component parts
C/M: Changed robot side block switched from V3 to V2 checked make sure no aluminum in hose or manifold What: Vacuum trouble
Why: Nitrogen was low
C/M: Added nitrogen to the accumulator
Recur: Possibly in time What: Vacuum trouble (2nd shift also had vacuum trouble)
R/C: Filter in vacuum pump full of oil
C/M: Installed new lines, checked manually working properly. Checked plex to verify numbers ok. Removed What: Vacuum trouble operator side
R/C: Inline screen filter to operator side plugged not allowing vacuum and air blow pressure to make it to block properly
C/M: Removed inline filter and cleaned rein What: Vacuum trouble operator side
Why: Filter clogged not allowing correct air flow to clean out vacuum block
R/C: No set life for Filter replacement
C/M: Removed all lines and blew out, Replaced Fil What: Vacuum trouble operator side
why: Block being blown
C/M: Changed out block adjusted spray and put .05mm shim behind chill block on operator side
Recur: possibly in time What: Vacuum trouble robot side
R/C: vacuum block and chill block not sealing correctly
C/M: Removed both chill blocks and measured for spec, shimmed behind robot side chill block due to flashing buil What: Vacuum trouble robot side
Why: Chill block loose allowing movement
R/C: No start up PM to verify die
Will it reoccur: No
C/M: Removed Operator checked inline filters and cleaned, verified hoses What: Vacuum trouble(running 6A0 M)
R/C: unknown
C/M: Noticed flashing on robot side around chill block/vacuum block, added shim behind r/b side block. Changed biscuit size setting from 20.0 to 28.0 m What: Vacuum trouble/Squeeze master trouble
Why: Plugged filters and slow speed air line, channel 4 bleeding off
R/C: Normal wear for filters, Squeeze master Loosing bleed
C/M: Cleaned and reinstalle What: Vacuum,
Why: Junction plugged for clear lines
Counter measure: Cleared junction What: Valve leakng in box off arm of spray cartidge.
Why: Air line popped off from fitting.
C/M: Removed collar and re inserted air ine and tighten down, turned air back on and confirmed ok and spray What: Valve manifold is leaking.
Why: Valve manifold is cracked.
C/M: Replacing valve manifold and replacing all o-rings.
R/O: NO. What: Valve on spray catridge leaking
Why: Valve internals bad
C/M: Replace leaking valve on spray cartridge What: Vibrator not knocking tabs off
Why: Welds broke on chuck finger allowing part to rotate at vibrator
Countermeasure: Rewelded chuck finger
Will problem reoccur: Possibly
Cycle time: No change What: Vibrator stopped and trim press saying part left in trim press
Why: Air fitting broke on vibrator and bolts fell out of sensor
Counter measure: Replaced air fitting and bolt
R/C: No
Cycle time: What: Wand broke
Why: Needle valve fell out
Counter measure: Replaced with new one wand "NON INVENTORY"
R/C: No
Cycle time: Unchanged What: Wand leaking
Why: Missing needle valve
Counter measure: Replaced needle valve What: Water Leak On the top of die due to small water line becoming free from its fitting.
Why: Excessive pulling on the hose due to its routing
C/M: Rerouted and seated line tested and confirmed no What: Water Leak causing porosity.
Why: Leak at top of die red hose side on slide core. What: Water Leak.
Why: Leaking at cooling joint.
Countermeasure: Replaced cooling joint. What: Water Leak.
Why: O-ring at the back end of the plunger shaft was bad.
Countermeasure: Replaced o-ring.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Water Leak.
Why: Pipe to the slide core moveable, robot side.
Countermeasure: Replaced pipe.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Water Leak.
Why: Water leak from Cooling pipe for movable side of die.
Countermeasure: Replaced coupler, installed new o-ring on one. What: Water Leak.
Why: Worn hose fitting.
Countermeasure: Replaced hose.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Water cooler had power but screen not coming on
Why: E-stop wasn't fully disengaged
C/M: tightened up e-stop button What: Water cooler not heating up
Why: Contactor no good
C/M: Replaced with new
Recur: Yes What: Water cooler wont heat up
Why: Contactor no good
C/M: Replaced contactor What: Water dripping below moveable die
Why: Brass fitting to quick connect on operator side loose
C/M: Tighten fitting What: Water flow to machine very low
Why: Filter to the chiller for in coming water was very low pressure
C/M: Replaced the A side filter on both the 100 ton and the 50 ton chiller Both A side
Recur: What: Water heater not coming up to temp
Why: Was supplying cool water while it was trying to heat up
Counter measure
R/C:
Cycle time: Unchanged What: Water hose broke.
Why: Wear.
Countermeasure: Replaced hose. What: Water leak
R/C: Sprue bushing leaking
C/M: Die maintenance replacing sprue bushing
Will it reoccur: Timing What: Water leak
R/C: Worn fitting on plunger shaft
C/M: Replaced fittings on plunger shaft inlet side
Will it reoccur: Timing
Cycle time: No change What: Water leak
WHY:sleeve cooling joint broken
C/M: replaced cooling joint
REOCCER: yes timing What: Water leak
Why: 1-1/4in hose by operator door had a hole in it
C/M: Replaced hose with non-inventory hose What: Water leak
Why: 2nd joint on end of shaft loose
C/M: Replaced o-ring and tighten joint
Recur: Possibly in time What: Water leak
Why: Aluminum melted a hole in water line.
C/M: Replaced water line. What: Water leak
Why: Aluminum melted hole in water line
Countermeasure: Replace water lines
Reoccur: Possible What: Water leak
Why: At sleeve area. Bad fitting
Counter measure: Replaced fitting What: Water leak
Why: Bad o ring in coupler for top of fixed side of die
Counter measure: Relaced o ring in coupler What: Water leak
Why: Bad o-ring on the Water supply line coupler to the sprue pin
C/M: Replaced coupler What: Water leak
Why: Bad spray valve in spray cartridge
Countermeasure: Replaced valve
Will problem reoccur: possibly
Cycle time: No change What: Water leak
Why: Bad sprue bushing
C/M: Replace sprue bushing
Recur: In time What: Water leak
Why: Cooling joint broke
Counter measure: Replaced cooling joint
R/C:
Cycle time: Unchanged What: Water leak
Why: Cooling joint broken
Countermeasure: Replace cooling joint and fittings
Reoccur: Possible What: Water leak
Why: Cooling joint for sleeve broke off
Counter measure: Replaced cooling joint
R/C:
Cycle time: Unchanged What: Water leak
Why: Cooling joint leaking
Counter measure: Replaced cooling joint
R/C:
Cycle time: Unchanged What: Water leak
Why: Cooling joint leaking
Counter measure: Replaced cooling joint
R/C: Yes
Cycle time: Unchanged What: Water leak
Why: Cooling joint popped out
C/M: Replaced O- Ring in cooling joint
Recur. Possibly in time What: Water leak
Why: Cooling joint snapped off in sleeve
Countermeasure: Replaced cooling joint What: Water leak
Why: Cooling joint/tube broken at tip/sleeve
C/M: Replaced cooling joint What: Water leak
Why: Cooling tube at sleeve broken
C/M: Replaced cooling tube What: Water leak
Why: Copper line from sprue pin damaged, operators side
C/M: Attempted repair with new compression fitting, NG. Replaced with new line and both compression fittings What: Water leak
Why: Coupler at sleeve leaking
Countermeasure: Replaced female couplers
R/C: No
Cycle time: Unchanged What: Water leak
Why: Coupler at tip leaking
Counter measure: Replaced coupler
R/C: Yes time
Cycle time: Unchanged What: Water leak
Why: Coupler at tip rod leaking
Counter measure: Replaced coupler
R/C: Yes time
Cycle time: Unchanged What: Water leak
Why: Coupler fittings on injection rod
Counter measure: Took coupler off. Hooked up direct What: Water leak
Why: Coupler leaking
Counter measure: Cleaned out coupler What: Water leak
Why: Coupler seal bad on injection rod
Counter measure: Replaced coupler male
R/C: Yes time
Cycle time: Unchanged What: Water leak
Why: Cracked sprue bushing
C/M: Replaced sprue bushing What: Water leak
Why: Cracked sprue bushing
Counter measure: Replaced bushing
R/C:
Cycle time: unchanged What: Water leak
Why: Degraded hose
C/M: replaced hose What: Water leak
Why: Hose clamp came loose
Countermeasure: Replace hose clamp
Reoccur: Possible What: Water leak
Why: Hose clamps bad
Counter measure: Replaced hose clamps operator side top read hose movable side What: Water leak
Why: Hose pinched in die and ripped hole in line
C/M: Replaced hose What: Water leak
Why: Hose pop off to Die release tank
Counter measure: Replaced fitting and reattached hose What: Water leak
Why: Hose rubbed guard back at injection rod cooling
Counter measure: Replaced hose What: Water leak
Why: Line on top of die had a pinhole in it.
C/M: Replaced line and confirmed no leak. What: Water leak
Why: Main hose to movable side leak behind yellow operator door
Counter measure: What: Water leak
Why: O-Ring for coupler to rod leaking
Counter measure: Replaced o-ring
R/C: Yes
Cycle time: Unchanged What: Water leak
Why: Operator bottom slide core bolts loose. Blew O-ring out
Counter measure: Changed 14P O -ring
R/C: No
Cycle time: Unchanged What: Water leak
Why: Pin holes in water supply line to sleeve.
C/M: Replaced water line and found a second line leaking- replaced it also What: Water leak
Why: Robot side die water lines got metal on them and melted
Countermeasure: Replaced water lines
Will problem reoccur: Possibly
Cycle time: No change What: Water leak
Why: Sleeve cooling joint bad
Counter measure: Replaced cooling joint What: Water leak
Why: Sleeve cooling joint broke
C/M: Replaced
Recur: In time What: Water leak
Why: Sprue bushing leak
Counter measure: Replaced sprue
R/C:
Cycle time: Unchanged What: Water leak
Why: Sprue bushing leaking. 5BA #5
Counter measure: Replaced sprue bushing
R/C: Yes time
Cycle time: Unchanged What: Water leak
Why: Tip cooling line quick connect coupler bad
Counter measure: Replaced
R/C: yes time
Cycle time: Unchanged What: Water leak
Why: Tip couplers leaking
Counter measure: Replaced couplers
R/C: No
Cycle time: Unchanged What: Water leak
Why: Tip female fitting
Counter measure: Replaced female fitting
R/C: Yes time
Cycle time: Unchanged What: Water leak
Why: Tip rod male fitting leaking
Counter measure: Replaced fitting
R/C: Yes time
Cycle time: Unchanged What: Water leak
Why: Tip shaft extension unscrewed/loose
C/M: Tightened extension
Recur: Posible What: Water leak
Why: Tip water quick connect cooling line coupler bad
Counter measure: Replaced tip quick connect cooling line coupler
R/C: Yes time
Cycle time: Unchanged What: Water leak
Why: Water line brittle and fitting half melted
C/M: Replaced both water lines going to the injector sleeve and one fitting What: Water leak
Why: Water line on top of die got a hole melted into it by aluminum.
C/M: Replaced water line and confirmed no leak. What: Water leak
Why: Worn hose
C/M: Replaced 3/4" hose What: Water leak
Why: hit cooling joint
Counter measure: Replaced fitting What: Water leak
Why; Injection rod hose fitting
Counter measure: Retaped threads What: Water leak
why: hole in hose
C/M: replaced hose
Recur: Possibly in time What: Water leak
R/C: Worn fitting on robot side of die
C/M: replaced worn fitting on die and checked for leak
will it reoccur: No What: Water leak
Why: Cracked sprue bushing
C/M: Replaced bushing
Reoccur: Yes in time What: Water leak
Why: Cracked sprue bushing
Countermeasure: Replace sprue bushing
Reoccur: Possible What: Water leak
Why: Fitting loose
Countermeasure: Retighten fitting
Reoccur: No What: Water leak
Why: Movable side leaking fitting for hoes to sprue
Counter measure: replaced fitting What: Water leak
Why: O-ring in cooling joint back of injection rod
Counter measure: Replaced o-ring
R/C: NO
Cycle time: Unchanged What: Water leak
Why: Sprue bushing leaking
C/M: Replaced sprue bushing and stripped water line fitting. Pressure tested for leaks What: Water leak
Why: Top squeeze pin fitting. Big one
Counter measure: Replaced fitting and squeeze cooling joint. Re did lines to joint like other die. Put O-ring in between cooling joint and holde What: Water leak
Why: tip unthreaded
Countermeasure: Install a new tip
Reoccur: Possible What: Water leak
Why: Aluminum in o-ring not sealing up
Countermeasure: Clean o ring and reinstall What: Water leak ( RPY M Die # 5)
Why: Cracked sprue bushing
Counter measure: Replaced sprue bushing
R/C:
Cycle time: Unchanged What: Water leak (6A0 M)
Why: Bottom slide core leaking
Counter measure: Tightened water lines going into slide core. They were loose
R/C: No
Cycle time: Unchanged What: Water leak & part out of spec
Why: Hole in sleeve water line & soldering cav. 1
C/M: Replaced hose and fitting. Polished cavity 1 What: Water leak & porosity
Why: Sprue bushing leaking
C/M: Replaced sprue bushing What: Water leak (Die 5A2 P/M #29) and fixed side getting hot
Why: Water leak was hose not in fitting good. Fixed side sprue bushing water line threaded up in to far
Counter measure: Re-hooked up wate What: Water leak (Wand)
Why: Hose had holes in it
Counter measure: Replaced hose
R/C: Yes time
Cycle time: Unchanged What: Water leak (sprue bushing area) 6A0 P Die
Why: Out let pipe to sprue bushing loose
Counter measure: Pulled fixed half of die. Tightened out let pipe to sprue bushing What: Water leak (tip area)
Why: Bad fitting
Counter measure: Replaced fitting
R/C: No
Cycle time: Unchanged What: Water leak 6A0 M die #6
Why: Cracked sprue bushing
Counter measure: Replaced sprue bushing
R/C:
Cycle time: unchanged What: Water leak 6B2 #7
Why: Cooling joint for upper slide core leaking
Counter measure: Tightened fitting
R/C:
Cycle time: Unchanged What: Water leak Fixed core movable side core. #4 slide core
Why: Fitting was damaged
Counter measure: Pulled slide core and Replaced fitting
R/C: Yes time
Cycle time: Unchanged What: Water leak after die change. 5BA chain tench #3
Why: Sprue piping leaking
Counter measure: Made new pipe
R/C:
Cycle time: Unchanged What: Water leak and trim problem
Why: Water leak top of die.
Trim press problem biscuit fling every where when trimming.
Counter measure: Pulled die for water leak. biscuit problem put bracket back o What: Water leak at R/B side of die.
R/C: Quick disconnect fitting not properly engaged to fitting on die.
Countermeasure: Separate clean and re-seat connector.
Will it re-occur: No What: Water leak at injection rod
Why: Bad quick connect
Counter measure: Replaced quick connect What: Water leak at plunger
R/C: Cooling line to sleeve broke allowing water to leak
C/M: Removed, retapped, and installed new cooling joint on sleeve
Will it reoccur: Yes, Any buildup on plunger shaf What: Water leak at plunger
Why: Operator hit water line
C/M: Put new line on
Recur: In time What: Water leak at plunger rod
Why: Water line got cut but drip pan
C/M: Replaced water line and Fitting also took off drip guard and cut down
Recur: Possibly in time What: Water leak at slide core
Why: Slide core o rings bad
Counter measure: Replaced o rings
R/C: yes time
Cycle time: Unchanged What: Water leak at sprue bushing (RPY P/S #7 Die)
Why: Sprue bushing cracked
Counter measure: Replaced sprue bushing
R/C:
Cycle time: Unchanged What: Water leak at the tip/sleeve. Parts out of spec
Why: Cooling joint broken. Cavity 4 trim damage
C/M: Replaced cooling joint. Cleaned cutter cavity and shims, replaced 1 worn cutter What: Water leak at tip
Why: Aluminum build up not allowing clamps to be tightened
Countermeasure: Remove build up trim ends of water lines and install new hose clamps
Reoccur: Timing if build up reoc What: Water leak at tip
Why: Bad O-ring on tip cooling joint
Counter measure: Replaced O-ring
R/C: Yes Time
Cycle time: Unchanged What: Water leak at tip
Why: Burnt hole in hose
Counter measure: Replaced hose
R/C:
Cycle time: Unchanged What: Water leak at tip
Why: Water line to tip rod wont stop leaking
Counter measure: Replaced hose
R/C:
Cycle time: Unchanged What: Water leak at tip and sleeve
Why: Bad fitting and hoses had holes in them
Countermeasure: Replace hoses and fitting
Reoccur: Possible What: Water leak at tip and sleeve
Why: Hose connection leaking
Countermeasure: Replace hose
Reoccur: Possible What: Water leak at tip and sleeve
Why: Leaking at fittings
Countermeasure: Remove fittings and retape What: Water leak at tip and sleeve.
Why: Damaged fitting at cooling joint.
Countermeasure: Replaced damaged fitting. What: Water leak at tip rod coulpers
Why: Couplers were worn
Counter measure: Replaced all fittings
R/C: Yes
Cycle time: Unchanged What: Water leak back side of die after die changed 5A2 S
Why: Line became loose
Counter measure: Pulled movable half to fix What: Water leak back side of die. RPY one rocker #5
Why: Slide core cracked
Counter measure: Pulled die
R/C: Yes time
Cycle time: Unchanged What: Water leak back side of movable side. (Die trial)
Why: Hose popped off
Counter measure: Production pulled die What: Water leak cavity 3 helper side bottom
Why: Broken slide core
Countermeasure: Replace slide core
Reoccur: Possible What: Water leak coming from water lines behind fixed side of die
Why: Hose leking on inside of die
Countermeasure: Had DH change die What: Water leak cooling joint sleeve
Why: Broke cooling joint
Counter measure: replaced
R/C: Yes time
Cycle time: Unchanged What: Water leak due to melted water line.
Why: Material dripped from die melting line.
Countermeasure: Replaced damaged lines and cleaned debris from die What: Water leak from cooling joint
Why: Aluminum melted hose
C/M: Replace hose What: Water leak from cooling lines on bottom side of movable die
Why: Age and wear
Countermeasure: Replaced fittings What: Water leak from spray cartridge
Why: Bad spray valves
C/M: Replace spray valves What: Water leak going into the die
Why: Worn out Orings
C/M: Replace Orings What: Water leak in die
Why: Bracket for coolant fitting loose on die for slide core
Counter measure: Tightened bracket What: Water leak injection rod
Why: Bad O-rings in cooling rod
Counter measure: Replaced O-ring
R/C: Yes time
Cycle time: Unchanged What: Water leak mat die
Why: Water line smashed in die
Countermeasure: Replace water line
Reoccur: Possible What: Water leak on back of moving die 59b 1 rocker die #5
Why: unknown
C/M: die change to 59b 1 rocker die #6
reoccur: yes What: Water leak on die
Why: Bad fitting
C/M- Replaced fitting
Reoccur timing What: Water leak on die
Why: Broken barrel fitting on line
C/M: Replaced copper line on movable side of die What: Water leak on die
Why: Fitting came loose for top slide core
Counter measure: Tightened fitting. Had to make a special wrench
R/C: No
Cycle time: Unchanged What: Water leak on die. (Water passage)
Why: Fitting leaking on upper slide core
Countermeasure: Replaced fitting and squeeze pin and bushing
R/C: No
Cycle time: Unchanged
"NON INVENTORY"
-KQB2W08-01 What: Water leak on fixed side of die
Why: Cracked sprue bushing
C/M: Replaced sprue bushing on fixed side of die. 5BA P-S F12 die What: Water leak on fixed side of die
Why: One of the blue water line fittings pulled apart so the line couldn't be held in any longer
C/M: Replaced fitting for water line and trimmed line down to cle What: Water leak on fixed side of die
Why: Water hose going to operator side fixed die leaking from coupler fitting
C/M: Replaced coupler fitting and replaced hose What: Water leak on helper side of moveable die side
Why: Fitting worn and leaking at swivel joint
C/M: Replaced fitting What: Water leak on movable side of die.
Why: Water lines had a pin hole melted into it.
C/M: Replaced line on die and confirmed no leaks. What: Water leak on movable side, robot side main line, also on plunger lube
Why: Defective fittings for both
Countermeasure: Replaced What: Water leak on plunger shaft
Why: Female fitting o-ring leaking, male end damaged hose stuck on
C/M: Replaced both the female and male end of quick connect fitting. What: Water leak on plunger shaft
Why: fitting bad also leaking from where fitting goes into the shaft
C/M: Replaced with new fitting and re-taped where goes into the shaft
Recur: Possibly in time What: Water leak on sleeve
Why: Small fitting loose on sleeve
C/M: Took both hoses and fittings off, retaped threads on fittings and reapplied What: Water leak on sprue bushing. Why: cracked sprue bushing. CM: Replaced sprue bushing. What: Water leak operators \ movable side
Why: Worn quick connect
Countermeasure: Replace quick connect What: Water leak plunger rod
Why: Female connector leaking
Countermeasure: Replace connector
Reoccur: No What: Water leak sleeve
Why: Cooling joint for sleeve broke
Counter measure: Replaced cooling joint
R/C: Yes time
Cycle time: Unchanged What: Water leak slide core
Why: Cooling joint to cavity 6A0 S-1 was out of holder
Countermeasure: Replaced Slide Core
R/C: No
Cycle time: Unchanged What: Water leak slide core
Why: Slide core broke
Counter measure: DH replaced slide core What: Water leak sprue bushing area
Why: Farrell leaking on copper line
Counter measure: Replaced copper line What: Water leak, Tip rod
Why: inlet hose clamp loose
Counter measure: Tightened hose clamp
R/C: Yes time
Cycle time: Unchanged What: Water leak, bottom op side slide core
Why: Cracked slide core
C/M: Replaced slide core
Recur: Possible in time What: Water leak, on movable side
Why: Bad coupler
C/M: Replaced both male and female pieces of coupler on operator side What: Water leak, sprue bushing
Why: Suspect pipe fitting leak
C/M: Re-taped water line fittings and it was still leaking, suspect bad sprue bushing. Removed stationary die and bench tested die cavity What: Water leak.
Why: Bad fitting.
Countermeasure: Replaced damaged fitting on cooling joint SW43 on die F-11 water passage. What: Water leak.
Why: Broken hose.
Countermeasure: Replaced blown hose.
Will Problem Reoccur?: Timing.
Cycle Time: No Change. What: Water leak.
Why: Coming from inside the die.
Countermeasure: Die was pulled. What: Water leak.
Why: Plunger tip water leaking at quick connect.
Countermeasure: Took apart and cleaned quick connect. What: Water leak.
Why: Movable side sprue
Counter measure: Tightened sprue piping What: Water leaking behind die.
Why: Damaged lines and fittings.
Countermeasure: Replaced fittings and lines. What: Water leaking from sprue bushing
Why: Cracked sprue bushing
C/M: Replaced sprue bushing
Recur: In time What: Water leaks
Why: Blowout RB side
C/M: Replace water lines, cleaned the die What: Water line came off. 1" hose
Why: Clamp let go and water started filling crucible with water. Looked like about 2" deep on top of aluminum.
Counter measure: Replaced both clamps. Let water boil What: Water line going to die release tank got a hole in it
Why: Age and wear
Countermeasure: Replaced line What: Water not flowing from mold heater.
Why: One of the wires to the electronic solenoid valve for movabale die side broke.
C/M: Re-terminated wire and confirmed working. What: Water passage F9 has build up.
Why: Needed Cleaned.
Countermeasure: Cleaned die. What: Water passage aluminum build up.
Why: Die 8 needed cleaned.
Countermeasure: Cleaned die. What: Water passage broke off in die
Why: Blow out at Vacuum block. Small biscuit robot missed. Operator didnt think it was down that long.
Counter measure: Die needed pulled What: Water passage die cleaning. Blow out too operator side chill block
Why: dirty
Counter measure: Cleaned die and replaced chill block Operator side
R/C:
Cycle time: Unchanged What: Water passage stuck in die.
Why: Happened during preheats.
Countermeasure: Used Die Cast 5 Casting Remains in die due to a machine or die malfunction procedure. What: Water passage trim press damage
Why: Unknown
Counter measure: Welded ramp back on
R/C: No
Cycle time: Unchanged What: Water running all over floor
Why: Hose connection on injection rod leaking
C/M: Replace male end of quick connect fitting on injection rod What: Water staying on the moving and fixed side
Why: The water valves for each side there was some type of foreign material in between where the poppet/ piston seats to close off the valve and water What: Water supply/pump overload fault on mold heater
Why: New valves installed on mold heaters over shutdown left closed
C/M: Opened valve What: Water temp on fixed side not flow correctly to cool the die
Why: Solenoid valve not opening to allow water to flow and turn on and off
C/M: Replaced with brand new valve and coil What: Way lube oil leak
Why: Hose has hole
Counter measure: Replaced hose
R/C: No
Cycle time: Unchanged What: Weight Scale no digital read outs
Why: Fuse was bad
C/M: Checked all wiring made sure nothing disconnected and put 2 new fuses What: Weight scale alarm 0011
Why: Unknown
Counter measure: Rebooted scale
R/C: Yes time
Cycle time: Unchanged What: Weight scales. Not shifting
Why: Bad wire to solenoid
Counter measure: Replaced wire What: Weights for scrap alarming (Both red lights flashing)
Why: Scrap conveyor was jammed and belt hung down in to sensor area
Counter measure: Unjammed part out of conveyor
R/C: Yes time
Cycle time What: When machine got put into full auto robot would automatically come in to get shot
Why: RB01, RB02, RB03, RB04 wires pinched and shorted in raceway. X02A (RB02) shorted to N24 (RB01) sending robo What: While running Breather Cover trim press not pressing all of the parts.
Why: Cavity 2 was getting stuck to the top of the trim press.
Countermeasure: Taught robot position PR[8] was not clearing What: While running robot holds onto shot and has a waiting for space to clear message
Why: Root cause unknown
C/M: Had operator start machine and issue did not reoccur while watching it What: Wire for upper limit probes broke at ring terminal.
C/M: Reterminated wire and confirmed ok. What: Wire to holding crucible meltal leak probes broke off.
Why: Operator cleaning after metal leak and hit it.
C/M: Re-terminated wire. What: Wires for safety door for crucible got ripped out
Why: Operator was sweeping and hooked wires and ripped them out
Counter measure: Re-terminated wires
R/C: No
Cycle time: Unchanged What: Wires showing out of liquid tight
R/C: wire bracket came loose allowing wires to droop
C/M: Removed broken liquid tight and terminated to box, installed new bracket to hold wires into position
What: Wiring for ingot loader damaged.
Why: Ingot reportedly fell on conduit severing conduit and wire.
C/M: Replace Damaged conduit / wire with BX cable. What: air leak
Why: General wear
C/M: Trimmed down end of splayed line and reattached What: alter M/C for new process What: aluminum leak
Why: half pipe/spout cracked
C/M: Replaced melting crucible and half pipe
Recur: In time What: aluminum stuck in die
Why: Excess aluminum was stuck to the surface of die causing a chunk of the casting to be left behind.
C/M: heated up excess aluminum to free it from die and had operator c What: axis 4 alarms, vacuum trouble, pressure build up time alarms
R/C: axis 4 alarms due to squeeze master had air in lines, vacuum trouble had dirty filters, worn hoses, .250um worth shims behind ro What: axis alarms on 1 and 3 cavities
R/C: squeeze master pressure and flow off after changeover. Settings on squeeze master on cavities adjusted.
C/M: Line bleed machine to verify no air in lines, Se What: bad slide core. Why: Cracked slide core. CC: Replaced slide core Cavity # 2. What: bad thermo coupler
Why: end of life
C/M: replaced thermo coupler now operational. What: bis size non adjustable
Why: Lower ladle unit had a catch in bearings
Counter measure replaced lower unit with rebuilt unit.
R/C: Yes Time
Cycle time: Unchanged What: blow back
Why: Tip and sleeve Worn. Why: 128,500 shots
C/M: Replaced both with new
Recur: in time What: blowback
Why: Sleeve had alot of aluminum build up inside ,operator said waterlines to sleeve were backwards
C/M: Replaced tip and sleeve and flange bushing
Recur: possibly in time What: broke slide core cav 6A0-M 2-4
Why: Flashing
Counter measure: Replaced bottom slide core
R/C: No
Cycle time: Unchanged What: broken half pipe
Why: ?
C/M: Replace upper ,lower crucibles half pipe and pedestals
Recur: In time What: build up of overflows
Why: 3 chutes were bent
C/M: Took off chutes and re-bent them and put gusset to strengthen and support
Recur: Possibly in time What: burr on bottom of part. Why: Chip on slide core. CM: Replaced slide core. What: burr on roller groove. Why: slide core #4 chipped. CM: changed slide core #4. What: casting alarm
Why; Biscuit too big
Counter measure: Adjusted biscuit down What: check #20 on filter system reading out of range
R/C: filter clogged allowing filter to read out of spec
C/M: replaced stage 3 hepa filter in filter system
reoccur: No, not until filter is clogge What: chip conveyor problem
Why: Inside falling apart
Counter measure: replaced links and cotter pins. What: collision detect at stationary jig and in trim press
Why: Unknown
C/M: Retaught Robot positions at stationary jig
Recur. Yes What: communication wire got Broke for the Vacuum machine
Why: Panel from SQM fell off and hit cable connector and broke it
C/M: Hard wired cable inside panel now ok
Recur: Possibly in time What: conveyor stop due to sensor at scrap press
R/C: Sensor not functioning properly sensing off allowing sensor to believe shot was left behind
C/M: Replaced sensor and adjusted to back due to side What: cooling water quick disconnect on R/B side leaking.
R/C: Connector NG
Countermeasure: Replace defective connector.
Will it re-occur: Timing What: crucible tower wont pull back
Why: Cant pull pin due to new air line placement
Counter measure: Cut bracket for air line
R/C: No
Cycle time: Unchanged What: die blowout on operator side
WHY: unknown
C/M: cleaned die replaced 2 water lines low speed air line and vacuum line on operator side
REOCCER: unknown What: die open cylinder leaking
Why: high pressure pipe leaking
Counter measure: Milled both mating surfaces and replaced o ring What: die release pump no good
Why: Worn out
C/M: Replaced with ebay model
Recur: In time What: die release pump not working
Why: Bottom filter plug not allowing pressure to pump
C/M: cleaned out filter and new pump
Recur: possibly in time What: die release pump not working
Why: No 24v power to run solenoids, 24v power supply NG, pressure release return line for pump became disconnected and covered interior of die release tank.
R/C: Pow What: die release pump not working right
Why: pump not making pressure
C/M: replaced pump
Recur: in time What: die release pump quit working
Why: Wear item
C/M: Replaced diaphragm pump What: die release pump was not pumping
R/C: pump was no good:
C/M: replaced pump.
Reoccur: timing>
no change to cycle time. What: die release pump was not woking properly
why: end of pump life
C/M: replaced pump
Recurr: eventually What: die release tank flooded
R/C: Float stuck due to buildup
C/M: Removed both floats and cleaned, verified valves closing properly by float
Will it reoccur: Timing
C/T: No change What: door needed reattached
Why: broke off
CM: worked with Mike Mowery to weld door back on What: door would not close
Why: debris is the safety door plug.
C/M: cleaned out door safety plug What: dust collector filter readings were in the red
Why: end of filter life
C:M/ replaced filters What: flame out
Why : Hot aluminum got leaned against panel burnt up wiring to the pilot valve and main gas valve
C/M: Replaced both valves and rewired
Recur: Possible in time What: flipper 4 and 1 was not working
Why: Parts jammed up
C/M: Pulled all parts out
Recur: Possibly in time What: flipper sensor
Why: Sensor bad
C/M: Replaced sensor What: foot fell off bottom of up and down trim press cylinder
Why: ripped off half of threads
C/M: replaced foot and cylinder
Recur: Possibly in time What: furnace repair What: furnace temp
Why: Bad thermo coupler
Counter measure: replaced What: half pipe cracked
Why: half pipe failure
Counter measure:replaced halfpipe
R/C: No
Cycle time: Unchanged What: high readings/out of spec, axis 4
Why: Suspect quick connect fittings
C/M: Replaced fittings What: holding temp bouncing around
Why: thermocouple no good possible broken wire
C/M: replaced thermocouple with new
Recur: Possibly in time What: hydraulic leak
R/C: slide core operator side main hard line on die leaking hydraulic fluid
C/M: Removed main line from fittings, replaced fitting on slide core and replaced line with extra line What: hydraulic leak
Why: Hose bad fitting
Counter measure: Replaced hose to tappet pins
R/C:
Cycle time: Unchanged What: hydraulic leak
why: squeeze master line from manifold to die hose leaking
c/m: Replaced leaking hose with new line, operator bleeding squeeze master
will it reoccur; timing
cycle time: unchanged What: hydraulic leak.
R/C: the welded hydraulic fitting was cracked.
C/M: had die maintenance reweld the fitting.
reoccur: timing What: hydraulic oil leak
Why: injector hydraulic line leaking at pre welded area that has been repair multiple times.
R/C: no replacement in stock
C/M: Removed injector hydraulic line, grinded down What: ingot loader issue
Why: Ingot loader not home
Counter measure: Got home What: ingot loader paddles missing
Why: bolts missing and some loose
C/M: replaced paddle and put some bolts in where they were missing
Recur: possibly in time What: ingot loading bucket will not go up
Why: Key-way fell out of shaft
C/M: Made new key-way now ok
Recur: Possibly in time What: investigate replacement of TDCAC-1 analog O/P card. Does it need information loaded to it or is it plug and play.
Why:
C/M: No inof found on line, I asked Mr. Taka about this, he is going to mak What: keeps getting ladle forward limit switch alarms
Why: faulty wiring
Root cause: cabling is worn out over time
Countermeasure: ran a permanent cable from the control panel to the junction box
Reoc What: ladle alarm
Why: Wire broke
Counter measure: Replaced wire What: ladle arm locked up
Why: Bearings bad
Counter measure: Replaced whole ladle arm unit What: ladle bar electrode malfunction.
R/C: Ceramic sleeve for electrode assembly broke.
C/M: Replaced 2 of the ceramic sleeves.
Reoccurrence: Timing. What: ladle bar issue
Why: Aluminum build up
Counter measure: Cleaned off aluminum and replaced broke ladle What: ladle bar malfunction
Why: Probe end missing
C/M: Replaced with stainless rebuild probes
Recur: Possibly in time What: ladle bar malfunctions
Why: Aluminum from back side of ladle rubbing bars
Counter measure: Replaced ladle bar porcelain sleeve. What: ladle broke
Replaced ladle What: ladle broke
Why: Aluminum left in it What: ladle broke
Why; Unknown
Counter measure: Replaced ladle What: ladle crash inside at sleeve
Why: Ladle chain broke at turnbuckle
C/M: replaced broken turnbuckle and master link
Recur: Possibly What: ladle electrode bar mal
Why: Insulator broke
C/M: Replaced ladle probes
Recur: Possibly in time What: ladle electrode bar malfunction
Why: Ceramic sleeve on bulb probe broken
Countermeasure: Replaced ceramic sleeves
Will problem reoccur: Possibly
Cycle time: No change What: ladle electrode wire break
Why: Wire Kinked broken wire
C/M: Replaced with new wire
Recur: Possible in time What: ladle forward L.S. mal-function
WHY: unknown
C/M: replaced cable from main cabinet to ladle wire box for forward limit sensor x60
REOCCUR: unknown but we ran temp cable m/c ran 1.5 hrs no faults What: ladle wont move
Why: Chain broke and lower unit seized up
C/M: Replaced lower unit
Recur: Possibly in time What: little scrap conveyor stopped
Why: Was jammed up
Counter measure: Un jammed
R/C: Yes time
Cycle time: Unchanged What: little scrape conveyor jammed
Why: Piece from vacuum block jammed in chain
C/M: Pulled conveyor worked conveyor back and forth till it fell out and un jammed
Recur: Yes In time What: losing Blocks 5 and 6
Why: Bolts not long enough
C/M: Put M6 x70 in all blocks
Recur: Possibly in time What: lower ladle locked up
Why: To hot for bearings that we use/ being left over furnace
C/M: Replaced lower unit with brand new
Recur: Possibly in time What: lube line broke.
Why: worn out.
C/M: replaced lube line What: machine stopping What: machine will not run in auto, home position
why: Robot position not home, x14E for door interference
cm: Ran home program to move robot to home positon, door operation not corret on helper sid What: melting burner fan housing got hot melted igniter off and melted damper fan switch
Why: Excess build up of re-melt sludge in melting crucible
C/M: Replaced ignition wiring and igniter and glass What: melting crucible break/splash leak
Why: Possibly had alot of remelt liquid in upper when loaded it splashed out over causing it to metal leak
C/M: Replaced upper melting crucible What: melting metal leak
Why: Halfpipe broke
C/M: Replaced halfpipe and pasted filter at top What: mist collector filters bad
Counter measure: Replaced filters What: mold heater not coming on
Why: Contactor melted What: motor overload
Why: proximity sensor tracking motor shaft was too far in always giving a signal
C/M: backed sensor off to get proper signal What: motor overload at trim press
why: scrap conveyor 1 bount not turning
c/m: Removed covers and found full off scrap and other debris, Cleaned out jammed parts and debris, Verified operqtion and oi What: motor overload on the small scrape conveyor.
Why: chain was loose and jammed up.
C/M: cleared jam and tensioned the chain. What: movable core 2 alarm
Why: Movable Cores got stuck in. New Operator ran out with out heating die up 1st. Broke ejector pin
Counter measure: Talked with operator about what happened and told them What: moveable core 2 faults at start up
why: lead switch for top move core smashed in between die breaking wires
c/m: Replaced broken lead switch and verified operation
will it reoccur; timing
cycle What: moving core 2 faults
Why: Bad cable
C/M: Replaced cable
Recur: Possibly in time What: not seeing part at part detect
Why: Robot needed adjusted
Counter measure: Adjusted robot What: ok bucket wont go up
Why: Set screws and keyway were missing
C/M: Tore apart put keyway back in and long set screws so i know they hit bottom What: ok carrier wont return or advance
why: shaft on the top of ok conveyor is broken
CM: find an old one in warehouse What: ok conveyor bucket sensor bracket fell off
Why: bolts stripped and broke
C/M: drilled new hole for bolt from top of block
Recur: possibly in time What: ok conveyor jammed
why: conveyor jumped tooth on conveyor
c/m: Loosed bucket and realigned sprocket with chain
will it reoccur: timing
cycle time: unchanged What: ok conveyor not returning
R/C: Wear block worn on conveyor
C/M: Removed left wear block and installed new, adjusted chain on left side to allow conveyor to work properly
Will it reoccur: Timing What: ok table not rotating
why: table top bolts in shaft broken/stripped
c/m: Removed stripped bolts and broken. Installed new flat head bolts in table top. verified rotation ok
cycle time: unchanged What: operator door lock not working
WHY: lock broke
C/M: removed switch lock from dc 6 to dc5 so dc5 could run
part will be here tomorrow What: operator reports squeeze pins will not advance
why: squeeze pins work fine in manual but wouldnt adv/ret in auto. found loose connection on SQM sensor (bottom left on outside of main control pan What: part detect sensor in the trim press problems.
Why: sensor was loose and kept losing its position.
C/M: tighten sensor and adjusted set points. What: part sticking in trim die cavity 4
R/C: parts sticking it trim press die ap4-s-1
C/M: lowered trim press down position , checked all flappers changed out trim press with spare
re-occur: monito What: passed on from 3rd moveable core 2 would not operate
Why: Hydraulic lines not installed correctly
R/C:
C/M: tested hydraulic line connections and reattached, manually worked ok
Will it reoccur What: plunger not returning ,ejector pins not returning and vacuum faults
Why:Setting was wrong in vac machine
C/M: set to correct setting
Recur:Possible in time What: plunger rod leaking from coupler
Why: O-ring no good
C/M: Replaced with new shaft and O-ring
Recur: possibly in time What: plunger tip not returned completely, filled sleeve with aluminum
R/C: Unknown
C/M: Removed tip and plunger shaft, removed aluminum and reinstalled
Will it reoccur: unknown due to unknown r/c What: product detect sensors no good
Why: Lost sensitivity
C/M: Replaced cavity 1 and 2
Recur: Possibly in time What: robot Top 6A0 S-1 cracked
Why: ?
C/M: Replaced with new
Recur: in time. What: robot alarms WAP
Why: Robot not gripping part at mid point solid
Counter measure: Retaught robot at mid point and set down in trim press
R/C: Unknown
Cycle time: Unchanged What: robot crashed
Why: Big claw bolts broke
Counter measure: Replaced bolts
R/C: Yes
Cycle time: Unchanged What: robot door sensor broke
Why: Worn
C/M: replaced sensor with new
Recur: Possibly in time What: robot fault.
Why: fan was bad on the controller.
C/M: replaced fan What: robot faults at the trim press
Why: Robot chuck part locate pin missing causing it not to grab in correct position also had to reteach final set position
C/M: Replaced pin with a new one
Recur: What: robot stopping
Why: Ng conveyor broke jammed flippers
Counter measure: What: robot trouble at trim press
Why: robot taking shot in at weird angle and they were using RPY P,S program which is NG
C/M: Retaught robot in 5BA program and deleted RPY P,S program
Recur: No What: safety door for ingot loader was not locking/latching.
Why: the saftey lock device was too far away from the safter key to reach as well as the latch.
C/M: modified and piece of metal to extend What: safety door handle came off the door
R/C: screws backed out allowing handle to come off
C/M: Removed diamond style holders behind screws and installed strait to allow better hold on door
Will it What: scale not working
Why: Wiring smashed and burned
C/M: Metler Toledo coming in to replace all
Recur: Possibly in time What: scheduled down for furnace repair
Why: Side door in need of repair
C/M: Removed old and patched side door, completed seansoning and left at weekend shutdown temp.
Will it reoccur: Timing
CYcle t What: scrap conveyor
Why: Jamming up due to paddles broke off
Counter measure: Un jammed all the paddles and Welded all but 2 paddles that broke off What: scrap conveyor
Why: Jammed
Counter measure: Un jammed What: scrap conveyor faults
WHy: chain loose allowing trip sensor to be made
C/M: tightened chain on scrap conveyor
will it reoccur: timing
cycle time: unchanged What: scrap press guide shaft no good
Why: Linear Bearings fell out
C/M: replaced both shafts and linear bearings
Recur: Possible in time What: scrap press not working
Why: Scrap sensor not working correctly
C/M: Changed Sensor out
recur: possibly in time What: screen is frozen
Why: operator cleaned with Windex , moisture trapped in touch panel
CM: take apart to dry it out What: shot Breaking
Why: no lube, spraying on sleeve
C/m: Replaced tip
Recur: Yes in time What: shot detect sensor
Why: Not reading zero
C/M: Replaced sensor
Recur: Possibly in time What: shot detect sensor problem
Why: Blowback around sensor
C/M: Removed sensor and cleaned
Recur: Possible What: shot not stamping out
Why: Trim press ramps bent
Counter measure: Fixed bent ramp
R/C: Yes
Cycle time: unchanged What: shot operation malfunction
Why: Flashing around shot sensor.
C/M: Removed sensor and cleaned... no signs of damage. Put back together and confimed ok. What: shot position sensor/ wire break
Why: Sensor no good
C/M: put new sensor and cleaned hole of debris
Recur: Possibly in time What: shot sensor alarm
Why: Sensor dirty
Counter measure: Pulled out and cleaned hole and sensor What: shot sensor issue
Why: Bad shot sensor
Counter measure: What: shot sensor no good
Why: Scratch on shaft reading end
C/M: Replaced with new
Recur: Possibly in time What: shot sensor wire break fault.
Why: sensor was dirty.
C/M: cleaned sensor What: shot sensor wire broken
Why?
C/M: Went in pulled apart and cleaned and blew out out sensor housing and hole
Recur: Idk What: slide core cracked P-1
Why: Unknown
Counter measure: Replaced
R/C: yes time
Cycle time: Unchanged What: soldering (Water passage)F3
Why: Aluminum build up
Counter measure: Cleaned die. Checked spray points. Ok
R/C: Yes
Cycle time: Unchanged What: soldering on P2 and P4
Why: Coating wore off
C/M: Replaced both
Recur: Possibly in time What: spray cartage leaking
Why: Bad Valve
Counter measure: Replaced valve What: spray cartage leaking
Why: Bad valve
Counter measure: Replaced valve What: spray cartage leaking
Why: Spray valve bad
Counter measure: Replaced spray valve What: spray cartridge hitting fixed die
R/C: Changeover from 6A0 to chain tensioner spray cartridge length must be adjusted due to smaller die
C/M: loosened set bolts and adjusted spray cartridge to t What: spray cartridge not working in auto operation.
Why: Solenoid valve no good
C/M: 3rd replaced with new but spray constantly stayed on valve was on upside down JR Otto looked at dc 5 found the val What: spray cartridge will not turn to the home position.
Why: turn solenoid will not shift.
R/c: no PM schedule for solenoids.
Temporary Counter Measure: manually shifted solenoid valve to return to What: spray point on spray cartage not working
R/C: Tip plugged on spray point
C/M: Removed tip and cleaned, adjusted spray point back after reinstall
Will it reoccur: Timing What: spray valve leaking
Counter measure: Replaced valve What: sprue bushing leaking. Why: cracked sprue bushing. CM: Replaced sprue bushing. What: sprue cooling hose broke off
Why: Hit when die changing
Counter measure: Replaced end What: squeeze master trouble
Why: squeeze pin/cavity 4 not operating correctly, squeeze pin on cavity 4 loose.
R/C: Squeeze pin did not have lock tight on threads, Die new and die has not been torn do What: squeeze pin Cavity 1 Depth running low out of spec Die #4
R/C: Squeeze pin on die sticking out 5mm farther than other 3 cavities allowing parts to be out of spec
C/M: Die needs removed for die m What: squeeze pin cavity 3 and 4 would not move with squeeze master
Why: Air in lines not allowing pins to build pressure, hydraulic lines not hooked up to correct cavities
R/C: Hydraulic lines not co What: squeeze pin depth out of spec
R/C: Die #4 Cavity 1 squeeze pin came loose from cylinder
C/M: Pulled die apart robot side, Pulled squeeze pin and cylinder. Cleaned threaded added Loctite as count What: swivel joint for Die Release spray
Why: worn O-rings
C/M: replaced with new swivel joint
Recur: Possibly in time What: tappet pin out of spec (shallow)
Why:
R/C: What: temperature reading not consistant,
Why: Bad thermocouple on the moving side
C/M: Replaced thermocouple
Recur: in time What: tip and sleeve
Why: Washout of sleeve and broke cooling joint
C/M: Replaced the tip and sleeve and also cooling joint
Recur: In time What: tip seizing up in sleeve
Why: Aluminum build up in sleeve at tip insertion
C/M: replace tip and sleeve
Recur: Yes in time What: trim damage
Why: #5 cutter
Counter measure: Replaced cutter #5 and pulled locate pin for cutter out not enough movement What: trim damage
Why: Cutter broke
Counter measure: Replaced cutter
R/C: Yes
cycle time: Unchanged What: trim damage
Why: Tabs flipping up into trim die
Countermeasure: Made guide blocks so tabs cannot flip into die
Will problem reoccur: Possibly
Cycle time: No change What: trim damage cavity 1. (Trim die #1 59b one rocker)
Why: Aluminum Debris In cutter
Counter measure: Replaced cutter and moved cutter out away from part. Vacuum cutter What: trim damage on P1 and S1
Why: Had die repair on both cavities at the rocker shaft end leaving heavy trim on P1
C/M: Pull die for die maintenance to determine what to do i tried new cutter and a What: trim press damage all 4 cavities
WHY: new cutters installed needed adjusted
C/M: adjused all cavities pass on to second
reoccur: yes What: trim press faults.
Why: part detect sensor was out of adjustment.
C/M: work with Sergio and adjusted part detect sensor. What: trim press leaving cavity 1 and overflow tree on press
Why: Holes where the locate pins go were full of aluminum from die bushings in die are no good
C/M: Drilled out holes now ok nothing you ca What: trim pump making noise
Why: changed pump
C/M: Replaced Pump
Recur: In time What: turn table locking
Why: Pillow block bearing bad
3rd shift put back together. What: turn table problem
Why: Bolts broke off on disks center
Counter measure: Replaced bolts What: upper crucible broke
Why: Root cause unknown What: upper lid coming open by self
Why: Valve bad
Counter measure: Replaced valve What: vacuum Faults
Why: ?
C/M: replaced block with matt klines block
Recur: Possibly in time What: vacuum equipment failure faults
Why: Unreach to tank alarm
Countermeasure: Cleaned oil out of vacuum pump and filter
Will problem reoccur: Possibly
Cycle time: No change What: vacuum failure
Why: losing vacuum / sucking in aluminum in valve
C/M: Put 0.050mm shims behind vac blocks
Recur: In time What: vacuum operator side
Why: Low oil in tank
C/M: Refilled oil
Recur: Possibly in time What: vacuum problems.
r/c- vacuum hose manifold plugged. spray point on r/b side vacuum block off
c/m- unplug manifold block, adjust spray point
reoccur-no
cycle time before- 24.9
cycle time after- 2 What: vacuum pump no good
Why: No oil
C/M: Replaced pump with new that we had from another install
Recur: Possibly in time What: vacuum pump shaft broke
Why: Unknown
C/M: Replaced with the pump off Die Cast 6
Recur: Possibly in time What: vacuum trouble
R/C: Hole in hoses
C/M: Removed and installed new clear hose on r/b side due to worn hose. Removed and installed new air line for slow speed shot due to hole in op. side hose.
Wil What: vacuum trouble op. side
R/C: dirty filter/plugged inline filter
C/M: removed and installed new filter, pulled inline filter and cleaned out debris
Will it reoccur: Timing
Cycle time: unchanged What: wand not spraying water
why: water valve to spray not completely
cm: opened up water valve fully
will it reoccur; timing
cycle time: unchanged What: water leak
Why: Someone hit sleeve cooling joint
Counter measure: Replaced
R/C: Yes time
Cycle time: Unchanged What: water leak
Why: Upper squeeze pin fitting leaking water
Counter measure: Replaced fitting and added O-Ring to cooling joint in squeeze pin to keep fitting from melting fitting seal.
R/C: Yes tim What: water leak
why: Spray cartage leaking, 2 separate valves
c/m: Removed leaking valves and disassembled, cleaned and reassembled verified in machine ok.
will it reoccur; timing
cycle time: unchang What: water leak
why: sleeve cooling joint broke, leaking due to excessive amount of aluminum coming out back of sleeve after shot
R/C: What: water leak on at plunger shaft coupler
R/C: O-ring bad on cooling joint inside plunger shaft
C/M: Removed plunger shaft and tip, Pulled apart and replaced cooling joint o-ring, tapped and reinst What: water leak on sprue bushing. Why: Cracked sprue bushing. CC: replaced sprue bushing. What: water leak on sprue bushing. Why: Cracked sprue bushing. CM: Change sprue bushing. What: water leak top slide core. Why: broken water fitting. CC: replaced water fitting. What:: Ingot loader issue
Why: Sensor bad the detects ingots
Counter measure: Replaced sensor What:Axis 3 alarms, vacuum trouble, pressure build up alarms (Running 6A0 S parts)
R/C: Air in lines for squeeze master on axis 3, vacuum trouble R/C unknown, pressure build up alarms un known
C/M: Li What:Cleaning heat exchangers. What:Die Crashed, all 4 slide cores broken
R/C: No other explantion other than operator error.
Countermeasure: Confirm location and operation of part detect sensors.
Will it Re-occur: Yes, can not con What:Fixed side of Die Fixed Pin feature cracked and leaking water.
Why: Failure
Countermeasure: Pull fixed side of Die and Replace fixed pin feature
Replaced F3 and F4 fixed pins, F5 and F6 squeeze p What:High shot speed
Why: Tip worn
C/M: Replaced tip
Recur: In time What:Holding crucible filter failure. Filter frame also cracked and not repairable
Why: Filter failure
Countermeasure :Replace crucible and filter
Recur: Possibly in time What:Hot Trim piece landed on the scale wiring causing scale malfunction
Why: Scale wiring installed without protective conduit
Countermeasure: Repair wiring and Install protective conduit
Reoccur: No What:Injection cycle time out
Why investigating
Countermeasure: Inspect and clean shot sensor and replace wear bushing.
Reoccur: Monitoring What:Investigate bottom shots tree breaking in Die when ejecting.
Why:Broken bottom Helper roller slide core
Countermeasure: Replace slide core and inspect both sides for free movement What:Leaking sprue bushing.
Why: Sprue bushing cracked
Countermeasure:Replaced the leaking sprue bushing. water tested OK Verified cooling. (JEFF)
Reoccur: Timing What:Piston Vibrator not working
Why: Piston not moving full stroke
C/M: Replaced with new Piston Vibrator and bumped up air pressure
Recur: Possibly in time What:Recent overflow of Aluminum caused a build up of Aluminum and corundum around the crucible spout moving the Filter forward towards the Ladle and the Ladle was making contact with the filter resul What:Robot chuck sensor no good
Why: Bare wiring
C/M: Ran new sensor direct from chuck to control box on robot
Recur: Possibly in time What:Robot not unloading shot off die
Why:Robot arm was bent
C/M:Replaced arm
Recur: Possibly in time What:S2 Slide core chipped and leaving soldering.Replaced s2 slide core What:Slide core crack with raised area showing up on part
Replace S-2 Slide core What:Trim Press cylinder unthreaded from trim lift nut Cylinder rod threads much damage.
Why. Nut threads pulled out
Countermeasure:Replace trim cylinder and nut.
Reoccur: No What:Vacuum multiple times on 3rd shift
Why: Spray cartride missing a mounting bolt and spray ports not aligned and spray valve turned off to spray cartridge.Change over start up failure
Countermeas What:changing holding crucible and half pipe.
Why: Aluminum Failed testing for quality Multiple times What; AL01 alarm melting furnace
Why: Thermo coupler bad
Counter measure: replaced thermo coupler
R/C: Yes
Cycle time: Unchanged What; Blowback, biscuit size bouncing around
Why; Possibly bad tip
C/M; Changed tip Shot life- 31,000 What; Changing tip, Shot life 15,000
Why; High shot speed alarms
C/M; Replaced old tip with new What; Heavy flashing (Blow out in die)
Why:Operator did not set Lock low limit correctly. It was at 70% when it should be no lower than 86%
Counter measure: Changed from 70% to 86% and cleaned die
R/ What; Ladle operating erratic bouncing, not filling up ladle
why: Ladle probes covered in buildup aluminum due to dropping to far
c/m: replaced ladle arm probes, verified probe settings on rebuild pro What; Melting Crucible spout broke
Why: Worn been in furnace since December Both upper and lower
C/M: Replace upper and lower,pedestal's and half pipe
Recur: Yes in time What; OK parts turntable
Why; Lots of chips and flashing underneath+bearings sticking
C/M; Replaced five bearings and blew chips out
Reoccur; Possibly with time What; Parts getting stuck in trim press
Why; Broken spring pusher
C/M; Replaced spring and end piece that was missing, also had aluminum jammed in trim press, removed aluminum What; Scrap conveyor not moving
Why: Mesh had a hole in it allowing scrap to fall in stopping conveyor
Countermeasure: Replace mesh scrap conveyor
Reoccur: Possible What; Spray cartage leaking
Why: Leaking spray valve
Counter measure: replaced valve What; Tip and Sleeve, shot life 45,000
Why; Blowback and flashing
C/M; Replaced tip and sleeve with new What= Holding metal leak detect
PRC= broken/cracked crucible - over flow on holding crucible
C/M= follow safety protocol, open leak detect door and very little hard aluminum contacting probe. believe What= OK incline conveyor moving What= Vacuum problems. Why- Maybe dirty die release filter. C/M- Replaced operator side hoses and cleaned die release filter. Reoccur- Yes in time. When Die Cast machine cycle is Auto hydraulic pump is turned off.
jermey worked on When I came in plunger shaft was pulled and I was told machine had excessive blowback. I was instructed by Darrell to see if plunger shaft was bent which it was. Got a new shaft tip and sleeve and ins When new safety gates were installed the nitrogen line was not considered, now that the operator needs to add nitrogen to crucible a new access pipe will have to be added for the nitrogen line. While doing die change operator damage all 4 draw bars. Got 4 draw bars and gave to DH. Wires by unload table are exposed. Protective cover is split and coming off. Wires on safety plug pulling out
C/M: Reattached connectors to safety plug. Work Request Aattached. Work Request Attached. Work Request Attached.
Replaced button cover Work Request Attached. DG A temporary repair has been made until parets can be ordered Work Request Attached. Status Complete. Work Request Attached. Status complete. Work Request Attached. Work Request Cancelled Due To No Follow Up by EHS With Contractor. Work Request Attached. Work Request Cancelled Due To No Follow up by EHS With Contractor. Work Request Attached. status Complete. Worked on scrap conveyor while machine was already down.
Fixed bent paddles, replaced missing paddles. Worn Worn Plunger tip Worn part Worn,
Gave to Roger O X60 FORWARD LADLE LIMIT SWITCH FAULTS
SENSOR WAS BAD AFTER PHATOM (SAFETY) WORKED ON YAMAGUCHI, GAVE TO SCOTT T. a lot of downtime for low aluminum
confirmed thermocouple and replaced
also adjusted gas pressure up to increase burner output. a/b 21 stationary
sa/p 22 moving accumulator making moaning noise
Fix: replaced PLCSOL Pressure cut valve on injection unit. added alarm output to melkeeper through relay to robot input xoae. added input x0ae to robot abnormal output to diecast machine. if ev2 triggers and stays for 2 seconds output will trigger robot abnor added interlocks for the squeeze pins. see attached file added low melt temp alarm output from melkeeper through robot to diecast machine. added timer t94 and output y073 to melkeeoper to input x0a6 in robot when melt temp is low triggering ev2 for 2 seconds. relay turns on input x0a6 in robot sending robot abnormal to die cast machine c adjusted timer t052 to open robot door as soon as mold opens. changed timer t052 from 0020 to 0001
cycle time went from 25.5 to 24.2 air blow not working correctly for plunger lube and sleeve air blow staying on when turned off on spray cartridge air bowl at vacuum leaking air bowl broken air bowl for inside door leaking. Replaced with new one should not happen again. air leak
main air line
routed different so it cant b cut by the pipe clamps on floor from people stepping on air leak at robot chuck air leak on unchuck side of the chuck cylinder. had a hole melted in the unchuck air line. air leak(spindle oil air purge bowl cracked) air leak,sleeve air blow line broke going into air and lube cylinder for plunger shaft air line catching on helper door air pressure drop alarm would not stop aluminum high level probe insulators and wires came out aluminum leak detect keeps alarming aluminum upper limit detect probes melted too short amp meter not working.. and exhaust temp reading too high assisting production and die maintenance with major hydraulic leak. Tank was emptied during leak assisting production for dropping parts issue. assisting production with axis alarms. Been getting them all night, only ran 186 shots and only about 10 of them were good parts. Also dropping parts. R/B position off at scrap press assisting production with vacuum equipment failures. assisting production with vacuum failures during pre-heat shots. assisting production with vacuum problems. assisting production with vacuum trouble assisting production with vacuum trouble. (operator side) assisting production. chill block trees sticking in trim press causing shots to sit in press wrong and crushed parts. assisting production/ Craig R. with die problem (move core 2 limit switch faults) automatic ingot feed conveyor broke. axis alarms off and on all night. Made adjustments while m/c was running axis alarms. Had problems most of the night but M/c was only down about 2 hours I adjusted while running mostly. All parts ran were good parts approved by Quality axis problem
- chunking squeeze pin hole #2 axis reading coming and going issue. back door on furnace not shutting back door on melting furnace leaking aluminum on floor and loader back door to furnace door not holding it's up position, bleeding off.
-Fix dcv was bad back furnace door bad,
gave to John C. base not secured to floor bearing in scrap press fell apart bearing on ok conveyor ng (right side) bent cover on top of die biscuit thickness problems. bearings in the lower ladle unit was locked up. operator was having to switch key switch several times to get in manual. biscuit reading high on screen but is actually not bisket not matching thickness on screen bisket thickness and reference point not correct on shot sensor. blew vacuum blocks and hoses. while checking die release I noticed air bowl for vacuum was leaking air. blocked air blow on trim press on the downward motion. requested by Scott Taylor. Blocked M125 with a M9037 bit for the M124 coil. Will run trial to see if this helps with scrap being left on the pres blow back blow back
sleeve and tip bad
plunger lube spray nozzle plugged up blow back
tip bad
plunger lub spray tip clogged blow back replaced tip only
gave to john c. blowing vacuum blocks blown vacuum block blown vacuum blocks blown vacuum blocks. When removing hoses oil dripped out. blue good conveyor jammed blue good conveyor rail missing bolts blue ok conveyor both P slide cores were cracked both chains came off ok parts carrier. both top (P) slide cores were cracked bottom Absolent air filter gage out of spec
replaced stage 1 HEPA filter
no downtime bracket on scrap press broke broke broke ladle wire broken broken Ladle broken crucible & half pipe on "12-23-16" broken cutter #3 in trim press broken cutter cavity 1 broken cutter on trim press broken electrode assy, bolt broke when taking assy off broken ladel broken ladle broken ladles broken slide core (P2 cavity) primary operator side broken slide core 5A2 P2 cavity (operator side) broken slide core 5BA p/s die operator side. broken slide core pin 5A2 P operator side (P2) broken slide core pin 5A2 P robot side broken slide core pin. P1 (robot side) broken tappet pin (P) part top robot side. broken tappet pin cav #1. replaced broken tappet pin on cavity #1. broken tappet pin on cavity #1. replaced tappet pin on cavity #1. broken tappet pin robot side bottom broken thermocoupler. button broke on control panel. safety audit said replace can not get die temperature in spec. have been fighting this issue all night. down time was at least 4 hours was not able to keep accurate time due to other m/c problems cavity #4 slide core broke, replaced cavity #4 slide core. replaced Cavity #4 tappet pin as well. cavity #4 squeeze pin bushing has a chip in it. replaced squeeze pin bushing on cavity #4. cavity 1 cutter broke cavity 3 trim damage ch. 1 on squeeze master out.1st channel 1 bleeding off ,has hesitation coming out. ch. 3 axis alarms chain broke on ok conveyor chain fitting pulled out of ok parts carrier change NG P2 slide core change P1 slide core for burr issue change cracked slide core M1 change cracked sprue bushing change over change over from chain tensioner to 1RKR. changed crucible filter changed ladle back to original (1.0) size changed sprue bushing for porosity changed t52 from 10 to 15 so robot side door would not open and close twice after each shot. (Toshiba PLC) changed tip/sleeve during changeover shot life
109,000 shots changeover inspected sleeve wash out/blowback
gave DH new sleeve changeover to 1rkr changing thermocouple moveable side. charge loader stopping in middle of loading. operator window, melted. chart paper replacement checked tie bar bushing clearance for moving side die
had to adjust both slide shoes used a .152mm feeler gauge all 4 tie bars child parts washer 3 cylinder leaking air. See attached picture. chip in slide core chip on P1 and S1 slide cores. replaced P1 and S1 slide cores. chipped chuck pos ref. # reading -15 supposed to be 0 clean and flush die release unit clean out exchanger clogged and saturated filter on vacuum pump and mist collector top filters are in the red. cmss wanted shot detect sensor position checked due to flashing buildup when running.
MACHINE STILL IN TRIAL STAGE, NO DOWNTIME. coating worn off slide core, change P1 slide core collar come loose on trim press. had it marked with paint mark. was checking it every hour. collision detect alarms at trim press. collision detect at scrap press, shot moving when hand opens at trim press causing scrap piece to make contact with block on scrap press collision detect faults when the shot is ejected from the die.
countermeasure: adjusted P5 and moved the softfloat command after the handclose command. collision fault on robot at trim press collision faults at the trim press
sub runner not being removed at the vibrator
3rd shift replaced the robot arm because it was bent. apparently it had been crashed concentration level for spray dropping below spec. replaced injector intake line and cleaned out uptake pipe. Ran several fill cycles until we had a consistent in spec level at 2.05. continuing to monitor ladle cup for breakage. continuious flame outs.. conveyor advance fault coolant line leaking, repaired.
Replaced SPOT COOLING LINE 2x..... cooling joint leaking core 2 limit switch malfunction countermeasure (machine down no downtime)
What: scrap getting caught in scrap press causing buildup, scrap conveyor open on end allowing scrap to fall out causing buildup
R/C: No cover
C/M: Build and countermeasure m/c planned downtime
problem: ok tables in need of repair
cause: normal wear
countermeasure: removed both ok unload tables, installed repaired tables and confirmed working
reoccurrence: countermeasure work
Problem: selector switch for V-check is opposite of tag
cause: 3 way selector switch was installed should be a 2 way
countermeasure: Installed correct switch and wired for v-check, crack on P1 and P2 slide core out of spec. What:P1 and P2 slide core cracked. CC: replaced P1 and P2 slide core. crack on top slide core on cavity #1. replaced top slide core on cavity #1. cracked cracked P1 slide core 5BA F- 20 cracked and leaking cracked ladle cracked slide core A2 robot side. slide core broke again due to a water cooling slide in slide core bent. cracked sprue bushing. replaced sprue bushing. crashed ingot loader crashed unloading robot at trim press crucible broken crucible combustion blower went out crucible filter had holes in it causing aluminum to be NG crucible lid bouncing
when coming open cup has been dropped and dented out of round cutter no good cutter on scrap press chipped missing scrap clean out bracket cutter on trim press breaking cavity 3 (robot side left if looking in from outside m/c) cylinder on helper door came unscrewed from door damaged cooling line. replace with new line. diaphragm pump out of spec running at .2 when spec is .3-.5
pump ng did not have all fittings to do job second took apart will ask tomorrow if they still have zero downtime die cast 2 needed new chill block. JBS die cast 8 leak on sight glass on hyd.tank die cast lube shortage. filling lube 2times a shift die cast machine would move a little bit when the die would open and close die casting machine lubrication malfunction alarms b-122 die change was done on previous shift. when operator on 3rd started m/c shot scrap was bouncing very bad and not being cut by scrap press. die close cylinder supply pipe leaking die height forward push button selector switch was missing knob and button die is over heating. die lock force malfunction alarms die lock force malfunction. injection force malfunction. die not opening die not opening all the way in manual and auto. ch.3 ch.4 axis faults die open operation malfunction occurred while running die release concentration reading low out of spec
cleaned the floats in the die release tank. die release machine not filling up with water. Water in and on the contacts of the power supply. die release piston pump not working.. die release pump not working shutting off die release tank not filling with water. die temp rising too high die-lube pump not working diecast machine lubrication malfunction faults. dirty bowl filters and air leak door switch broken on operator door down for scheduled refractory rebuild. drag flight on scrap conveyor tripping sensor drill and tap hole for sleeve clamp, no down time m/c down for die change dropping parts
tip very worn, they are cleaning sleeve before replacement of tip dropping parts from shot when die ejects shot dropping shots dropping shots (sticking to tip). had production pull tip and it was bad so I had them replace it dropping shots. found that shots are sticking to sprue pin dropping shots. operator noticed that all shots except the ones being dropped show signs of plunger lube. dropping shots. plunger lube spray tip plugged dropping the shot intermittently during change over dh got alignment pin stuck into sleeve
sleeve damaged
also no plunger lube and over pour during changeover DH noticed sleeve had a crack
replaced tip and sleeve at changeover
tip and sleeve had 31,177 shots during changeover we replaced tip an sleeve due to excess ware
tip and sleeve shot count is unknown ejector pins came out while slide cores were in. broke slide cores. Fault showing ejector limit position control off. electrode bar malfunction fault. 3 of the wires broke off at the copper connector. electrode bar malfunction/break faults electrode for rebuild ex haust temp control throwing al01 alarm excessive blow by, shot sometimes falling off die because of blow by. Replace sleeve and tip excessive build up in furnace. Furnace inside temp too high excessive play in the ladle.
Cause: the upper and lower chains were loose on one side of the sprockets.
tightened the chains exh a/b 21 stationary
EXH A/B F-21 MOVING exhaust gas temp. controller al-o1, thermo-coupler open. f-16 moving filter filter life filters out of spec finish installing and setting crucible fix core switch was missing turn knob fixed air leaks around m/c during downtime
replaced a broken air bowl fixed side temperature alarms flame out flame out resets for holding burner and melting burner flame out, won't re-fire flipper #3 flipper 1 error flipper 1 on trimpress not operating sometimes flipper 2 loud and hanging up flipper sticking #4 flipper 2 out of adjustment bolt stripped
trim height ng floats in die lube unit sticking flow line in parts follow up from 3rd. worked with jim h. forward ladle switch and forward travel switch malfunction forward ladle switch limit alarm forward limit switch alarm furnace and crucible change furnace back door flame coming out of bottom
inner linear of door bad furnace back door seal bad furnace is popping when the melting furnace is loading material.. furnace rebuild. replaced melting furnace and new crucible.
seasoning new furnace and crucible gave to DH old on broken gave to John C.
Blow Back , Vacuum trouble gave to John C.
worn gave to John C.,
cracked gave to eng. modification gave to operator, old one bad at life getting biscuit alarms. after biscuit alarms DH noticed that he had to reset shot stroke origin every time. getting blowback, tip and sleeve over tool life good chain conveyer good conveyor alarm good parts conveyor#2 not turning good parts turn table for #1 and 2 guide wheel fell off blue good conveyor guides on ingot loader fell off had to reset small scrap conveyor starter contactor, tripped. having low and high shot speed alarms having robot issues wanted light replaced to trouble shoot having the operator pull the fixed side of die to do a small weld repair on cavity S1. help side door would not close. helper door back roller loose. helper door bouncing helper door bouncing when it goes to shut.
checked limit switches and all bolts. added time to timer. rung 07008 in book. 00731 in plc. timer t052 from 3 to 20. stopped the bouncing . helper door bracket broke. helper door broken bracket causing faults helper door faults helper door faults (when door closed)
cylinder loose tightened back up, adjusted limit switch bar helper door limit switch alarm helper door limit switch malfunction helper door not making ls2 sensor. helper door not shutting all the way helper door open limit switch helper door open limit switch failure helper door plexy glass broke . replaced helper door was not moving. The door cylinder bracket broke. helper door wheel broke helper side door helper side door helper side door (robot side) cylinder mounting bracket broken helper side door bouncing
Fix- tightened rollers helper side door close limit switch failure helper side door close limit switch faults helper side door jamming into back stationary door and faulting.
Cylinder bracket for side door became loose and was missing a bolt..areplaced bolts and re-aligned door to bracket.Now OK helper side door limit switch errors helper side door limit switch fault helper side door limit switch malfunction helper side door not working helper side door selector switch knob missing on operator panel. helper side door wont open in full auto hepa filter clogged/ life hepa filters reading clogged. high aluminum fault probe insulators disintegrated high aluminum probe came off high shot speed alarm due to negative readings. holding crucible change due to hole in filter hood over die come off track hook up motor on ingot lift hyd line leaking at accumulator end of M/C hydraulic hose got pinched during die change hydraulic leak hydraulic leak behind press hydraulic leak for the injection cylinder line block hydraulic leak from 2nd (pipe for injector pins) hydraulic leak in main line. hydraulic leak on back cylinder hydraulic line leak
pass down from 1st hydraulic pump shaft sheared off inget loader crashed.( possible cause was bolts out of a bracket for ingets ) worked with kevin ingot charge loader wont return down after loading ingots ingot charger faulting when loading, melting furnace doesn't seem to be getting hot enough. working on it while running NO DOWN TIME ingot conveyor ingot elevator door broke ingot lift ingot load table at home pos. saying ingot loader empty. ingot loader ingot loader
-Fix adjusted cushion down and up sensor down ingot loader
not make down sensor all the time ingot loader . Ingots hitting newly patched back door bottom. Adjusted ingot lift up position. and also showed the operator and team leader an issue with the ingots . some are warped on one end an ingot loader crash ingot loader crash on conveyer ingot loader crashed ingot loader crashed. (we kept the m/c running in during repairs) ingot loader drifting up. ingot loader fault tower bulb blown ingot loader hitting back door to furnace knocked door off track
plunger shaft quick connects leaking
hydraulic filter out of spec ingot loader jammed
cradle bent up used jack to straighten ingot loader not stopping at home position. pushing cage forward ingot loader pass on from 3rd
1. ingot detect switch bracket welded in wrong location.
2. ingot platform was bent. ingot loader slamming when returning ingot loading problem ingot table is not going up injection only moving half stroke making noise
aluminum built up behind the tip causing m/c to jam injector slide is reading 1.3mm off. installed helper side door flow controls installed original size (1.0) ladle intermittent ladle forward moving limit switch faults, wires melted through inverter fault ladle pour {not moving)
lower ladle arm bearings locked up it was brought to my attention that the crucible hoods on d/c 2 & d/c 3 will not pull back without the dh hitting the pipe. It looks like the t is out of round jammed trim press scrap conveyor#2 ladel arm malfunctions ladel arm not moving ladel arm not operating smoothly, arm will go in and pour but wont return. ladel arm wiring, ladel arm wont move,wiring came loose, past on to 2nd
** 2nd shift* electrode had missing insulator on bulb end. ladel arm wouldn't move. ladle ladle 90 position wrong causing ladle to pour all over plunger shaft ladle arm ladle arm hitting sleeve
and screen freezing ladle arm inverter fault, disassembled to inspect bearings and chains for locking up ladle arm not moving ladle arm stopping at bend, inverter alarm ladle arm will not move ladle arm would go in and pour and stop. m/c wasn't getting a fault. ladle arm would not move. 2) ladle dipping too far in aluminum. ladle bar malfunction ladle bouncing in aluminum ladle broke ladle broke
- trying a different setting. ( wait position) ladle broke
-wait setting from sleeve to furnace ladle broken wire ladle button and die close button were melted . due to crucible lid being split in middle. ladle cracked ladle cracked and dripping no aluminum build up ladle cup chunked out ladle elect. alarms. ladle electro bar malfunction
Fix: Ladle Bars loose and allen head wrong way causing short. ladle electrode bar break/fault ladle electrode bar malfunction alarm ladle electrode bar malfunction, broken insulator. ladle electrode break alarm ladle electrode break alarm. ladle electrode break error. ladle electrode broken wire ladle electrode cable caught and torn loose ladle electrode faults ladle electrode malfunction ladle electrode wire break ladle electrode wire break
replaced lade electrode wire ladle faults
lower ladle bearings locked up ladle full of hardened aluminum and cracked. ladle inverter fault. found that lower ladle cross arm bearings were locked up ladle limit switch malfunction ladle not moving ladle not moving
lower ladle unit locked up ladle not working in auto. ladle pour unit not moving, bearings locked up ladle rebuild ladle stopping ladle travel limit switch malfunctioning ladle traveling forward limit switch malfunction ladle wasn't filling up.bearing in ladle unit alittle rough. worked with kevin ladle wires pulled out of copper terminals ladle would not move large holes in mesh leaking left ok table not turning limit switch 2 flickering limit switch on trim press door broke little scrap conveyor load % not holding when die is running load meter not reading correctly loader door not opening broken wire in cannon plug loader not coming down after pushing ingots pusher 2 advance switch melted pusher 1 return air fitting leaking loose wire on ladel low air pressure fault low shot speed alarms low speed shot alarms
Spec .400 m/s to .440 m/s
Actual .399 to .402 with .399 m/s being NG low temp low gas flow lower ladle unit dipped too far into aluminum and locked up lower ladle unit went into aluminum and bearings locked up m/c cycle timing out, cmss thinks its one of four flippers sticking under the trim press. m/c down for problem with crucible filter from 2nd? 2nd shift maintenance started installing cannon plug for crucible since m/c was down m/c's 1,2,3 machine getting flame outs, would not reset with external nor with the flame detect reset button its self. Took off the ignitor box and cleaned all components and reinstalled then the melting burner f machine pm maint. request form
operator panel switches melted
mist collector filters clogged [rightside] melted buttons on control panel melting burner cycling too fast not maintaining temp not melting aluminium. melting burner flame outs
FIX: replaced UV SENSOR melting burner flame outs.. melting burner flameout. melting burner not firing melting burner not firing.
Cleaned and dressed ignitor rod tip, and replaced star insulator. also changes out the pilot valve relay as well as the actual pilot valve.
No change. Pass over to enginee melting burner short cycling. temp jumping up and down not letting burner fire long enough and temperature being inaccurate. melting burner temp jumping around melting burner temp jumping around and getting melting burner flame outs melting furnace melting furnace temp jumping
thermocouple wire smashed missing from m/c from start up missing hydraulic hoses
Made new hose's that run slide core's mist collector filter mist collector filter change out of spec mist collector filter in red on gauge mist collector filters bad stage 3 mist collector filters out of spec
replaced stage 3 filters mist collector out of spec mist collector out of spec
replaced stage 3 hepa filter mist collector stage 1 filters in red mist collector top filter gauge in red. molten aluminum level low
melting burner would not fire molten level detect wire shorting out molten metal detect for metal leak not working molten metal low temp alarms. spec range allows for 1265 to 1292 actual is 1258 to 1258 move core 1 and fix core 1 switches n/g , (selector switches on main operator panel) move core 2 faults multiple flame outs new water passage set-up no charging light. no good part conveyer not starting or moving slow not setting shot in trim press noticed water leak coming from plunger area ok carrier alarms
chain tension too slack
chain jumped tooth ok carrier getting stuck at the top after dumping parts. ok carrier would not move. Found that chain tension was off causing bucket to pull one side more than the other and bind up bucket ok chain conveyor was bad. ok conveyer box fell a part ok conveyer jamming
tub guide plates worn causing tub to jam ok conveyor : broken and missing bolts from guide rails ok conveyor chain came off sprocket ok conveyor crashed, broke chain, sensor x117 hit ok conveyor getting jammed ok conveyor getting stuck going down ok conveyor hanging up at top ok conveyor hanging up causing machine to fault ok conveyor jammed ok conveyor jamming ok conveyor moving erratically ok conveyor not running Part stuck in conveyor. ok conveyor not working ok conveyor not working, key was out of gear box, shaft on gear box was in bad shape. ok conveyor sticking at discharge position ok conveyor would not move. ok part carrier getting stuck in the up (advance) position ok part carrier jamming. Also missing roller/bearing. ok parts box broke ok parts carrier not getting return light causing robot to leave shot in trim press and fault ok parts carrier will not move ok parts conveyor not working ok parts going into the ng conveyer ok small conveyor not turning ok table 2 not rotating, shaft is broke ok table not rotating ok table not turning overload alarm ongoing issue with robot dropping shots (10++ dropped shots each shift).
production verified plunger lube and spray points on spray cartridge. operator closed safety block closed in die operator crashed robot into door, either going too fast or not paying attention operator dropped and broke operator having robot fault in trim press operator said ladle would not work properly operator saying ingot conveyor is not properly working in auto. operator saying robot dragging shot operator says m/c has not been sounding right in plunger area for about a week. so he shut m/c down to check and see if there was anything in the plunger lube line tip. when reinstalling the plunger l operator says they have been losing a lot of tonna 68 oil. operator side door close limit switch errors operator side door loose out of spec over-flow leak on front crucible door. overflows falling off the shot when the die opens p/m 14 moving p/m 15 moving p/m 19 moving
DREW p/m f-13 moving p/m f-14 moving p/m f-17 moving p/m f-18 moving p/m f15 moving
m/c #5 p/m f17 moving p2 slide core leaking water. replaced p2 slide core. part damaged part quality 59b 1RKR cavity 1 and 2 cracks around the pressure hole part request part request
P/M F-9 part request P/S F-13 part request,
crucible change parts coming out hot on ok table. one part was not being submerged in water inside tank. also water was steaming and hot to touch. parts has marks from trim press. parts jammed under bottom trim die, chute mangled up parts request parts sticking on cavity 4 of trim press pass down from 2nd shift lower ladle arm passed down from 1st scrap press head loose passed down from 2nd (No actual downtime due to Aluminum quality testing in lie lab)
What: Load percentage would not adjust about 2%
Why: die adjustment forward/backward not adjusting. Breaker NFB3 in passed down from 2nd hourly monitoring of ladle cup passed down from 3rd broken cannon plug for robot hand. passed on from 2nd main hydraulic line leaks passed on from 2nd shift. w/o 8618. after r/b was mastered (1) r/b dropping shots in water tank and other times not grabbing shot from die, (2) parts getting damaged in trim press, and (3) r/b getting passed on from 2nd that table 3 & 4 wasn't turning passed on from 2nd w/o 14026. after they verified system, bled sqm, checked for leaks and did not see improvements I decided to have production try changing die to eliminate or prove die issue. Die wa passed on from 2nd.
operator side door safety lock key and lock switch broken. passed on from 2nd. installed new seal in plunger rod seal cap and installed plunger rod seal cap over plunger rod. installed shot position sensor and plunger shaft coupler. Also had leaking water qui passed on from 2nd. trim press was pulled out and after reinstalling robot was not setting shot in press. passed on from 3rd. scrap and trim press not moving platform broke on ingot loader. plexi glass on side of ok conveyor broken plexy glass door frame for crucible broke plugged up plunger lube tip plunger lube
FIX - Adjusted lube to 0.4 cc plunger lube bracket broke. had to remove and weld it back together plunger lube spray tip broken off bracket plunger lube tip plugged plunger lube wasn't working, plunger rod seals leaking by bushing. shot position sensor wire break alarm plunger seal very small leak plunger tip damaged on install
replaced tip pm #13 pm #18, pm #13 pm f-15 moving pm#11 pm#14 porosity found in X-Ray position wrong at scrap press causing shot to bounce or not be in position for scrap press to cut. press not going up problem with flipper, faulting robot out inside trim press problem: Trim press faulting
cause: sensor on scrap press not reading
countermeasure: replaced reflector, sensor ok adjusted to shot reading ok
reoccurrence: No, sensor reading as it should, reflector problem: broken draw bar during die change
cause: temperature change on steel threads
countermeasure: replaced draw bar with new
Reoccurrence: No problem: ejector would not advance or return
cause: v-check switch in on position not allowing ejector to move manually
countermeasure: Turned v check switch to off position to allow manual operations problems with scrap conveyor, jamming up probs on crucible for high aluminum alarming out product detect #2 not seeing part product detect 3 and 4 not reading part. product detect 4 not working product detect 4 sensor was not working product detect not working product detect sensor at trim press faulting product detect sensor#4 not working for the part detect at unloading robot production could not find old cup production trying to do die change and could not unclamp tie bar nut because selector switch knob was missing program problem on A/B (Type-02)
Fix: Set positional data for PR24-PR29 using Type99 Position Master information. Touched up points as needed and set speeds appropriate for travel between trim press pulled holding crucible filter out for Darrell to install new on 1st shift. pusher #2 solenoid valve had burn hole in it leaking air put in scrap press sensor we were waiting on and put back in plc and robot program
also replaced fixed side cooling water solenoid valve that was having issues rear helper door not opening all the way rear-side helper door rollers broken, door slamming no speed control. rebuild red coolant line leaking on plunger shaft refers to W059118
bad punch on top side of trimpress, cavity 1 reflector for trim press damaged reoccurring changeover problems
product detect (operators not trained to set
collision detect at stationary (too long of bolt put in R/B finger again, installed correct size.)
vibrator not knocking ta reoccurring issue with scrap press leaving shot scrap behind causing robot crash at scrap press repeated flame outs. replace P1/S1 slide core, cracked replace Plunger tip only
Shot Sticking to tip replace broken plexiglass on trim press door replace contactor replace cracked plunger lube air bowl replace cracked sprue bushing replace leaking rod seal set. Finished cap seal assembly, reassembled unit, tested for leaks. No leaks, verified shot
sensor reading correct stroke. turned over to production replace robot clamp pawls. replaced cavity 3 slide core for chip. replaced cracked P2 slide core replaced main breaker on trim press and installed new disconnect. non inventory.
"FUJI ELECTRIC CIRCUIT BREAKER EW100AAG-3P100B4B", FUJI ELECTRIC HANDLE BZ6N10D" replaced melted buttons and switches replaced ok conveyor chain. freed up adjusters and anti-seized. test ran good replaced spray valve replacing P1 slide core due to crack. replacing P1 slide core for a crack. replacing P1 slide core. replacing P2 slide core for soldering. replacing S1 slide core as per quality. replacing S1 slide core for crack. replacing S1 slide core. replacing ejector pins 25 and 26. i must have put the wrong ejector pins in when i worked on it last. replacing fixed side thermocouple due to temperature issues. replacing moveable side thermocouple. replacing ok conveyor chain belt replacing ok conveyor drive chains. removed all adjusters and freed and anti-seized adjusters. tested good. replacing slide cores 2,3 and 4 for soldering as per TAKA. replacing upper and lower crucible request for lot mark pins retaught robot at scrap press ribbon robot at chopper operator had it twisted and when trying to home put it into singularity. robot at scrap cutter dropping shot needs touched up
after running several good shots the shot must have slipped in the hand, causing it to catch on the bottom cutter upon entry into the chopper causi robot changeover chuck re-build
robot chuck all components worn causing excess movement
re- built robot chuck with all new parts robot chuck limit switch error robot collision at trim press robot collision detect alarm
at trim press robot crash into trim press, problems with biscuit thickness robot crash into trim press, scrap conveyor fault robot crashed in die robot crashed into door robot crashing in scrap press (collision detect) robot crashing into trimpress robot crashing into water tank when leaving home position. Collision detect alarm robot dropped 4 shots. robot dropped shot at die and melted robot chuck air lines robot dropping parts
three O-rings missing
one nozzle plugged
ladle dipping in aluminum robot dropping shot robot fault due to scrap press {debris}
linear bushings bad replaced
adjusted down sensor because top an bottom cutters hitting robot fault in trim press robot fault servo 111, soft float time out robot faulted at scrap press robot faulting at trim press robot faults at scrap press. shot hitting bottom cutter robot faults at trim press robot faults at trimpress at start of shift
robot not contacting biscuit with all 4 fingers robot getting collision alarms at trimpress and hitting scrap press after changeover
still having problems at scrap press I think robot position ok but the cutters r two wide leaving pieces behide cau robot getting erratic fault signal from die-caster robot hand malfunctions robot hitting product detect with shot robot jamming going into trim press robot loading at trim press seems off.. robot move fault robot needs retaught in trim press taking chunks out of parts robot needs taught in scrap press. robot not chucking on part at trim press right robot not moving after trim press. robot not setting part in trim press correctly causing machine to fault robot not setting shot in trim press
and trim press would not return up robot not setting shot in trim press correctly causing press to smash roller groove on some parts robot not setting shot into trim press correctly operator verified die has not been moved, robot not adjusted robot pendant cable out robot pick up point bad robot position needs touched up. robot problems at trim press and scrap press. trim press positions needed touched up and scrap was hit stop on scrap press. stop was bent. robot problems from 2nd robot side door safety sensor came off door and wiring separated from terminals robot stopped in die robot stuck at diecast m/c. Helper side (robot side) door was not getting open limit switch light. robot top squeeze pin cylinder in leaking. replaced top cylinder. robot would not move robot would stopping in front of the die cast machine and would fault out robot malfunction. Took over for Darrell Cagnon after change over. rod seal leaking s f-5 moving s f-9 s f-9 moving s f-9 stationary sa/p 23 moving sa/p f-21 sa/p f-22 stationary safety requested a counter measure to aluminum splashing from ladle during cycle stop. sb #16 moving scheduled down doing PM. scheduled down doing PM. Inspecting ok conveyor (M7) scheduled down time doing pm took apart ok parts turn tables scheduled down time repairing scrap conveyor scheduled down, doing PM. checking trim press flipper diverter cylinders and connections/bushings scheduled down, doing PM. installed new ok parts carrier scheduled down. scheduled down. Doing PM scheduled down. Doing PM on ladle arm scheduled down. Doing PM. scheduled down. Rebuild Ladle arm. scheduled down. Working on NG conveyor scrap chopper bearings exploded scrap chopper not returning, relays burned up scrap conveyer #1 for trimpress jamming up and completely stopping passed down by 3rd shift at shift change. scrap conveyer 2 jammed
found broken cotter key allowing rod to move and jam on housing scrap conveyor 1 faults scrap conveyor 1 jammed scrap conveyor 1 locked up. pulled motor and gear box, still locked up. pulled conveyor out and pulled chain. checked bearings started cleaning, passed on to 2nd scrap conveyor 2 cotter key broke scrap conveyor faulting scrap conveyor faulting out. scrap conveyor flight tripping safety sensor scrap conveyor is jammed. dammaged hinge pin. scrap conveyor jammed scrap conveyor jammed
C/M: UN JAMMED IT scrap conveyor jamming up scrap conveyor missing cotter pins rollers and links. rods were bent scrap conveyor one locking up scrap conveyor stuck and missing chain link also broken linear bearing on trim press scrap cutter scrap fouling spring loaded pusher in top die of trim press. scrap hopper still faulting scrap press scrap press
FIX-Welded holder for shot scrap press add on piece bent (piece that prevents scrap from sticking in cutter) scrap press cutter broke scrap press head loose and right side bushing destroyed. scrap press jammed scrap press jammed. scrap press return sensor was staying on. scrap press shot detect sensor bad. scrap press will not go up scrap re melt trim press not cutting scrap scrap-press will not go up, breaker trip, cp4. replaced relays G2A-432A x2. screen in inget loader door torn screen on squeeze master cracked seal-tite connector on backside of die came loose wires dangling sensor for scrap press shot detect ng (x095) sensor on robot chuck - unchuck not making shot getting bent in die? shot plunger leaking hydraulic fluid shot position N/G. shot position going negative. shot position problem. shot position reading high shot position sensor alarm shot position sensor break alarm shot position sensor wire broken faults shot position sensor/ wire broken faults. replace shot position detect sensor. machine is ok turned over to production. shot sensor shot sensor broken wire alarm.
wire insulator in cannon plug off. Repaired tested, ok. shot sensor broken wire fault shot sensor broken wire fault
sensor ng
replaced shot detect senor shot sensor wire break alarm shot sensor wire break alarm
-FIX clean debris from around sensor and in sensor mounting hole shot slipping in robot chuck
Cause: worn gripper pawls
Countermeasure: Replace 2 worn pawls shot stoke problem shot stroke reading negative. biscuit thickness jumping around shots falling out of scrap press when robot unchucked before able to be cut sleeve mounting bracket to hold plunger sleeve in place was off and sitting on tray underneath where operators drag aluminum from tip and sleeve area out. slide core NG change P1 slide core P1 Cav. what- p1 nogo gauge would not go in all the way. why sodering build up. c/m replaced p1 slide core. slide core chunked out NG. Change s1 slide core crack Cav. P-1. Will replace P-1 slide core. slide core faults when dies moving slide core pin right side broken slide core primary pin (tappet pin) broke on P2 cavity (operator side top) slied core p1 soldering on cavity #1 slide core. replaced cavity #1 slide core. solenoid came lose on tie bar clamp. draw bar broke also. solenoid for pusher 2 damaged by hot aluminum leaking and pusher creeping solenoid for vacuum on die is not engaging solenoid valve for cooling water inlet. fixed platen side. Given to second shift E/S for installation. someone over the weekend broke the touch screen for the squeeze master
Passed onto 1st shift spec problem wit cav 3 and 4 bottomslide cores Only 1000shots spray cart. not spraying. spray cartage base broke spray cartage swing not swinging spray cartridge cylinder leaking out of front seal spray cartridge leaking out of pipe robot side spray cartridge not spraying squeeze master
# on squeezing jumping squeeze master hyd. pump motor noisy. will schedule for repair. squeeze master spec problems
flow jumping all over the place
found axis 1 hydraulic quick connect fitting leaking bad squeezemaster OL tripped sqweez master, having line filter choke alarm. stage 1 and 2 filters in the red on gauge stage 2 HEPA filter out of spec stage 3 HEPA filter gauges out of spec.replaced stage 3 filter needs changed stage 3 hepa filter needed changed start push button light not coming on started replacing left side rail still dropping shots. tip and sleeve are used from different m/c so not sure how many shots on them, but we had to unplug plunger lube tip earlier and DH says when he got here beginning of shift water still getting limit switch faults when the ladle is coming out of the crucible still getting negative readings on shot stroke switch for hydraulic pump broke on squeeze master swivel fitting for spray cartridge leaking taiyo pump for die release stopped pumping tappet pin check out of spec on cavity 3 (low) teach pendant faulting (bad cable)
THIS CABLE IS ORDERED, DELIVERY 11/16 OR 11/17 (JR) teach robot at scrap press temp jumping up and down fast on furnace terminal box fell off of robot swinging by wiring terminal box for shot sensors and etc. main terminal wires hanging out bottom, of box. the nitrogen valve relocation project had to be put on hold until end of next month (hope for down days)because the nitrogen shutoff valve had different threads than coupler. SAM (larger hydraulics) i thermo coupler for upper crucible went bad. Replaced with one on css desk. No down time ( Omega TJ36-CAXL-316U-18)non inventory thermo coupler on loading lid bad thermo coupler throwing alarm thermocouple not reading on the fixed side of die. pulled fixed side of die to replace the thermocouple. thermocouple was broken during install of die. replaced thermocouple. these parts were not issued to a certain m/c
Charged out as die cast area tightened up shoe bolts on inside and outside on operator and helper side of movable die, reattached water tower to side of die tip and sleeve change. 12.500 shots tip change for taka tip project (new tip life 15,000-20,000 shots)
replaced tip
tip had 23,450 shots tip change for taka tip project (new tip life 15,000-20,000 shots)
replaced tip
tip had tip change for taka tip project (new tip life 15,000-20,000)
replaced tip
tip had to re-teach robot from take out all way thru trim press. The chuck fingers were only grabbing 2 positions on the biscuit at take out. took over for 2nd ingot lift foot pedal switch sticking took over for 2nd. helper door problem took scrap conveyer 1 out of trim press because m/c is down due to touch screen
put conveyer in dc3 tool change
replaced tip because of blow back
we are having sleeve machined for cooling joint tool life top HEPA filter out of spec on oil mist collector system. No downtime top gauge on oil mist filter system out of spec top slide core has a water leak. replaced 2 water fittings on top slide core assembly. no leaks. top slide core leaking water. broken water fitting on the squeeze pin. replaced water fitting on the squeeze pin. good now. top slide core leaking water. replaced water fittings on squeeze pin to fix water leak. top slide core leaking water. squeeze pin cap came loose. redid the thread tape and retightened. no leaks. toscast screen bottom operation buttons not working total width out of spec. replaced op-s21 slide core pin, cleaned up around slide core area tray under plunger to catch aluminum came unattached from m/c causing plunger to hit tray when injecting trim damage cavity 3 & 4 59B1RKR die F15 Trim Die #2
Changed trim press #2 to trim press #3. Trim die #3 is original trim die condition before large overflow die change
Cause: overflows remaining on trim damage cavity 3 and 4 tappit surface 59B 1 RKRK
cause : robot position NG
Countermeasure : teach P24 and P25 trim damage on cavity 2 found that overflows getting blown back onto trim die found that the bracket for the shaft hole cutter overflows was bent removed it and straightened it out and reinstalled now trim damage water passage parts on water pump mounting surface
cause: gauling caused from slide core when pulling out of the part. no spray in that area.
countermeasure: adjust spray position. trim height out of spec on s-1 part trim press trim press
FIX- Removed aluminum between punch and guide. Put new cutters on. Adjusted air blow trim press airline blew out trim press bleeding down trim press breaking RPY side cutter 2 of lower die. trim press breaking bottom cutter #1 cavity. trim press cutter bolt broke while adjusting for trim height issues trim press cylinder drifting down. (internal seals) trim press cylinder leaking oil out of front seal getting on parts trim press cylinder leaking out of front seal trim press damage. vacuum faults trim press failing good parts sensor not always detecting parts trim press fault robot needs homed trim press flipper 1 sticking trim press flipper 1 was not working properly. trim press issue trim press issues. trim press leaking hydraulic fluid
machine down for furnace rebuild . trim press leaving marks on parts (die 4) trim press linkage shoulder bolt came out and flipper bushing bolts broke trim press lower die stuck trim press ok conveyer jamming trim press ok conveyer jamming at top
top bolt missing on left rail trim press passing bad parts flapper 1 bracket bolt broken trim press position of robot needs touched up. 2nd dh worked on it for five hours trim press robot needed touched up. trim press table clamp ng. no pressure trim press was going down but not returning home trim press wont return. trim press, part presence not working. so the press is not able to cycle. trim wouldn't auto start, start and run for about 30 sec. and fault out. trim-press cylinder drifting down. trimpress and scrap press not working trimpress not coming back up. trimpress waiting to press part
flapper 1 jamming not getting advance light
broken bolt on flapper shaft mounting flange turn table #2 turn table not turning unload table left side jamming up. unloading table not turning upper crucible lid not working consistently.
Replaced air solenoid and working OK now
Asked Aeronica to order the Lid cylinder . We do not have one in inventory It will need replaced soon. SMC CBA2D upper limit probe assembly fell in holding crucible. making new probe assembly used P1 slide core that I put D/C 7 cracked to 10 put in new slide core using alot of tella 68 vacuum
FIX -air line off to valve #2 gauge in vac machine. hooked back up air line vacuum block blowing operator side mostly. vacuum data not showing data and main panel. vacuum failures. vacuum would not come on during automatic operation and blocks and hoses kept blowing. 2nd changed vacuum blocks and hoses. checked filters. Also they pulled hardened aluminum out of vacuum faults
inlet filter covered in oil vacuum issues vacuum issues after changeover vacuum issues not building pressure vacuum issues operator side vacuum leak on operator side vacuum not working vacuum problem vacuum problems vacuum problems
FIX- Clear hose had hole in it replaced hose. vacuum problems
parts sticking to moveable side of die top vacuum problems
operator side valve #3 vacuum problems blowing vacuum blocks vacuum problems operator side vacuum problems, valve 2 robot side. vacuum problems. air regulator is leaking vacuum pump making noise vacuum trouble operator and robot side. vacuum v1 blowing blocks. verified no air leaks on gripper water in the vacuum hose operator side / un-reach to tank fault
cause: vacuum hose not connected at the junction block water leak water leak coming from catily 3 slied core replaced slide core water leak coming from op top slide core. replacing op top slide core and o-rings on water lines. water leak in plunger shaft water leak in top squeeze pin movebale side. tear down top slide core to fix water leak. replace slide core, squeeze pin+bushing water leak on cavity #4. replaced p4 slide core. slide core was broke. put shims behind chill block and cavity #4 collar to try stop blow outs on that cavity. replaced water fitting on op side sprue c water leak on die water leak. op.bottom
RG back slide core cooling joints loose. thread tape and reinstall cooling joints water leaking out of the fittings for the plunger shaft water pump on diecast 1 will not prime. water tower leak at union on operator moveable side way lube leak for die leaking. way lube oil for die leaking. wear went through the previous 2 work orders found that the module card from machine 1 was still in machine 2. Troubleshooting for original problem for HMI screen freezing up. what robot wont home / move in jog
why: waiting for space to clear
c/m: got DCM all home and was able to move robot home what : trim press getting sensor error
why: slow down sensor staying on
c/m: replaced the slow down sensor on trim press cylinder up/down what parts sticking at die ?????
C/M: REPLACED WATER LINE THAT HAD HOLE IN HOSE... POLISHED DIE,,, what : robot position reteach req by Mehaa
why: not double clamping
c/m: retught robot at trim press what : not picking part up after trim die operation
c/m: retaught position #64 what : air leak on pot lid valve
why ; infeed pipe cross threaded
c/m : replaced pipe what : ok (mesh) c/v to table parts jammed under
why: holes in mesh
c/m: replaced mesh c/v belt what : ok conveyor
replaced motor gearbox ( cannibalized from 7) what : scrap bins not switching
why : wires puled out of valve
c/m : rewired valve and reset bin unit what : scrap conv. wont run
c/m : tightened conv. ; still jumps in one spot (marked with a green x) what : spray cartridge up / down cylinder blow seal . cylinder drifting down losing up sensor what : unload conv. jamming
why : PIECES FALLING off
cm: replaced bent conv part and re tensioned cov
faulted again at 10am and have to replace a guide pin and 3 coder pins. unit is still binding up. what :blow back
why:tip was broke on shaft.
countermeasure: replace shaft end and tip ONLY.
recur: possible what noisey vaccume pump on squeezemaster
why : pump not creating vaccume
c/m: replaced vaccume pump what ok conveyor gets stuck at top
c/m: adjusted chain skipped teeth what operator side door lock no locking
why: worn out
c/m: changed what robot chuck faults
why: chuck sensor staying on all time
c/m: replaced robot chuck sensor what sleeve worn (wash out)
why; tool life
c/m: replaced tip sleeve during a changeover no downtime
reoccur: timing what trim damage
why- cutters worn
C/M: changed out trim press with different trim press that had old style cutters
REOCCER: yes what upper door wont close
WHY wire pulled out of the cannon plug possibly someone forgot to unplug prior to pulling back upper melting furnace
COUNTERMEASURE reattach wire in cannon plug
WILL IT REOC what water leak
why: old contaminated fittings
c/m: replaced water fittings what, P1 slide core would not plug gauge. why, P1 slide core no good. C/M, replace P1 slide core. what- (1)ladle arm not moving out of aluminum. (2) Ladle not pouring at sleeve
why- ladle unit rebuilt incorrectly. upper ladle chain was twisted and backwards. ladle unit dunking in aluminum
c/m- rep what- 3 out of 4 ingot guide (paddle) bolts came out
why- installed without lock washers
c/m- put in new bolts with lock washers
reoccur- no what- AL-01 on melting thermocouple
why- NG
c/m- replace thermocouple
reoccur- in time what- AL-01 on melting thermocouple
why- terminal ends corroded
c/m- re-terminate
reoccur- in time what- AL-01 on melting thermocouple
why- thermocouple NG
c/m- replace
recur- timing what- Cav 4 Roller Groove slide core NG. Why- During Confirmation checks radius measured Ng(FTP slide core). C/M- Replaced slide core with TEG slide core. what- Half pipe cracked
why- Power outage. No back up power to safety equipment
c/m- Replace upper/lower crucibles and half pipe
reoccur- Yes what- NG conveyor not moving
why- scrap piece wedged in chain
c/m- removed scrap piece
reoccur- possibly what- NG conveyor not turning
why- belt torn
c/m- replace mesh belt
reoccur- in time what- NG conveyor torn would not move/flipper 1 jammed would not move
why- part jammed in conveyor on 2nd.operator didn't say anything and parts backed all the way up to flipper
c/m- remove all parts what- P1 slide core cracked
why- unsure
c/m- replace
reoccur- yes what- S2 slide core water leak. Why- cracked cooling joint. CM- replaced cooling joint. Fixed water leak. what- Sodering on all cavities. Why- Aluminum build up. C/M- Polished all cavities what- Water leak sprue bushing. Why- Cracked sprue bushing. C/M- Replaced sprue pin. what- air leak
why- air bowl cracked
c/m- replace air bowl
reoccur- in time what- air leak
why- cracked air bowl
c/m- replace air bowl
reoccur- yes in time
c/t- unchanged what- air leak
why- cracked air bowl
c/m- replace bowl what- air leak (die lube)
r/c- cracked air bowl
c/m- replaced air bowl
reoccur- no what- air supply shortage alarm on trim press
why- air hose hole right behind air fitting going to scrap conveyor switch
c/m- cut end of hose where hole was
reoccur- no what- al-01 on both melting furnace thermocouples
why- wire broke in plug/ thermocouple NG
c/m- replace thermocouple/ soldered wire
reoccur- yes what- al-01 on melting burner
why- thermocouple NG
c/m- replace
reoccur- in time what- al-01 on melting exhaust temp
why- thermocouple NG
c/m- replace
reoccur- in time what- al-01 on melting thermocouple
why- thermocouple NG
c/m- replace
reoccur- in time what- all 4 axis's high
why- sprue bushing cracked
c/m- replace sprue bushing
recur- in time what- aluminum blew out of sleeve everywhere and set off fire alarm
why- condensation build up in sleeve?
c/m-had operator heat inside sleeve hole longer to get rid of any condensation
reoccur- no what- aluminum blow out at bottom of die
why- Bottom slide core slides sticking
Countermeasure; Pulled die and corrected sticking and damage to slide core holders
Reoccur In time what- aluminum blow out of die
why- ?
c/m- clean die
reoccur- yes what- aluminum blow out of die
why- ?
c/m- free up bottom slide cores, clean die
reoccur- yes what- aluminum blow out of die
why- aluminum build up
c/m- clean die
recur- timing what- aluminum blow out of die
why- bottom slide cores stuck?
c/m- cleaned die and slide cores, adjust die lock force
reoccur- unsure what- aluminum blow out of die
why- build up of aluminum in die pockets
c/m- clean build up
reoccur- timing what- aluminum blow out of die
why-?
c/m- cleaned aluminum from die and slide cores
reoccur- yes what- aluminum blow out of die
why-aluminum build up
c/m- clean die and slide core pockets
reoccur- possible what- aluminum blowing out of sleeve pour hole
why- plunger shaft extension loose and plunger shaft wet possibly from extension being loose
r/c- moisture from leaking plunger extension
c/m- thread ta what- aluminum blowout of die
why- chill block shim not behind chill block and mangled
c/m- put new shim behind chill block what- aluminum covering the entire hole of sleeve and could not pour in
why- operators not paying attention to machine letting it over pour for hours
c/m- spent half hour cleaning aluminum build up ou what- aluminum melted in without holding burner on
why- holding burner was not on when melting furnace was loaded
c/m- replace upper+lower crucible, stands, and half pipe
recur- possible what- aluminum overflowed crucible in back and molten metal leak alarm never went off
why- furnace not maintained/cleaned/jackhammered/ leak detect spark rods N/G
c/m- production jackhammered furnace what- axis 1 alarms anytime m/c stops and starts back up
why- hydraulic hose NG
c/m- replace hydraulic hose
reoccur- in time what- axis 1 and 3 alarms
why- squeeze pin lines hooked up wrong
c/m- connect lines to correct part
reoccur-yes what- axis 2 alarms
why- fitting NG
c/m- changed channel 2 inlet fitting on hose at die manifold
reoccur- ? what- axis 2 low
why- air in hydraulic lines
c/m- line bleed
reoccur- no what- axis 4 slow causing part to stick in die
why- debris stuck in valve
c/m- swapped valve with channel 3
reoccur- unlikely what- axis alarms
why- quick connect fitting on die manifold leaking
c/m- thread tape fitting
reoccur- no what- axis alarms
why- squeeze master hydraulic lines in wrong place/leaking hydraulic fittings
r/c- operator training
c/m- put hoses in correct spots. replace leaking fittings
reoccur- yes what- axis alarms and squeeze pin depth out of spec
why- squeeze master hydraulic leak on fitting on fixed die manifold
c/m- pull fitting apart and thread tape what- axis low channel 4
why- squeeze pin cylinder came loose and blew seal out
c/m-replace cylinder
reoccur- unlikely what- bad blow back, plunger lube tip keeps plugging
why- tip/sleeve NG
c/m- replace tip/sleeve
reoccur- in time what- bad blowback coming outside m/c and plugging plunger lube tip several times
why- unsure
c/m- replace tip. hone sleeve to smooth rough spots
reoccur- yes what- bad blowback/ robot dropping shots
why- tip/sleeve NG
c/m- replace tip
reoccur- yes what- bad blowback/flashing
why-tip/sleeve NG
c/m- replace tip/sleeve
reoccur- yes what- bad blowback/plugging plunger lube tip
why- tip/sleeve
c/m- replace
reoccur- in time what- bad flashing on shots
why- bottom slide cores sticking
c/m- remove and clean
reoccur- yes, aluminum gets built up in the cavities and causes them to stick and need cleaned what- biscuit breaking off shot
why- water leak
c/m- replaced sprue bushing what- biscuit randomly going too high
why-
c/m-
reoccur- what- biscuit randomly going too high
why- nitrogen low
c/m- add nitrogen
reoccur- in time what- biscuit size inconsistent
Why: Lower unit on ladle bad
C/M: Replaced lower unit and probes
Recur: In time what- biscuit size inconsistent
why- ladle arm bearings locked up
c/m- change ladle arm with rebuilt non-inventory
reoccur- in time what- biscuit sticking in sleeve
why- ladle over pouring covered plunger lube tip
c/m- set ladle position
reoccur- ? what- biscuit thickness alarms/ accumulator not intensifying
why- tip/sleeve NG
c/m- change tip/sleeve
reoccur- in time what- biscuit thickness dropping, bad blow back
why- tip/sleeve NG
c/m- change tip/sleeve
reoccur- in time what- biscuit thickness prob.
why- what- blow back, flashing, dropping shots
why- tip/sleeve NG
c/m- replace tip/sleeve
reoccur- in time what- blow out robot side
why- ?
c/m- cleaned die
reoccur- yes in time
c/t- unchanged what- blow outs robot side
why- chiller block worn
c/m- replace chiller block what- blowback
why- ran without lube or water
c/m- replace tip
recur- yes what- blowback
why- tip and sleeve n/g
c/m- replace tip and sleeve what- blowback plugging plunger lube tip several times a shift
why- tip/sleeve life
c/m- replace tip/sleeve
reoccur- in time what- blowback/ biscuits breaking off in fixed side
why- tip/sleeve NG
c/m- replace tip/sleeve
recur- in time what- blowback/flashing
why- tip & sleeve
c/m- replace
recur- timing what- blowing vacuum blocks operator side
why- dirty filter ?
c/m- cleaned inline filter, checked lines for leaks what- blowing vacuum blocks robot side
why- inline filter dirty, inlet and suction filters dirty
c/m- cleaned inline filter, replaced inlet and suction filters
reoccur- yes in time
c/t- unchanged what- broken slide core pin
why- unsure
c/m- replace slide core pin
reoccur- no what- broken trim press cutter
why- unsure
r/c- unsure
c/m- replace and watch run to make sure of no problems
reoccur- yes what- burr on part NG
why- slide core chunked out
c/m- replace slide core s1
reoccur- in time what- cant pass k-molds
why- crucible filter NG
c/m- replace holding crucible
reoccur- yes what- cant pass k-molds
why- filter cracked
c/m- replace crucible
reoccur- yes what- cast pressure/biscuit thickness/axis alarms/ no fill pressure for accumulator sometimes
why- nitrogen low
c/m- add nitrogen
reoccur- possible what- cavity 1 tappet pin leaking
why- cylinder seals NG
c/m- change tappet pin cylinder for cavity 1
reoccur- in time what- cavity 3 and 4 coming out NG conveyor sometimes
why- flashing causing part to stick in press
c/m- pulled press and verified all flippers working properly
reoccur- yes what- cavity 3 no tappet hole
why- cavity 3 hydraulic hose not hooked up during die change
r/c- training
c/m- hook hydraulic hose to manifold
reoccur- yes what- cavity 4 parts coming out NG conveyor instead of ok carrier sometimes
r/c- flipper 1 out of position
c/m- turned flipper 1 to correct position so part could not fall behind it
reoccur-no
cycle t what- cavity 4 running low
why- squeeze pin cylinder in die bleeding bye
c/m- remove die and replace cylinder
reoccur- yes in time
c/t- unchanged what- change slide core
why- NG
c/m- replace p1 what- changed over to water passage, robot position off in die, at vibrator, stationary jig, trim press
why- bolt on robot chuck gripper too long sticking out past grip point
c/m- replace with correct what- changed slide cores # 1 and #2 S-1 10182 shots S-2 8747 shots what- changeover to 1RKR changing spot cooling joint for sleeve
why- old had been hit last time sleeve was in and was leaking
c/m-replace with new. ground one side to hopefully prevent getting hit
reo what- channel 2 squeeze pin hole too deep
why- hole in return line
c/m- replace hydraulic line
recur- timing what- channel 4 not bleeding correctly
why- quick connect fitting leaking at die manifold
c/m- thread tape quick connect fittings on channel 4
reoccur- no what- channel 4 on squeeze master says it is out but is actually returned.
why- flow meter NG
c/m- swap flow meter with one off of #4
reoccur- in time what- charging m/c not loading scrap
why- not making lid up light
c/m- adjust limit switch what- chip in slide core s-1
why- wear
c/m- replace slide core what- chunk missing out of part
why- aluminum stuck in slide core was not able to get out with die in machine
c/m- had production pull die to work on slide core
reoccur- yes what- collision detect
why- j6 axis NG
c/m- replace J6 reducer and servo motor
reoccur- in time what- collision detect at scrap press
why- r/b position off
c/m- touch up position
reoccur- no what- collision detect at stationary jig
why- biscuit too big causing bolt in chuck to gab instead of chuck finger
c/m- lowered shot weight to make biscuit smaller
reoccur- yes what- collision detect at trim press and scrap press
r/c- r/b position off at trim press and scrap press
c/m-touchup trim press set pos and scrap press set pos
reoccur-no
cycle time before-28.5
cycle what- collision detect coming out of trim press
why- r/b pos.
c/m- touch up r/b
reoccur- unlikely what- collision detect faults in trim press
why- r/b position off
c/m- touch up r/b positions
reoccur- yes what- collision detect in die
why- ejection from die too far pushing r/b too much
c/m- verify r/b position in die. change eject from 28mm to 27 mm
reoccur- no what- collision detect in die and trim press
why- r/b position off in die. Locate pins NG
c/m- touch up r/b in die. change locate pins
reoccur- in time what- collision detect in trim press what- collision detect in trim press
why- biscuit getting stuck on trim press after trimming
c/m- made biscuit bigger
reoccur- possible what- collision detect in trim press
why- bolt broke on ramp in press
c/m- straighten ramp put new bolt in and added an air blow line
reoccur- not likely what- collision detect in trim press
why- change over (r/b positions off)
c/m- add oil to vibrator. add positions to r/b program, and touch up other positions
reoccur- yes what- collision detect in trim press
why- heavy flashing on part not allowing to set on chuck change jig
c/m- touch up r/b position at chuck change jig to allow it to grab part higher
reoccur- yes what- collision detect in trim press
why- part supports on chucks lose and chill block tree sticking
c/m- tightened supports/ add air blow to blow tree off
reoccur- unlikely what- collision detect in trim press
why- r/b pos off
c/m- touchup r/b pos
recur- timing what- collision detect in trim press
why- r/b pos. off
c/m- touch up r/b in press
reoccur- yes what- collision detect in trim press
why- r/b pos. off in die and trim press
c/m- touch up in die for 4 points of contact in die. touch up in trim press what- collision detect in trim press
why- ramp for chill block tree to fall off was badly bent
c/m- straighten ramp, adjust air blow
reoccur- possible what- collision detect in trim press
why- relay ng
c/m- replace relay y09c
reoccur- in time what- collision detect in trim press
why- scrap ramp bent
c/m- straighten ramp
reoccur- yes what- collision detect in trim press
why- upper air blow too high
c/m- lower air pressure on upper air blow
reoccur- unlikely what- collision detect in trim press and at stationary jig
why- guard bent, r/b pos. off
c/m- straighten guard, touchup pos. at stationary jig
reoccur- possible what- collision detect in trim press/ leaving tab on from vibrator
why- Positions removed due to cycle time?
c/m- added positions in r/b program to knock tab off
reoccur- possible what- conveyor 2 motor overload
why- conv. jammed up
c/m- free up conveyor what- cooling joint broke in sleeve
why-unsure
c/m- replace
reoccur- no what- cooling joint broke off in sleeve
why- unknown m/c apart when I started the job
c/m: added a extension pipe a 90 and a 45 to get cooling joint away from plunger shaft
reoccur: unknown but not li what- cooling joint extension broke for sleeve cooling
why-?
c/m- replace extension
reoccur- yes what- cooling joint in sleeve broke
why- ?
c/m- replace
reoccur- yes what- cooling joint in sleeve broke
why- unsure
c/m- replace cooling joint with a spare we had
reoccur- yes
(LT) what- cooling joint in sleeve broke off
why- flashing
c/m- install longer cooling joint to get back away from flashing
reoccur- possible what- could not get home/start position light
why- shot detect sensor failure
c/m- replace shot sensor
reoccur- no what- couldn't read 5ba on part cavity 1
why- slide core worn
c/m- replace slide core what- cracked slide core
why-?
c/m- replace (s1)
reoccur- yes what- cracked slide core (P1)
why-?
c/m- replace
reoccur- yes
SHOT LIFE ????? what- crucible change
why- cracked around upper crucible spout. Lower crucible showing enough wear and cracking to change at this time also.
c/m- replace upper, lower, half pipe
reoccur- in time what- crucible filter NG
why- cracked down the center and aluminum failed inclusion testing after dipping out twice and retesting
c/m- replace
reoccur- in time what- crucible level alarm
why- wire broken
c/m- terminate wire what- crucible lid would not open
why- broken solder on wire in cannon plug
c/m- solder wire back on
reoccur- yes what- cutter broke on trim press
why- upper guides were loose and bolts bent and air blow was off
c/m- replace cutter. replace guide. put lock washers on both guides to help them stay in place, adjust what- damper door close L.S NG
why- heat
c/m- replace L.S
reoccur- in time what- dent in tappet area cav.2&3 scrape too deep cav.4
why- trim press
c/m- adjust cutters& guides
reoccur- possible what- die blow out, aluminum covered die, die and sprue overheated
why- no water/ mold temp controller not running
c/m- clean die change chill block and turned mold temp controller on
reoccur- possibl what- die casting machine lubricant shortage, die height lubricant shortage
why- xa05 was disconnected to PLC during mold heater integration
c/m: reattached xao5 once found in PLc to proper input. Xa0 what- die height malfunctions while running
Why: die height not adjusting correctly due to wiring issue for adjusting motor
R/C: Wiring on starter for die height replaced during safety modification, I what- die lock changed after injection
why- die lock load sensor NG
c/m- replaced load sensor
reoccur- no what- die release diaphragm pump NG
why- seals worn
c/m- replace
reoccur- in time what- die release dripping onto spray cartridge pedestal
why- poor pipe to manifold connection
c/m- thread tape pipe and reinstall in manifold
recur- unlikely what- die release leak at spray cart.
why- spray valve holes stripped
c/m- drill tap and install helicoil
reoccur- yes what- die release pump not working
why- air bowl cracked
c/m- replace air bowl
reoccur- in time what- die release tank overflowing
why- float sticking
c/m- replace float switch
reoccur- should not what- dropping parts
why- die release pump NG
c/m- replace diaphragm pump
reoccur- in time what- dropping parts
why- sprue bushing cracked
c/m- replace sprue bushing
reoccur- yes what- dropping parts (top operator)
why- squeeze pin coupler on die manifold leaking
c/m- thread taped and reinstalled couplers
reoccur- ? what- dropping parts/ squeeze pin pushing out on part when it should not be out causing part to break off
why- channel 1,2,3,and 4 in time and out time set incorrectly (optional set screen)
c/m- set a what- dropping shots
why- not getting enough plunger lube
c/m- fix plunger lube leak. adjust tip to spray in sleeve correctly
reoccur- yes what- dropping shots
why- r/b hit large biscuit in die
c/m- replace r/b chuck bracket
reoccur- possible what- dropping shots
why- sticking to tip
c/m- replace tip
reoccur- possible what- dropping shots
why- tip/sleeve
c/m- replace t/s
reoccur- in time what- dropping shots
why- tip/sleeve NG
c/m- change tip/sleeve
reoccur- in time what- dropping shots
why- tip/sleeve NG
c/m- replace
reoccur- yes what- dropping shots
why- tip/sleeve
c/m- replace
reoccur- in time what- dropping shots/ high shot speed alarms
why- tip/sleeve NG/ tip was loose on plunger shaft
c/m- replace
reoccur- in time
SHOT LIFE ON SLEEVE: 20,030 what- ejector pins turning shot in r/b chuck. trim damage
why- ejector pins coming out too far. r/b pos off in trim press
c/m- set ejector pins from 15mm to 13mm. touch up r/b in trim press
reoccur- what- electrode ladle malfunction
why- aluminum build up on electrode
c/m- clean electrodes what- emergency stop pressed alarm
why- breaker tripped in main safety panel
c/m- reset breaker
reoccur- possibly what- erratic temp on holding furnace
why- thermocouple NG
c/m- change what- excess flashing
why- bottom slide cores not moving
c/m- pull slide cores, clean slide cores/holders, stone slide core holders, clean all slide core cavities
reoccur- yes what- excess flashing on shot
why- aluminum build up in bottom slide core cavities
c/m- pulled slide cores cleaned all cavities
reoccur- yes what- excessive blowback and flashing
why- tip and sleeve worn 75,000, 75% life expectancy
R/C: Unknown cause for premature wear (unknown if true shot life on tip/sleeve)
C/M: Removed and installed n what- fence open alarms
why- Operator door safety switch no good not sending signal to plc and had a pinched wire
C/M: replaced front door Safety switch now ok
Recur: Possibly in time what- filter broke on holding crucible
why- unsure
c/m- replaced filter
reoccur- yes what- flame out/ temp low holding and smelting furnace
why- what- flashing
why- bottom slide core stuck
c/m- free bottom slide core what- furnace loading door not opening
why- valve leaking by
c/m- replace solenoid valve
reoccur- in time what- furnace side door handle weld broken
why- wear
c/m- re-welded handle and reattached to machine what- furnace side door jackhammered out
why- side door refractory damaged
c/m- patch side door
reoccur- yes what- go, nogo gauge was out of spec. Why- p2 slide core was bad. c/m- replaced p2 slide core. what- guide bars on scrap press broke
why- linear bushing failed causing misalignment and stress
c/m- replace both guide bars and both bushings
reoccur- in time what- half pipe broke
why-unknown
c/m- replace upper crucible and half pipe
reoccur- yes what- heavy flashing
why- the 2 bottom slide cores are bound up and not moving freely
c/m- clearance the to bottom slide cores.
reoccur- most likely what- heavy flashing around parts
why- bottom slide cores not moving
c/m- cleaned slide cores
reoccur- yes what- helper side auto door limit switch errors
why- roller on bottom of door loose
c/m- tighten roller what- high shot speed alarms
why- running without plunger lube destroyed tip and sleeve
c/m- replace tip and sleeve
reoccur- yes what- holding and melting burners wont fire
why- bad connection
c/m- tighten terminal strip
reoccur- unlikely what- holding crucible door not sealing
why- refractory NG needs busted out and patched
c/m- put wool in to block heat until crucible can be ladled out to fix door
reoccur- yes what- holding crucible filter broke
why- unsure
r/c- unsure
reoccur-yes
cm-replace crucible and pedestal what- holding crucible filter broke (bottom fell out)
why- unsure
c/m- put new filter in
reoccur- yes what- holding crucible filter broken what- holding crucible filter broken
why-unsure
c/m- replace holding crucible
reoccur- no what- holding crucible showing AL01 and showing over temp when temp was actually low
why- thermocouple bad
r/c- no life expectancy for thermocouples
c/m- replace
reoccur-yes what- holding crucible upper limit probe wire came off
why- wire pulled too tight
c/m- terminate wire, fastened wire so that it has slack
reoccur- no what- hyd pump overload tripping on squeeze master when bleeding
why- filters plugged
c/m- replace inline filter and return filter
reoccur- no what- hyd. oil temp high
why- heat exchanger plugged
c/m- clean heat exchanger
reoccur- in time what- hydraulic filter fault
why- life of filter
c/m- change filter what- hydraulic leak
r/c- hydraulic line to plunger cylinder leaking
c/m- welded up line where leak occurred
reoccur- no what- hydraulic leak
r/c- way lube line leaking
c/m- replaced hose
reoccur- yes in time what- hydraulic leak
why- bad hyd. line on movable cores
c/m- make new line and replace what- hydraulic leak
why- ejector hydraulic pipe
c/m- weld pipe x2 now ok
reoccur- yes what- hydraulic leak
why- ejector plate hydraulic pipe damaged from previous welding
c/m-replace o-ring
reoccur- yes what- hydraulic leak
why- fitting leaking for slide core hydraulic line (hard line R/B side inner line closest to die)
c/m- cut line back put new ferrule and nut on
reoccur-no what- hydraulic leak
why- hose blew
c/m- replace
reoccur- no what- hydraulic leak
why- hydraulic pipe cracked
c/m- re-weld
reoccur- yes what- hydraulic leak
why- incorrect couplers
c/m- take couplers from another die
c/m - investigate all hydraulic fittings and correct. what- hydraulic leak
why- injection hydraulic pipe
c/m- pulled off and welded
reoccur- yes what- hydraulic leak
why- metal slide core hydraulic line cracked
c/m- replace with line from another die
reoccur- yes what- hydraulic leak
why- slide core steel hyd. line fitting loose
c/m- tighten fitting
reoccur- no what- hydraulic leak
why- steel hydraulic pipe leaking
c/m- weld hole in pipe shut
reoccur- yes what- hydraulic leak
why- trim press hydraulic manifold fitting came loose
c/m- tighten fitting
reoccur- possible from hydraulic shock what- hydraulic leak
why- cracked weld on fix core hydraulic pipe leaking
c/m- pull pipe off and weld
reoccur- yes what- hydraulic leak under injection unit
why- manifold block had hole in it
c/m- remove injection hose manifold and re-weld, re-installed
reoccur-no what- hydraulic pump wont turn on
why-bad connection for manual S.S
c/m- re-terminated and tightened connections for S.S
recur- not likely what- inconsistent biscuit
why- ladle probes too low
c/m- raise ladle probes adjust shot weight
reoccur- no what- ingot conveyor wont move
why- dead short
c/m- replace gear motor
reoccur- in time what- ingot detect sensor (melting furnace) not working
why- sensor flashing
c/m- reset sensor what- ingot loader crash
r/c- limit switch 1,2
c/m- straighten out loader plate and other bent plates. started adjusting limit switches to work properly
reoccur- unsure what- ingot loader crashed
why- ingot loader came down on and bent ingot stop sensor and bent ingot loader up
r/c- unsure
c/m- straighten sensor bracket/ingot loader and verify ingot loader would not what- ingot loader door drifting down
why- cylinder bleeding by
c/m- replace cylinder
reoccur- in time what- ingot loader jammed up on pusher
why- pusher plate bent up
c/m- straighten plate what- ingot loader lift cradle sagging
why- welds broke
c/m- re-weld cradle
reoccur- in time what- ingot loader out of cycle
why- possibly operator error
c/m- put back in cycle what- ingot loader pusher 2 wont return
why- return pipe nipple broken
c/m- replace pipe nipple
recur- timing what- ingot loader safety slide broke
why- ?
c/m- replace safety slide key
reoccur- possible what- ingot pusher 2 L.S. melted
why- heat
c/m- moved L.S. location/installed new L.S
reoccur-unlikely what- injection abnormal
why- shot sensor had oil on it and was not reading correct
r/c- ?
c/m- wipe sensor clean and reinstalled
reoccur- yes what- injection hydraulic pipe leak
why- leaking at weld from shock
c/m- re-weld
reoccur- yes what- injection hydraulic pipe leak
why- shock/ cracked weld
c/m- weld
reoccur- yes what- injection hydraulic pipe leaking
why- cracked around weld from shock and movement
c/m- re-weld
reoccur- yes what- injection not reading returned
why- plunger cylinder shaft worn
c/m- clean shot sensor/ turn plunger cylinder
reoccur- yes, cylinder shaft worn what- insulator block for upper limit probe broke
why- timing/ wear
c/m- replace block what- ladle arm locked up
why- wear and heat from molten aluminum
c/m- replace ladle arm assembly (all 3 arms and ladle unit)
reoccur- yes what- ladle bar electrode malfunction alarm
why- broken spot in cable
c/m- replaced ladle electrode cable what- ladle bouncing
why- electrode insulator broke
c/m- replace insulator
reoccur-yes what- ladle bouncing causing to pour inconsistent biscuit thickness, sometimes not making full shot
Why: Bearing going out
C/M: Replaced all 6 bearing
Recur: In time what- ladle bouncing/dunking in aluminum
why- ladle electrode bulb missing and ladle electrode rod loose
c/m- replace non-inventory bulb and tighten electrode rod
reoccur- unlikely what- ladle dunking/bouncing in aluminum and aluminum build up faulting ladle
why- unsure
c/m- ladle started working properly during troubleshooting
reoccur- yes what- ladle electrode bar malfunction
why- broken ladle wires
c/m- terminate wires what- ladle electrode bar malfunction
why- insulator broke
c/m- replace electrode assembly
reoccur- yes what- ladle electrode bar malfunction
why- ladle electrode wires rubbed through insulation grounding on ladle arm
c/m- change ladle electrode wire
reoccur- in time what- ladle electrode bar malfunction
why- probes covered in aluminum from ladle going down too far and bouncing
c/m- clean aluminum off probes
reoccur- yes what- ladle electrode bar malfunction alarms
why- possibly electrode touching ladle arm
c/m- adjusted electrode what- ladle electrode break
why- wire broke
c/m- terminate wire what- ladle electrode malfunction
why- ladle probe insulator broke
c/m- replace insulator
reoccur- in time what- ladle electrode malfunction alarm
why- broken wire
c/m- crimp broken wire what- ladle electrode malfunction alarms
why- wire broken on electrode
c/m- terminate wires what- ladle electrode wire break
why- wiring exposed
c/m- cut back wiring/ re-terminated
reoccur- yes in time what- ladle electrode wire came out
why- ladle wire clips missing
c/m- put clips on ladle wire
reoccur- no what- ladle limit switch malfunction
why- wire losing connection
c/m- ran new 24v wire from ladle forward L.S (X060) to main cabinet
reoccur- unlikely what- ladle limit switch malfunctions and ladle jumping around/dunking on previous shifts
why- bad connection in original ladle wire terminal box
c/m- moved wires to get better connection
reoccur- yes what- ladle manual/auto switch not working sometimes
why- switch NG
c/m- replace switch
reoccur- in time what- ladle pour wont move
why- motor NG
c/m- replace ladle pour motor
reoccur- in time what- ladle pour would not move
why- chain master link separated
c/m- replace master link
reoccur- no what- ladle spilling aluminum in sleeve before pouring
why- ladle pour 90 off
c/m- adjust 90 and set wait position to furnace what- ladle still over pouring as it was before ladle unit was changed
why- ladle arm position off at sleeve
c/m- adjust ladle arm position and slow down ladle fast pour
reoccur- no. will monitor what- ladle stopped at sleeve while running from aluminum build up
why- ladle bouncing/dunking in aluminum
c/m- ?
reoccur- yes what- ladle traveling forward L.S. malfunctions
why- sensor too close to bracket
c/m- moved sensor up to get farther from bracket
reoccur- ? what- ladle travelling L/S and ladle forward L/S malfunctions
why- 24v wire NG
c/m- ran new 24v wire for ladle forward L/S
reoccur- unlikely what- ladle travelling forward L.S. malfunctions
why- sensor sticking on
c/m- replace forward L.S. X60
reoccur- yes what- ladle unit bearings locked up
why- heat/wear
c/m- replace ladle unit
reoccur- yes what- ladle unit locked up
why- heat/wear
c/m- replaced ladle unit
reoccur- no what- ladle unit locked up
why- ladle dunking in aluminum
c/m- replace ladle unit
reoccur- yes what- ladle wont move
why- vertical arm locked
c/m- replace vertical arm and top cross arm
reoccur- in time what- large biscuit
why- accumulator sight glass not filled with oil
c/m- did v-check
reoccur- possible what- large biscuit, all 4 axis alarms, biscuit breaking off in die
why- low nitrogen
c/m- add nitrogen
reoccur- unsure what- lot mark stuck
why-?
c/m- pull die to remove lot mark
reoccur- yes what- lot mark stuck in die
why- head of bolt stripped
c/m- remove lot mark what- low holding temp
why- thermocouple NG
c/m- replace thermocouple
reoccur- in time what- low temp alarms on melting. temp sporadic
why- thermocouple NG
c/m- replace
reoccur- in time what- lower crucible broken filter on 2nd shift
why- unsure
c/m- ladled aluminum out pulled old filter out and patched new filer in
reoccur- yes what- lower crucible overflowed back and set off leak detect
why- sludge build up behind filter
c/m- cleaned aluminum out of leak detect area. repaired leak detect probes. cleaned aluminum sludge buil what- lower ladle unit locked up
why- unsure
c/m- replaced ladle unit
reoccur- in time what- lube malfunction alarm
WHY: water leaking from roof on lube unit
C/M:replaced pressure switch on lube unit
REOCCER; unlikely what- m/c alarm for high hydraulic temp
why- unsure
c/m- shut m/c 1,2, and 3 down to let hydraulic temps come down
reoccur- yes what- m/c flashes cycle stop in full auto with no alarm on screen
why- mold temp controller faulted
c/m- reset fault
reoccur- possible, no alarm to let operators know the controller has a fault what- m/c stopping with no fault and everything in position it should be then cycle times out
why- injection not returning in time
c/m- replace plunger rod bushing
reoccur- in time what- machine runs one cycle then stops with no faults
why- operator not starting m/c correctly
c/m- had DH start m/c with no issues
reoccur- yes what- machine wont do v-check
why- injection position off
c/m- origin reset injection
reoccur- unlikely what- mark on part
why- spring in trim press guide broke
c/m- replace spring
reoccur- in time what- melting blower air pressure low
why- what- melting burner flameout
why- bad spark plug wire
c/m- make temporary spark plug wire
reoccur-no what- melting burner flameout
why- burner assy. dirty
c/m- pulled burner assy. verified spark. cleaned and reinstalled and is now working
recur- possible what- melting burner not lighting
why- flame eye plug NG
c/m- replace flame eye plug and flame eye
reoccur- in time what- melting crucible leaking
why- spout broke
c/m- replace crucible half pipe and crucible stand
REOCCER: yes timing what- melting crucible lid cylinder came apart from knuckle
why- jam nut loose
c/m- tighten jam nut
reoccur- no what- melting crucible thermocouple bad
why- in too far
c/m- replace thermocouple
reoccur- in time what- melting damper door wont open
why- valve NG
c/m- replace solenoid valve
reoccur- in time what- melting door creeping up
why- valve bleeding buy
c/m- replace valve what- melting exhaust thermocouple NG
why- unsure
c/m- replace
reoccur- in time what- melting flameout
why- ignition rod covered in soot
c/m- cleaned ignition rod and ignition ground. also replaced worn isolator (non-inventory)
recur- in time what- melting furnace temp would not get above 1300
why- thermocouple bad
c/m- replace thermocouple
reoccur- no what- melting leak
why- half pipe cracked
C/M: replaced lower an upper crucible, half pipe, pedestals
REOCCUR: yes timing what- melting temp jumping aluminum not melting fast enough
why- thermocouple bad what- melting thermocouple AL01
why- thermocouple NG
c/m-replace
reoccur-yes what- metal leak
why- Aluminum overflow
c/m-
Recur: Possibly in time what- metal leak
why- crucible cracked around spout due to excess corundum build up in crucible spout
c/m- replace
reoccur- yes what- metal leak
why- half pipe broke at spout
c/m- replace upper crucible/stand and half pipe
reoccur- in time what- metal leak
why- spout broke off upper crucible, also crucible cracked around outside
c/m- replace upper, lower crucible, stands, and half pipe. Remove and replace inner ring on upper furnace co what- metal leaking out detect door when it was closed
why- furnace refractory was chipped out
c/m- patch what- metal leaks in melting furnace
why- half pipe separation from spout
c/m- replace half pipe
reoccur- unlikely what- missing insulation on probe
why- fell off
c/m- installed insulation what- mold heater not heating up
why- contactor not pulling in
c/m- tightened contactor screws what- mold temp controller blowing fuses at main disconnect
why- wires melted from furnace heat(too close to furnace)
c/m- run new wires from main disconnect to secondary disconnect
reoccur- possibly what- mold temp controller fault (02-medium short)
why- float sticking
c/m- clean float
reoccur- in time what- mold temp controller not working
why- drain valve NG
c/m- replace drain valve
reoccur- in time what- mold temp controller overheating
why- ?
c/m- open bypass valves on die
reoccur-yes what- molten aluminum upper limit fault
why- short in probe wires, insulation wrapped around wires
c/m- pull back insulation what- molten metal high limit
why- possibly aluminum build up on probe
c/m- clean probe what- molten metal leak
why- holding crucible cracked
c/m- replace crucible what- molten metal leak upper crucible
why- crucible cracked
c/m- change crucible
Recur: in time what- motor overload
why- scrap conveyor 2 connecting rod bent causing bind
c/m- replace connecting rod
reoccur- in time what- motor overload
why- ok carrier going too far
c/m- move sensor back
reoccur- no what- motor overload (scrap conveyor 1)
why- aluminum scrap build up
c/m- clean out build up
reoccur- yes what- move core 2 fault
why- lead switch extension NG
c/m- replace lead switch extension
reoccur- no what- move core 2 limit switch malfunction
why- junction box NG
c/m- replace junction box
reoccur- no what- move core 2 malfunction
why- aluminum stuck between slide core and die
c/m- remove aluminum
reoccur- possible what- move core 2 malfunction
why- read switch NG
c/m- replace r/b side read switch
recur- timing what- move core 2 malfunctions
why- r/b side read switch NG
c/m- had production change die
reoccur- possible what- move core 2 malfunctions
why- r/b side slide core cylinder NG
c/m- replace cylinder
reoccur- in time what- move die temp high
why- move die cooling valve plugged
c/m- replaced valve
reoccur- yes what- mvcr core 2 limit switch malfunction
why- bad connection
c/m- tightened connections for moveable core 2
reoccur- no what- nitrogen gauge reading incorrectly
why- gauge NG
c/m- replace gauge
reoccur- in time what- not getting in light for movecore2
why- reed switch NG, wire smashed
c/m- replace reed switch what- not getting plunger lube
why- plunger lube tip plugged/ lube line had hole
c/m- unplug lube tip/ replace lube line
reoccur- possible what- not getting plunger lube in auto running
why- solenoid NG
c/m- replace solenoid valve
reoccur- in time what- not melting aluminum fast enough
why- melting thermocouple NG
c/m- replace
reoccur- in time what- oil fittings for squeeze pins leaking
why- fittings needed taped
c/m- taped fittings
reoccur- yes in time
c/t- unchanged what- oil mist collector gauge way out of spec
why- filter
c/m- replaced both stage 3 HEPA filters
reoccur-in time what- ok (mesh) conveyor stopped and pinched in on mesh belt
why- bearings locked up
c/m- replace bearings
reoccur- no what- ok carrier
why- chain came off
c/m- put chain on and set tension
recur- timing what- ok carrier bucket bolts broke and bucket came off
why- bucket too wide, hitting bucket guide (left side)
c/m- replace bolts. put spacer in left side guide
reoccur- no what- ok carrier bucket broke and fell off and sensor bar damaged sensor
why- bolts worked loose got hit and broke
c/m- replace ok conveyor
reoccur- no what- ok carrier bucket broke/fell apart
why- unsure
c/m- replace bucket
reoccur- no what- ok carrier bucket came off
why- bolts came out
c/m- put new bolts in with threadlocker
reoccur- no what- ok carrier chain came off
why- shot scrap build up under chain sprockets
c/m- reinstall chain, tension, remove shot scrap tabs from around this area
reoccur- yes when build up gets bad and jams what- ok carrier gear box shaft key sheared
why- clutch setting
c/m- replace gear box/clutch. set new clutch
reoccur- no what- ok carrier guide rail bolts broke
why- bucket too heavy for this setup
c/m- replace bolts
reoccur- yes what- ok carrier mount plate bolts loose
why- vibration? or improperly assembled previously?
c/m- apply thread locker, tighten bolts
reoccur- no what- ok carrier not going up all the way
why- wheel guide at top of carrier in too far
c/m- modify spacer for wheel guide
reoccur- yes what- ok carrier not moving
WHY: gearbox key fell out
C/M: removed motor and gearbox installed key
REOCCUR: unlikely what- ok carrier not moving
why- carrier drive shaft keyway sheared
c/m- swapped with spare, took tension off clutch
reoccur- no what- ok carrier not moving
why- gearbox shaft key came out
c/m- tack welded key into keyway
reoccur- no what- ok carrier not moving
why- key fell out of gearbox
c/m- replace key put in set screw
reoccur- not likely what- ok carrier sensor stuck on
why- carrier sensor bar came loose and hit sensor
c/m- replace sensor (x16) replace bolts in sensor bar and put medium strength thread locker on
reoccur- no what- ok carrier stopping before returning fully
why- sensor bar hitting conveyor cross bar and came loose
c/m- replace sensor bar bolts and tighten. move sensor bar so it does not hit crossbar
reoccu what- ok carrier upper slow down sensor sticking on
why- got hit?
c/m- replaced (x17) and lowered sensor to avoid being hit
reoccur- in time what- ok carrier wheel guide bolt broke
why- Bucket became misaligned and stressed these bolts
c/m- modify spacer replace pillow block bearing
reoccur- yes what- ok carrier wheel guide bolt broke
why- ok carrier bucket too heavy
c/m- got rid of spacers and made pins
reoccur-? what- ok carrier wont move
why- chain jumped tooth on sprocket
c/m- reset chain tension equal on both sides
reoccur- timing what- ok carrier would not go up all the way
why- missing/broken bolts in rails
c/m- replace bolts and added lock washers
reoccur- yes what- ok carrier would not move
why- gearbox key fell out
c/m- tack key in keyway
reoccur- no what- ok carrier would not move
why- sprocket coupler set screw was loose
c/m- tighten set screw
reoccur- no what- ok carrier would not move
why-chain jumped tooth on one side
c/m- moved chain where it needed to be
reoccur-? what- ok conveyor belt torn
why- carrier chute dragging on conveyor belt
c/m- replace mesh belt, adjust so that carrier chute and conveyor had gap
recur- timing what- ok conveyor not advancing
why- key fell out of motor
c/m- installed key what- ok conveyor not advancing all the way
why- rollers fell off
c/m- installed rollers what- ok conveyor not going all the way down
why- advance sensor bracket loose hitting on shaft at bottom of conveyor
countermeasure- straightened bracket and replaced bolts
reoccur- yes in time what- ok conveyor would not advance
r/c- guide plate bolts came loose and plate fell out (door side)
c/m- reinstalled plate and tightened bolts, also checked bolts on other side also loose tightened
r what- ok parts coming out NG conveyor
why- latch stuck in PLC
c/m- clear latch
recur- not likely what- ok parts table (M4) not turning
why- table shaft sheared
c/m- replace shaft
reoccur- in time what- operator die side vacuum hose quick connect locked up
why- debris/ something jammed in release
c/m- cleaned quick connect fitting and worked release to free it
reoccur- no what- operator door safety switch broke
why- unsure
c/m- replace
reoccur- in time what- operator noticed water leaking out of sleeve
why- plunger tip unthreaded
c/m- reinstall tip with thread tape
reoccur- possible what- operator says a lot of sparks came flying out of machine and tripped breaker for trim press
why: Ok parts getting dropped when putting on conveyor
C/M: Replaced power leads to the trim press hyd what- operator says back door doesn't close and the robot goes home
why- product detect alarm (dropping parts)
c/m- die release low, added die release
reoccur- yes what- operator says check 43 out of spec
why- ?
c/m- verified toscast matched gauge, verified gauge working properly and in spec
recur- possible what- operator says r/b faulting in trim press
why- did not fault in the time I was watching
c/m- watched run with no problems. told operator to call if issue came back
reoccur- unsure what- operator says there is a hydraulic leak
why- did not see a leak
c/m- moved slide cores and squeeze pins to look for leak did not see anything leaking
reoccur- unsure what- operator tried to close die, it made loud noise when it hit and would not fully close
why- slide core cylinder bracket loose
c/m- tighten slide core cylinder bracket
recur-possible what- p1 tappet pin broke and s1 slide core cracked on 2nd
why- not known
c/m- replace
reoccur- yes what- p2 injector pin protrusion amount to low
why- injector pin sticking out to far
c/m- ground down pin what- part moving in r/b chuck and hitting trim press
why- wrong fingers on r/b chuck
r/c- training?
c/m- operator put correct fingers on
reoccur-yes what- part sticking in die
why- squeeze pin not returning
c/m- replace hyd. line on die side channel 1. line bled
reoccur- yes what- part sticking in die (cavity 3)
why- build up on die?
c/m- clean die
recur- timing what- parts falling out of ok carrier
why- carrier not back far enough
c/m- move carrier back
reoccur- no what- parts getting stuck in ok conveyor to table
why- guard up too high letting parts get under
c/m- replace guard with old one that fits better
reoccur- no what- parts sticking in trim press (cavity 2)
why- parts coming out of die NG causing pins to bend in press
c/m- clean die. replace guide pins on trim press
reoccur-possible what- plc link fault
why- possible communication error between plc and squeeze master
c/m- cycle power to both and restart what- plunger coupler came apart
why- injection rod worn
c/m- put new shims between coupler and injection rod
reoccur- yes what- plunger coupler came loose
why- plunger cylinder rod worn (coupler loose on cylinder rod)
c/m- Changed tip and sleeve, put in new spacer to reduce movement of plunger rod, put shim in coupler to what- plunger lube assembly plugged with aluminum
why- unsure
c/m- repair plunger lube line assemblies ,reinstalled
reoccur- yes, what- plunger lube spray tip plugged
why- blowback?
c/m-replace plunger lube spray tip
reoccur- yes what- plunger lube tip plugged
why- blowback
c/m- clean aluminum out of plunger lube tip
reoccur- will monitor for blowback what- plunger lube tip plugged
why- pour too fast causing aluminum wave splash out of sleeve
c/m- replace plunger lube tip slow down pour, lowered shot delay from .3 to .1
reoccur- ? waiting to see r what- plunger rod extension broke off of plunger rod leaving tip and extension in sleeve
why- unsure
r/c- tool life not set for joint for replacement
c/m- Replace tip. sleeve. plunger rod. plunger rod what- plunger rod leaking
why- bad seal
c/m- replace seal
reoccur- yes in time
c/t- unchanged what- plunger shaft water leak
why- quick connect worn out
c/m- replace quick connect fitting
reoccur- yes what- plunger tip came lose
why-?
c/m- reinstall tip and verified tight
reoccur-no what- porosity in parts
why- sprue bushing cracked
c/m- replace sprue bushing
reoccur-? what- product detect
why- robot position was set to hit product detect
c/m- touch up robot to correct position
reoccur- possible what- product detect
why- sensor NG
c/m- replace product detect 2
reoccur- in time what- product detect
why- top right product detect NG
c/m- replace
reoccur- in time what- product detect
why- r/b position off
c/m- touch up r/b/adjust product detect
reoccur- no what- product detect
why- sensor mode
c/m- change sensor to correct mode
reoccur-no what- product detect not seeing p-2 part
why- sensor alignment
c/m- adjust sensor what- product detect not working
why- r/b program
c/m- added instruction to tell mc to stop if product detect NG
reoccur- possibly on other models what- production jackhammered all patch out of melting furnace side and back door
why- unsure
c/m- patch furnace at side and back door
reoccur- yes what- pusher 2 forward L.S stuck on
why- melted
c/m- replace L.S
reoccur- yes what- pusher 2 not getting ret. light
why- switch not hitting stop
c/m- adjust switch what- r/b chuck mount plate and chuck finger bent
why- r/b hit biscuit
c/m- straighten r/b chuck mount plate and finger
reoccur- yes,I am not sure what happened as I was not here to see it what- r/b chucks then unchucks shot in trim press or die and goes home
why- r/b chuck sensor flickering on sometimes
c/m- replace r/b chuck sensor
reoccur- no what- r/b collision detect in trim press
why- r/b position off
r/c- unsure
reoccur- yes
c/m- touch up r/b in trim press what- r/b door cylinder mount broke
why- stress from door movement
c/m- welded
reoccur- in time what- r/b door not opening
why- cylinder leaking by (was in bind due to too thick of spacers)
c/m- replace door cylinder
reoccur- yes what- r/b door wont close
why- r/b safety bump sensor NG
c/m- changed sensor
reoccur- in time what- r/b fault at m/c startup and wont move
why- chuck sensor not getting un-chuck light
C/M: Replaced un-chuck sensor
Recur: Possible in time what- r/b pos. off in die and trim press
why- changeover?
c/m- touch up r/b in die and at press
reoccur- yes what- r/b pos. off in trim press
why- ?
c/m- touch up pos. in trim press
reoccur- yes what- r/b position off at stationary jig and trim press/ vibrator not knocking tab off
why-?
c/m- vibrator out of oil(added) touch up r/b at stationary and vibrator
reoccur- yes what- r/b puts shot in trim press pulls it back out and drops it on scrap conveyor then press comes down
why- sensor misaligned
c/m- aligned shot detect sensor in trim press
reoccur- no what- r/b side door close L/S malfunction
why- cylinder mount holes NG.
c/m- drill and tap cylinder mounting holes.
reoccur- no what- r/b unchuck sensor NG
why- Control wiring from the robot chuck terminal box to the Robot main terminal box had aluminum melt the wire
c/m-Replace 8 conductor control wire, Test
reoccur- in tim what- r/b unchuck sensor broke off cylinder
why- ?
c/m- replace sensor
reoccur- yes what- r/b wiring harness got caught coming out of die and faulted r/b
why-harness support loose
c/m- re-route wiring harness and tighten
reoccur- no what- r/b wont go in to get shot. Sets at back door
why- RP7 relay bad for ejector pins
c/m- Replaced relay
recur- in time
Cycle time: Unchanged what- replace squeeze pin and bushing cav.1
why- squeeze pin bent
c/m- replace what- robot chuck air line got hole burned in it
why- shot got on air line and burned it
c/m- cut back hose where hole was, replaced air fittings on chuck cylinder, replaced tip
reoccur: yes timing what- robot chuck extension broke
why- unsure
c/m- remove the other 3 extensions put chucks directly on chuck bracket and touch up all robot positions
reoccur- no what- robot chuck moving
why- shoulder bolt broke
c/m- replace non-inventory shoulder bolt
reoccur- yes what- robot chuck not opening
why- air fitting with check valve preventing movement
c/m- replace fitting what- robot collision detect
why- robot position
c/m- teach positions 24 and 2 what- robot collision detect at trim press
why- pusher stuck in at take out, end of pin backed off, threads worn
c/m- tap and reinstall pin what- robot cover off
why- someone removed cover
c/m- replace cover what- robot crash in trim die
why- chuck finger loose/ bent bolt
c/m- replace shoulder bolt what- robot crashed into biscuit multiple times
why- large biscuit 124mm
c/m- production change die. replace bent robot chuck arm
reoccur- possible what- robot double stacking in press/dropping shots
why- robot had wrong finger on it from previous changeover
c/m- put correct finger on
reoccur- yes what- robot faulting at trim press
why- detect sensor n/g
c/m- replace sensor what- robot getting collision detection alarms
why- pinched air line for air cylinder in trim die
c/m- replace air line what- robot not picking up shot out of diecast m/c correctly
why- broken chuck finger
c/m- replace finger
reoccur- yes in time
c/t- unchanged what- robot not setting parts down in trim press correctly (sticking)
why- positions off
c/m- teach positions 24,25 what- robot position off at product detect, water tank, and water tank air blow
why- unsure
c/m- touch up r/b
reoccur- no what- robot side door came off
why- not enough support holding door
c/m- remove broken bolts install door with new bolts
reoccur- yes we will need to add support to door on each m/c to prevent this fr what- robot stopping at scrap press
why- scrap detect sensor n/g
c/m- replace sensor what- robot wont run or go home
why- un-chuck sensor wire pinched
c/m- run new wire to sensor
reoccur- unlikely what- robot would not return home for operator
why-?
c/m- returned robot home
reoccur- yes in time
c/t- unchanged what- roller fell off ok carrier
why- snap ring worn out/ fell off
c/m- replace roller, roller shaft, and snap ring
reoccur- no what- s-2 slide core leaving mark in parts
why- chip in slide core
c/m- replace slide core what- s1 and s2 slide core
why- cracked
c/m- replaced what- safety key for ingot loader door bent
why- ingot loader crash
c/m- straighten safety key
reoccur- possible what- safety latch broken. scrap loader broken
why- crashed loader
c/m- replace safety latch
reoccur- yes what- safety latch not working
why- wires got ripped out and wire plug broken
c/m- replace safety latch/ wire plug. correct wiring
recur- yes what- scrap build up on scrap conveyor 2 pushing conveyor out and causing more scrap build up on floor
why- conveyor not back far enough/scrap getting caught in guard gaps
c/m- modified guards so ther what- scrap chute diverter
why- broken air fitting and hole in air line
c/m cut back air line replace fitting
recur- timing what- scrap conveyor 1 and 2 jam ups (motor overloads)
why- aluminum build up caught in conveyors
c/m- clean out aluminum chunks
reoccur- no what- scrap conveyor 1 jammed up (motor overload)
why- unsure still need to pull apart
c/m- replace conveyor with rebuilt spare
reoccur- no what- scrap conveyor 1 locked up (motor overload)
why- scrap build up
c/m- remove chain clean out scrap reinstall
reoccur- yes what- scrap conveyor 1 motor overload
why- aluminum scrap wedged in conveyor belt
c/m- pull conveyor and belt out, cleared scrap
reoccur- in time what- scrap conveyor 1 motor overload
why- scrap jam
c/m- clear scrap
reoccur- in time what- scrap conveyor 1 motor overloads what- scrap conveyor 2 belt came off sprockets
why- ?
c/m- put chain back on verified belt not stopping
reoccur- yes what- scrap conveyor 2 jam up setting off scrap detect sensor
why- link cotter pin came out link flipped backward causing bind
c/m- replace link. replace all visible missing cotter pins
reoccur- yes what- scrap conveyor 2 sagging setting off scrap jam detect alarm
why- broken links in chain
c/m- replace broken links and bent through rods
reoccur- yes what- scrap conveyor 2 slacking/setting of scrap jam detect sensor
why- several links off/missing/bent on conveyor due to missing cotter pins
c/m- fix/replace links. put cotter pins in where missing
r what- scrap conveyor alarm
why- drag bar bent
c/m- straighten drag bar
reoccur- in time what- scrap conveyor fault
why- conveyor jammed/ rods bent rollers broken
c/m- replace bent rods and rollers what- scrap conveyor motor overload
why- scrap jammed in conveyors
c/m- clear scrap unjam conveyor
reoccur- in time what- scrap conveyor to jammed up ripped side cover off
why- gap between cover and m/c
c/m- tack welded piece on cover to get rid of gap
reoccur- no what- scrap press sensor alarming
why- reflector NG
c/m- replace r-6 reflector "NON INVENTORY "
reoccur- in time what- scrap press stuck down
why- return sensor stuck on
c/m- rep[lace sensor
reoccur- yes in time
c/t- unchanged what- scrap sticking in scrap press
why- caught behind air blow line
c/m- move air line up so scrap slides under
reoccur- no what- scratch on part coming out of die
why- sharp edge on die
c/m- polished die
reoccur- unsure what- selector switches melted
why- dog house door had build up under it and wasn't all the way down
c/m- replace ss for injection fix core 1 and hp side door. cleaned build up so door would shut
reoc what- sensor abnormal/trim press not getting start position light
why- chip on trim press cylinder down sensor (x21)/ok carrier not returned fully
c/m- wipe sensor/return carrier
reoccur- no what- setting shortage warning on vacuum m/c
WHY; pump not making vacuum due to fitting and hose from pump to tank
C/M: replaced line and fitting
reoccur: timing what- shot hitting trim press
why- sleeve cooling joint didn't get put in when m/c changed over
c/m- put cooling joint in sleeve
recur- possible what- shot not ejecting from die
why- reed switch for slide cores bad
c/m- replace robot bottom reed switch
reoccur- no what- shot position sensor not reading 0 when returned
why- injection shaft worn
c/m- rotate injection shaft
reoccur-yes what- shot position sensor/ wire broke faults
why- senor bad
c/m- installed shot sensor from DC5 now ok what- shot position sensor/wire break
why- shot position sensor NG
c/m- replace
reoccur- in time what- shot position sensor/wire break
why- shot sensor NG
c/m- replace sensor
reoccur- yes what- shot position sensor/wire break alarm
why- plunger bushing seals leaking hydraulic oil
c/m- replace plunger bushing
reoccur- no what- shot position sensor/wire break alarm
why- shot position sensor had oil on it
c/m- pulled sensor and wiped clean
reoccur- no what- shot position sensor/wire broken alarm
why- shot detect sensor NG
c/m- replace shot sensor
reoccur- no what- shot sensor alarm
why- shot sensor loose
c/m- clean and tighten sensor
reoccur- not likely what- shot sensor/wire break alarm
why- shot sensor area dirty
c/m- wiped sensor clean
reoccur- in time what- shot stroke not going back to zero
why- shot detect sensor NG
c/m- replace
reoccur-no what- shot stroke reading incorrectly (plunger thinks its not returned)
why- plunger rod cylinder shaft worn
c/m- turn cylinder shaft
reoccur- yes
(LT) what- shots sticking to tip
why- aluminum sitting in sleeve caused tip/sleeve failure
c/m- replace tip/sleeve
reoccur- yes
SHOT LIFE- 30,000 what- shots sticking to tip
why- plunger lube tip plugged and angled incorrectly
c/m- unplug tip/re-angle
reoccur- no what- shots sticking to tip
why- sleeve cooling lines hooked up backwards
c/m- change t/s
reoccur- yes what- side door on furnace patch
why- hit with jackhammer
c/m- patch
reoccur- yes what- sleeve air blow not working
why- bad plug connection on air blow solenoid
c/m- replace plug head
reoccur- not likely what- sleeve cooling joint broke
why- ?
c/m- replace
reoccur- yes what- sleeve cooling joint broke
why- aluminum build up
c/m- replace
reoccur- possible what- sleeve cooling joint broke
why- flashing
c/m- replace
reoccur- yes what- sleeve cooling joint broke
why- unsure
c/m- replaced cooling joint
reoccur- ye what- sleeve cooling joint extension pipe broke
why- aluminum on plunger shaft?
c/m- installed 90 degree elbow and 45 to move cooling joint away from sleeve so it cant get hit
reoccur- no what- slide core
why- burr out of spec
c/m- change P1 what- slide core
why- chipped out quality says NG
c/m- replace slide core
reoccur- yes what- slide core
why- chunk missing from slide core
c/m- replace (op top)
reoccur- possible what- slide core
why- chunked out quality says NG
c/m- replace p2 slide core
reoccur- yes what- slide core
why- crack out of spec
c/m- replace s1
recur-yes what- slide core
why- cracked out of spec
c/m- replace P1
reoccur- yes what- slide core
why- cracked out of spec
c/m- replace p1
recur- timing what- slide core
why- cracked out of spec
c/m- replace p2 slide core
recur- timing what- slide core
why- cracked, out of spec
c/m- replace P2 slide core
reoccur- in time what- slide core
why- die crash
c/m- change slide core cavity 4
reoccur- yes what- slide core
why- out of spec
c/m- replace s1
recur- yes what- slide core
why- crack out of spec
c/m- replace p1
recur- yes what- slide core (A) broke on fixed side end of 2nd shift
why- unsure
c/m- replace slide core (A)
reoccur- yes what- slide core (p2) out of spec
why- slide core too small
c/m- replace
reoccur- yes what- slide core (s1)
why- cracked
c/m- replace
reoccur- yes
SHOT LIFE: ? 11,000 what- slide core MID op side
why- shot shut in die
c/m- replace slide core
reoccur- yes what- slide core NG
why- coating worn/ wont plug gauge
c/m- change P1 what- slide core P1
why- cracked
c/m- replace
reoccur- yes what- slide core P1 and S1
why- quality says NG
c/m- replace
reoccur- yes what- slide core S1
why- cracked
c/m-replaced
reoccur- in time what- slide core change
why- chipped out of spec
c/m- replace s1 and p2 slide core
reoccur- yes what- slide core change
why- slide core cracked and chunked out
c/m- replace P1 slide core
reoccur- in time what- slide core cracked S1
why-unknown
c/m- replace
reoccur- yes what- slide core cracked above 10 mm
why- ?
c/m- change slide core
reoccur- yes in time
c/t- unchanged what- slide core leaking
why- cracked
c/m- replace slide core
reoccur- yes in time
c/t- unchanged what- slide core leaking (lower robot side)
why- o rings worn ?
c/m- replace o rings
reoccur- yes in time
c/t- unchanged what- slide core p-2 out of spec
why- wear
c/m- change slide core what- slide core s2
why- cracked out of spec
c/m- replace
reoccur- in time what- slide cores
why- chipped slide cores
c/m- replace p1&s1
reoccur- yes what- slide cores
why- radius out of spec
c/m- replace slide core 2,3 and 4
reoccur- possible what- slide cores not moving
why- hydraulic hose not fully hooked up
c/m- hooked hose up
reoccur- yes what- slide cores not working
why- slide core hoses made wrong
c/m- switch fittings so lines would hook up to correct side
reoccur- yes lines and fittings are being changed on all machines and dies what- slide cores stuck in
why- squeeze master not bled properly
c/m- bled squeeze master what- slide cores wont move
why- lines backwards
c/m- put lines on correctly
reoccur- possible what- slide cores working backwards
why- hydraulic hoses connected wrong
c/m- change hydraulic hose fittings to hook up correctly
reoccur- possible what- slide cores wouldn't open
why- hydraulic lines were switch around
counter measure- switch main lines around what- soldering
why- build up on die
c/m- clean die what- soldering
why-?
c/m- clean soldering
reoccur- yes what- soldering on slide core
why- coating worn off
c/m- die change
reoccur- in time what- soldering on slide core s2
why- building up in crack on slide core
c/m- replace s2
reoccur- yes what- speed acc filling malfunction/ acc not filling
why- ?
c/m- power m/c down and back up. did /v-check
reoccur- yes what- spray cartridge goes down sprays and goes back up but no airblow
Why: X36 relay for up was staying on
C/M: Replaced with new
Recur: Possible in time what- spray cartridge leaking
why- spray nozzle n/g
c/m- replace nozzle
reoccur- yes in time
c/t- unchanged what- spray cartridge leaking
why- spray valve NG
c/m- rebuilt spray valve
reoccur- in time what- spray cartridge leaking
why- spray valves NG
c/m- replaced 2 leaking spray valves
recur- timing what- spray cartridge leaking
why- valve n/g
c/m- replace leaking valve what- spray cartridge leaking
why- valve not closing all the way on one of the nozzles
c/m- replace valve
reoccur- yes in time
c/t- unchanged what- spray cartridge not getting up light
why- sensor out of adjustment
c/m- adjust sensor what- spray cartridge not going up
why- moving spray cylinder not getting return light- blow by in cylinder
c/m- swap spray cartridges what- spray cartridge not spraying
why- diaphragm pump NG
c/m- replace pump
reoccur- in time what- spray cartridge not spraying
why- pump n/g
c/m- replace pump see work order 68100 what- spray cartridge not spraying in auto
why- relay
c/m- replace cx2
reoccur- in time what- spray cartridge spraying water with airblow only on and filling main air line with water
why- unsure
c/m- drain water from system and blew out cartridge
reoccur-yes what- spray cartridge stays on when it goes up
why- diaphragm on spray side damaged from wear
c/m- ?
reoccur- yes what- spray cartridge wont spray in auto
why- spray extension cylinder forward sensor NG
c/m- replace
reoccur- in time what- sprue bushing
why- passed on from 2nd sprue bushing needed changed
c/m- replace sprue bushing
recur- timing what- squeeze master leaking hydraulic oil
why- pressure gauge NG leaking
c/m- replace gauge
reoccur- no what- squeeze master not bleeding properly
why- lines hooked up on wrong side from changeover
c/m- hook squeeze master lines up correctly
reoccur- possible what- squeeze master screen not working
why- screen broken
c/m- replace screen
reoccur- no what- squeeze pin channel 4 stuck out
why- hydraulic leak on fittings in manifold on die
c/m- thread tape fittings and reinstall. line bled and bled squeeze master
reoccur- no what- stage 3 HEPA filter
why- out of spec
c/m- change
reoccur- in time what- steel plunger lube line broken off at threads
why- unsure
c/m- replace plunger lube line
reoccur- no what- tappet cylinder cav.3 leaking
why- blown seal
c/m- replace cylinder
reoccur- yes in time
c/t- unchanged what- tappet pin broke
why- unsure
c/m- replace
reoccur- yes what- tappet pin cylinders leaking
why- seals bad
c/m- rebuild cylinders for previous die and had production switch back to that die
reoccur- no what- tappet pin hole too deep
why- slide core cracked leaking water
c/m- replace slide core s4
reoccur- in time what- tappet pin holes not deep enough
why- fittings on hydraulic hoses were wrong
c/m- swapped male and female fittings on hoses at die so they could hook up correctly
reoccur- possible what- tappet pin out of spec
why- bent
c/m- replace cav.3 tappet pin what- tappet pins and squeeze pins out of spec
why- air in lines
c/m- adjusted flows to be roughly the same. line bled tappet hydraulic hoses
reoccur- no what- temp alarms
why- mold temp controller unit not working properly
c/m- pulled water outlet valve apart cleaned and reassembled
reoccur- yes what- temp alarms
why- thermocouple wire got smashed/torn while putting die in
c/m replace what- temp mold controller overheating causing die to overheat
why-?
c/m- ?
reoccur- yes what- thermocouple
why- damaged during die change
c/m- replace moveable side thermocouple. what- thermocouple alarm
why- upper crucible plug wire pulled off at solder joint
c/m- solder wire back
reoccur- yes what- thermocouple fixed side operator bottom NG (broke off in die)
why- unsure
c/m- pull die. trying to get thermocouple out to put new in
reoccur- in time what- tip and sleeve worn, cooling joint cracked
why- wear/ life
c/m- change tip, sleeve, cooling joint what- tip broke off, die would not open (Running RPY-MID)
why- unsure
c/m- change tip/sleeve
reoccur-? what- tip stuck in sleeve and lots of blow back
why- tip and sleeve n/g
c/m- replace tip and sleeve
reoccur- yes in time
c/t- unchanged what- tip/ sleeve change
why- changeover from chain tensioner what- tip/sleeve
why- changeover to W/P old sleeve NG
c/m- change
reoccur- in time what- tip/sleeve
why- life
c/m- replace
reoccur- in time what- tip/sleeve
why- ran without lube
c/m- replace
reoccur- yes what- tip/sleeve (20,753 shots)
why- main water to m/c off
c/m- replace tip/sleeve
reoccur- yes what- tip/sleeve (28,000)
why- ran with no water
c/m- replace t/s
reoccur- yes what- tip/sleeve NG
why- aluminum sitting in sleeve due to m/c faulting before injection
c/m-replace tip/sleeve (15,554 shots on sleeve)
reoccur- yes what- tip/sleeve NG
why- not getting lube/tip cooling joint holes not aligned
c/m- replace tip/sleeve. align cooling joint for tip. put on temporary gravity feed plunger lube
reoccur- in time what- tip/sleeve NG
why- plunger shaft seized in coupler?
c/m- replace tip/sleeve
reoccur- yes what- tip/sleeve NG
why- ran without plunger lube
c/m- replaced tip/sleeve
reoccur-yes what- tip/sleeve NG
why- ran without water or plunger lube
c/m- change tip and sleeve
reoccur- possible what- tip/sleeve NG
why- running with no plunger lube/plunger lube tip plugged
c/m- replace tip/sleeve/plunger lube tip. verified plunger lube
reoccur- yes if m/c is ran without plunger lube tip and what- tip/sleeve NG (18,098 shots)
why- plunger coupler loose
c/m- replace t/s
reoccur- yes what- tip/sleeve NG causing R/B to drop parts
why- Life
c/m- replace tip/sleeve
reoccur- in time what- tip/sleeve NG/ excessive blow back
why- wear from running
c/m- replace tip/sleeve
reoccur- yes
SLEEVE LIFE: 71,099 what- tip/sleeve/sprue bushing
why- NG/sprue bushing cracked
c/m- replace tip/sleeve/sprue bushing
reoccur- in time what- took servo valve off to run d/c1#1
why- d/c#1 higher priority than d/c#7 what- top operator (P) slide core broke off in part
why-?
c/m- replace slide core and bent cooling joint
reoccur- yes what- toscast touch screen not working properly
why- believe that the screen calibration sequence had been initiated by the operator accidentally
Countermeasure- Perform screen calibration and verify what- toscast touch screen not working properly
why- unsure
c/m- took outer plastic trim piece off
reoccur- yes what- trim damage
why- NG
c/m- adjust cutters and guides
reoccur- yes what- trim damage
why- P1 trim die cutter worn
c/m- replace cutter
reoccur- in time what- trim damage
why- aluminum sticking to cutter
c/m- replace cutter
reoccur- yes what- trim damage
why- build up on cutter
c/m- polished cutter
reoccur- no what- trim damage
why- cavity 4 cutter worn
c/m- replace cutter. adjust cutters/ guides
reoccur- in time what- trim damage
why- cavity 4 scraping off back
c/m- adjust cutters/guides
reoccur- yes what- trim damage
why- cutter broke
c/m- change trim die
reoccur- yes what- trim damage
why- cutter misaligned r/b position off
c/m- move cutter so shot would sit in press. touch up r/b position in press
reoccur- no what- trim damage
why- cutter worn
c/m- replace cutter 4
reoccur- in time what- trim damage
why- cutter worn, out of adjustment
c/m- replace cutter (cavity-4) adjust cutters
recur- timing what- trim damage
why- cutters loose
c/m- adjust cutters and tighten
reoccur- yes in time
c/t- unchanged what- trim damage
why- cutters out of adjustment
c/m- adjust cutters
reoccur- yes what- trim damage
why- cutters out of alignment
c/m- adjust cutters
reoccur- yes what- trim damage
why- dent on tappet area
c/m- adjust cutters and guides
reoccur- yes what- trim damage
why- digging into back of part
c/m- adjust cutters and guides
reoccur- possible what- trim damage
why- guides in trim press too tight shot would not set in/ r/b position off in press
c/m- adjust guides touch up r/b position what- trim damage
why- poorly designed trim die
c/m- clean/adjust cutters
reoccur- yes what- trim damage
why- poorly designed trim press
c/m- adjust cutters
reoccur- yes what- trim damage
why- poorly designed trim press die
c/m- took all cutters guides out cleaned and re-adjusted over an over until trim good
reoccur- yes what- trim damage
why- r/b pos. off in trim press
c/m- touch up r/b
reoccur- no what- trim damage
why- r/b setting parts in press wrong
c/m- touch up r/b position in press
reoccur- yes what- trim damage
why- robot chuck arms
c/m- tighten lose chuck arm bolts. touch up r/b position in press. add extra support on chuck arm to keep part in place
recur- ? what- trim damage
why- too deep in tappet area
c/m- install original short tappet cutters
reoccur- yes what- trim damage
why- top punch worn
c/m- replace punch (s2)
reoccur- timing what- trim damage
why- trim press
c/m- adjust cutters
recur- yes what- trim damage
why- trim press
c/m- adjust cutters and guides
recur- yes what- trim damage
why- trim press
c/m- change trim press
recur- yes what- trim damage
why- trim press
c/m- replace cuter for cavity 3, adjust cutters/guides change trim press
recur- yes what- trim damage
why- trim press
c/m- replace front cutter for cavity 1 adjusted cutters and guides
reoccur- yes what- trim damage
why- trim press
c/m- replace non-inventory tappet cutter (cav.2)
recur- yes what- trim damage
why- trim press
c/m-adjust cutters/guides
recur-yes what- trim damage
why- trim press cutters alignment
c/m- adjust trim press cutters
reoccur-yes what- trim damage
why- trim press design NG
c/m- put in new style cutters/ replaced all cutters and adjusted
reoccur- yes what- trim damage
why- upper angle bent
c/m- straighten
recur- yes what- trim damage
why- cutters need adjustment
c/m- moved cutters
reoccur- yes what- trim damage
why- trim press
c/m- replaced roller cutter cavity 4 adjust cutters and guides
recur- yes what- trim damage 5BA P/S
why- poorly designed trim die
c/m- adjust cutters
reoccur- yes until we get properly designed trim die what- trim damage 5BA P/S
why- poorly designed trim press
c/m- adjust cutters and guides
reoccur- yes what- trim damage 5ba-p cavity 1 part
why- weld on die broken
c/m- change die what- trim damage cav.4
why- burr on cutter
c/m- remove burr, replace lock washers what- trim damage cavity 1 and 4
why- cutter worn
c/m- replace cutter (cavity 1)
recur- timing what- trim damage cavity 1&3 on back roller area
why- trim press
c/m- adjust cutters& guides
reoccur- yes what- trim damage cavity 2
why- cutter worn
c/m- replace
reoccur- in time what- trim damage cavity 2
why- cutter worn
c/m- replace cutter what- trim damage cavity 2
why- robot positioning
c/m- touch up robot position 25 and 26 what- trim damage cavity 4
WHY: cavity 4 out of adjustment
C/M: adjusted cavity 4 to a good shot
REOCCER: yes timing what- trim damage cavity 4
why- cutter misaligned
c/m- adjusted rear cutter what- trim damage cavity 4 tappet
why- trim press
c/m- adjust cutters
reoccur- yes what- trim damage in tappet area
why- cutters worn
c/m- replace cutters around tappet area on all 4 cavities
reoccur- no what- trim damage s2 part
why- ?
C/M: adjusted cutters on S2
Recur: Yes in time what- trim damage/ trim height
why- bad trim press design
c/m- change trim press. adjust cutters/guides
reoccur- yes what- trim height
why- poorly designed trim press
c/m- put different trim press in/adjust cutters
reoccur- yes what- trim height
why- trim press
c/m- adjust cutters/guides
recur- yes what- trim height
why- poorly designed trim press
c/m- adjust cutters/guides
reoccur- yes what- trim height 5BA P/S
why- cutters out of adjustment
c/m- adjust cutters
reoccur- yes what- trim height NG
why- poorly designed trim press
c/m- adjust cutters
reoccur- yes what- trim height NG all cavities
why- poorly designed trim press
c/m- adjust cutters and guides
reoccur- yes what- trim height NG cavity 3 between tappets
why- center cutter between tappets
c/m- adjust center cutter
reoccur- possible what- trim height NG cavity 4 between tappets
why- center cutter between tappets
c/m- adjust center cutter in
reoccur- possible what- trim height out of spec
why- ?
c/m- adjust cutters
reoccur-? what- trim height out of spec
why- bad trim press design
c/m- adjusted cutters until parts were ok
reoccur- yes what- trim height p1 and p2 parts
why- out of adjustment
c/m- adjusted trim die what- trim height/trim damage
why- poorly designed trim press/flashing around ejector pins on shot
c/m-adjust cutters and got rid of damage but still have trim height on P2 from flashing
reoccur- yes what- trim press alarming
why- scrap press sensor NG
c/m- replace scrap sensor
reoccur- in time what- trim press alarming
why- ok carrier not going up all the way to get advance light
r/c- ?
c/m- adjust chain tension (chain tension was not equal on both chains
reoccur- yes what- trim press breaking parts
why- shot not setting in press fully
c/m- adjust guides on press to get shot to sit all the way in
reoccur- yes what- trim press cutter 2 (back left) broke
why- scrap from shot stayed on press
c/m- replace cutter adjust air blow
reoccur- yes what- trim press cylinder pulled threads out of flange nut
why- not enough threads holding flange nut to cylinder
c/m- replace trim press cylinder, modified flange nut
reoccur- no what- trim press drifting down
why- blow by in cylinder
c/m- replace cylinder what- trim press drifting down
why- cylinder bleeding by
c/m- replace trim press cylinder
reoccur- yes what- trim press faulting out when shot loaded
why- sensor out of adjustment
c/m- adjust smart sensor what- trim press hydraulic pump whining while trim press is working
r/c- plugged return filter
c/m- replaced return filter
reoccur-timing what- trim press pin B broke
why- ?
c/m- replace pin
reoccur- yes what- trim press scarring part
why- sprue pin cracked
c/m- replace sprue pin Replaced ejector pins4,11 and 12.
reoccur- in time what- trim press valve stack on hydraulic tank leaking
why- valve stack not seated
c/m- pulled valve stack apart and verified o-ring seating and undamaged reinstalled valve stack
reoccur- unlikely what- trim too deep
WHY: out of adjustment
c/m: adjusted cavity 1,2,4 tightened cutters to part
RECOER: YES what- turn table 1 shaft sheared and sprocket teeth destroyed
why- clutch over tightened
c/m- replace shaft, sprocket, and chain
reoccur- yes if clutch gets over tightened again what- turn table 5 stopping
why- table top bolts broken
c/m- replace all 4 bolts and replaced bearings that were locked
reoccur- no what- turntable 2 motor overload from not turning
why- table bearings locked up
c/m- replaced 3 bearings under table top that were locked up
reoccur- in time what- upper crucible
why- corundum pushing ring up
c/m- replace upper crucible, stand, and half pipe
reoccur- in time what- upper crucible aluminum leak
why- half pipe loose and not angled enough
C/M: replaced both upper and lower crucibles half pipe installed new upper ring now the exhaust hood hitting new ring do t what- upper crucible broke
Why: Unknown but was cracked by spout
C/M: Replaced crucible and half pipe
Recur: In time what- upper crucible cracked
why- unsure
c/m- replace upper and lower crucible and half pipe Repair upper Lid and repair upper furnace refractory, Repair lower furnace refractory and repair lower leak what- upper crucible door drifting down on 2nd shift and into 3rd shift
why- upper crucible lid flow controls in air lines leaking by
r/c- no set life for flow controls
reoccur- yes
c/m- replace with what- upper crucible leak
why- broken half pipe
c/m- replace upper + lower crucible and half pipe
reoccur- yes what- upper crucible overflowed and set off leak detect
why- upper crucible spout plugged and when it came unplugged it overflowed half pipe?
c/m- clean out aluminum, repair leak detect probes
reoccur what- upper crucible side door not shutting
r/c- all thread stripped
c/m- replaced all thread with piece from rebuilt crucible
reoccur- yes what- upper crucible temp controller reading AL-01
why- bad thermocouple
c/m- replace thermocouple
reoccur- no what- upper furnace and loading door glowing red
why- exhaust thermocouple NG
c/m- replace
reoccur- in time what- upper furnace not working
why- wires broke in cannon plug
c/m- solder wires back in place
reoccur- yes what- upper horizontal ladle arm locked up
why- heat/wear
c/m- had production ladle crucible out/ changed arm
reoccur- yes what- upper limit probe assembly fell in holding crucible
why- was not tight on crucible
c/m- got out cleaned up replaced insulator block terminated wires back on
reoccur- no what- upper trim press moveable guide/pusher came apart and parts were sticking in press
why- poorly engineered
c/m- install new part pusher assembly with thread-locker
reoccur- yes what- vacuum
why- tip/sleeve NG
c/m- replace tip and sleeve
reoccur- in time what- vacuum
why- unsure
c/m- replace v1,v2, vacuum pump inlet, and exhaust filter. Had production change over
reoccur- what- vacuum
why- unsure
c/m- replace vacuum pump/machine inlet filters. added die release
reoccur-yes what- vacuum (op side)
why- vacuum hose manifold plugged with aluminum and low speed air line had hole in it
c/m- unplug manifold, replace low speed air line
reoccur- unlikely what- vacuum abnormal faults
WHY: air blow 1 solenoid sticking on
C/M: took a part cleaned
REOCCER: yes timing what- vacuum failures what- vacuum failures
WHY: found hole in operator line added oil to vacuum tank
C/M: added oil replaced vacuum line
REOCCER: yes timing what- vacuum failures
WHY: unknown
C/M: put a 1.0 shim behind operator chill block
REOCCER: yes what- vacuum failures
r/c- filters reached life and became blocked
c/m- replace plugged filters
reoccur- no what- vacuum failures
why- air pressure high?
c/m- turn pressure from .590 to .525
reoccur- no what- vacuum failures
why- die release concentration low
c/m- add die release
reoccur- no what- vacuum failures
why- filter plugged
c/m- replace V3 vacuum filter
reoccur- no what- vacuum failures
why- low speed air line had hole
c/m- cut air line behind hole
reoccur- possible what- vacuum failures
why- low speed air too low (set at about .41MPA should be .5MPA)
r/c-adjustment of low speed air pressure?
c/m- turn low speed air to proper setting
reoccur- possibly what- vacuum failures
why- not enough die release
c/m- adjusted die release pressure from .35 to .40
reoccur- no what- vacuum failures
why- operator side only unknown
c/m- put .05 shim behind vacuum block, adjusted biscuit to 16. it was set at 23
reoccur- yes what- vacuum failures
why- plugged vacuum pump filter
c/m- replaced vacuum filter and cleaned exhaust filter
reoccur- no what- vacuum failures
why- pump overfull on oil
c/m- drain oil
reoccur- possible what- vacuum failures
why- robot side vacuum hose had chunk of aluminum stuck in it and had hole in it
r/c- ?
reoccur- yes
c/m- replace hose what- vacuum failures
why- spray cartridge not on
c/m- turn spray cartridge valve on
reoccur- yes if valve is not turned on before running what- vacuum failures
why- tip/sleeve NG
c/m- replace t/s
reoccur- in time what- vacuum failures
why- unsure
c/m-
reoccur- yes what- vacuum failures
why- vacuum coupling came apart
c/m- replace non-inventory coupling
reoccur in time what- vacuum failures
why- vacuum ejector dirty
c/m- clean vacuum ejector
reoccur- no what- vacuum failures
why- vacuum pump coupler insert sheared
c/m- replace coupler insert
reoccur- in time what- vacuum failures
why- vacuum pump low on oil, die release concentration out of spec
c/m- fill vacuum pump oil, correct die release concentration
recur- ? what- vacuum failures
why- vacuum pump oil completely empty
c/m- had operator fill oil
recur- yes if machine checks are not done what- vacuum failures
why: unknown
c/m: dh added nitrogen
recur: yes what- vacuum failures R/B side
why- pinched o-ring
c/m- replace o-ring
reoccur-no what- vacuum failures and dropping shots
why- tip/sleeve NG
c/m- replace tip/sleeve
reoccur- in time what- vacuum failures first shot
why- vacuum m/c strainers full of aluminum
c/m- cleaned strainers
recur- timing what- vacuum failures operator side
why- filter saturated in oil
r/c- unsure
c/m- clean vacuum pump filter
reoccur- yes what- vacuum failures operator side
why- investigating
countermeasure: verifying system settings
reoccur: Yes what- vacuum failures r/b side
why- air pressure low (.45)
r/c- unsure
c/m- clean filters and vacuum ejectors. set air pressure to (.55)
reoccur- yes what- vacuum failures r/b side
why- plugged vacuum filter?
c/m- replace vacuum pump inlet filter. clean other filters. verify no leaks in vacuum or low speed air
reoccur- yes what- vacuum failures r/b side
why- water in air lines
c/m- drain water separator
reoccur-yes due to moisture accumulation in air lines what- vacuum failures robot side what- vacuum failures, both sides
Why: unknown
R/C: unknown
C/M: New vacuum hoses, Cleaned/verified settings, spray points, and filters. Added shim behind both chill blocks
Will it reoccur: yes
Cycle what- vacuum faults
why- hole in hose robot side
c/m- replace hose what- vacuum faults (tank pressure slow in top end not reaching set point in time)
why- actual pressure off from what amplifier was reading
c/m- set amplifier to 0 at 0 pressure
reoccur-? what- vacuum hose broken at fitting
why- wear
c/m- trimmed hose what- vacuum in preheat shots
why- low speed air pressure low
c/m- increase low speed air pressure to .60
reoccur- no what- vacuum motor/pump coupling broke
why- (plastic) got brittle and worn
c/m- replace coupler
reoccur- no what- vacuum operator and r/b side
why- leaking quick connect (r/b) and bad O-Ring at vacuum m/c on filter cover (operator)
r/c- no expected life for fittings and hoses
c/m- replace O-Ring and quick c what- vacuum operator side
why- unsure
c/m- remove filter had DH start m/c
reoccur- yes what- vacuum problem robot side
why- what- vacuum problems robot side
why- clogged filter
c/m- replace filter what- vacuum problems robot side
why- inline filters dirty, cracked air line
c/m- clean filters, trim back air line what- vacuum pump smoking and overheating
why- vacuum pump NG
c/m- replace vacuum pump
reoccur- in time what- vibrator not knocking tab off
why- vibrator not strong enough
c/m- touch up positions at vibrator
reoccur- yes what- vibrator not knocking tabs off
why- vibrator not moving/out of oil
c/m- free vibrator had operator fill oil (check 32a)
recur- yes what- vibrator not knocking tabs off (collision detect)
why- not enough positions to knock off tab
c/m- put extra position in and added to wait on another position
reoccur- yes what- water leak
why- bottom r/b slide core pipe fittings got broke during changeover
c/m- put new fittings in what- water leak
why- bottom slide core bolts loose
c/m- tighten bolts
reoccur- no what- water leak
why- cooling joint fittings/hoses
c/m- replace all leaking cooling joint hoses/fittings
recur- timing what- water leak
why- cracked sprue bushing
c/m- replace
reoccur- in time what- water leak
why- cracked sprue bushing
c/m- replace sprue bushing
reoccur- in time what- water leak
why- fitting bad
c/m- replace fitting what- water leak
why- fitting leaking
c/m- dh changed die what- water leak
why- fitting leaking on connecting rod
c/m- replace fitting what- water leak
why- fitting on plunger bad
c/m- replace fitting
reoccur- yes in time
c/t- unchanged what- water leak
why- hose fitting broken
c/m- remove top slide core and replace hose what- water leak
why- loose fitting in fixed core 1 (operator side)
c/m- tightened fitting
reoccur- unsure what- water leak
why- plunger cooling line
c/m- cut back water cooling line behind hole
reoccur- in time what- water leak
why- plunger rod crack
c/m- replace plunger rod
reoccur- in time what- water leak
why- set screw worn allowing squeeze pin to turn
c/m- replace squeeze pin set screw and water fitting what- water leak
why- sleeve cooling joint broke
c/m- replace
recur- timing what- water leak
why- sleeve cooling joint water line came out of fitting
c/m- cut water line tip, put back in fitting
reoccur- no what- water leak
why- slide core
c/m- change cav. 4 slide core what- water leak
why- slide core cooling joint holder lose
c/m- put holder in place and tightened
reoccur- no what- water leak
why- slide core cooling joint holder not in place
c/m- replace cooling joint
recur- yes what- water leak
why- slide core cracked
c/m- replace cav.1 RG slide core what- water leak
why- slide core cracked
c/m- replace cav.3 slide core what- water leak
why- slide core cracked
c/m- replace slide core P1
reoccur- in time what- water leak
why- slide core fitting leaking
c/m- remove slide core. installed new fittings and lines
reoccur- no what- water leak
why- sprue bushing cracked
c/m- replace what- water leak
why- sprue bushing cracked
c/m- replace
recur- timing what- water leak
why- sprue bushing cracked
c/m- replace
reoccur- in time what- water leak
why- sprue bushing cracked
c/m- replace sprue bushing
recur- timing what- water leak
why- sprue bushing cracked
c/m- replace sprue bushing
reoccur- in time what- water leak
why- sprue bushing cracked
c/m-replaced what- water leak
why-sprue bushing
c/m- replace
recur-in time what- water leak at sleeve cooling joint hose
why- aluminum rings falling on hose
c/m- adjust shot delay
reoccur- possibly, lines are not protected what- water leak fixed side
why- spru bushing leaking
c/m- replace bushing what- water leak in hose from mold heater
why- wear
c/m- replace hose what- water leak movable side
why- fitting n/g
c/m- replace fitting what- water leak on ball valve for mold heater
why- fitting on top of valve loose
c/m- tightened valve what- water leak plunger shaft inlet
why- quick connect fitting worn out
c/m- replace female quick connect
reoccur-yes what- water leak robot side of die
why- hole in line
c/m- replaced line what- water leak s2 slide core
why- cavity 2 slide core leaking, cooling joint o rings worn
c/m- replace slide core and o rings what- water leak, operator noticed before start up
why- die lock % not high enough, aluminum got on water lines and melted through
c/m- replaced 2 melted water lines. leak tested. gave back to product what- water leak- fitting on movable side
why- fitting n/g
c/m- replace fitting what- way lube leak
why- flex hose too short being pulled
c/m- replace with new longer flex hose
reoccur- unlikely what- way lube leak
why- way lube line NG
c/m- replace
reoccur- in time what- way lube leaking for die
why- flex hose NG
c/m- replace flex hose
reoccur- in time what- way lube line leak
why- wear/movement
c/m- replace flex hose
reoccur- in time what- wool fell out of furnace side door
why- fell apart
c/m- put new wool in
reoccur- in time what-Half pipe broke.
why- unsure
c/m- replace half pipe
reoccur- yes what-Replace Tip and Sleeve.
why- blowback
c/m- replace tip/sleeve
reoccur- in time what-Replace the tip and sleeve.
why-Change over and wear per JR
c/m-Change the tip and sleeve
Reoccur-yes what-aluminum blow out of die
why-?
c/m- clean die, free up bottom slide cores
reoccur- yes what-cracked slide core (P1&S1) Why- on going problem. C/M- Replaced P1/S1 slide cores. Reoccur- Yes. what-cutter 4 broke on trim press
why- scrap pieces of shot hanging up on cutter
c/m- adjusted air blows
reoccur-no
(LT) what-dropping shots
why- shot sticking to tip
c/m- replace tip
reoccur- in time what-high shot speed alarms low shot speed alarms pressure build up time alarms bad aluminum blow back
Why: Tip and Sleeve damage. (31,490 on tip and sleeve)
Countermeasure: Replace Tip,sleeve.plunger what-ladle arm locked up
why- heat
c/m- replace ladle arm
reoccur- in time what-ladle was not working properly would not pour and would not go all the way into sleeve
why- ladle wiring problem
r/c- blue and black wire for electrodes switched?
c/m-match black with black and b what-ok carrier would not move
why- guide plate sheared off in guide rails
c/m- replace guide plate
reoccur- in time what-r/b crashing at stationary jig
why- vibrator not working/turning shot in chucks
c/m- cleaned vibrator out
reoccur- yes what-r/b dropping shots/shots not setting in press product detect not being made exc.
r/c- changeover (r/b fingers originally on incorrectly)
c/m-touchup r/b positions
reoccur-possibly if changeover i what-scrap conveyor sensor alarm
why- links broken/missing
c/m- replaced links and missing cotter pins
reoccur- yes what-slide cores
why- cracked out of spec
c/m- replace p1 and s1 slide core
reoccur- yes what-top robot slide core leaking
why- what-trim damage
Why: 2 out of 4 chuck fingers ready to fall off
C/M: Tightened all back up and checked other 2 fingers
Recur: Possibly in time what-trim damage
why- bad trim press design what-trim damage
why- tabs getting stuck/angle iron bent
c/m- straighten angle iron guides on top of press
recur- possible what-trim damage
why- trim press
c/m- adjust cutters/guides/cleaned die for flashing/aluminum blow out
recur- yes what-trim damage
why- upper angle iron bent causing tabs to stay on press
c/m- straighten
recur- yes what-trim damage 5BA P/S
why- poorly designed trim press
c/m- adjust cutters/guides
recur- yes what-trim height out of spec 5BA P/S
why- poorly designed trim press
c/m- adjust cutters
recur- yes what-vacuum faults
cause-inline die release filter in die release box plugged
c/m-clean filter
reoccur-yes what-water leak
why- sprue bushing cracked
c/m- replace what. water leak on top slide core. why. fitting was loose. c/m. took apart slide core to tighten fitting. what: CAVITY 3/4 OK C/V NOT MOVING
why: missing motor shaft keyway
c/m: disassembled c/v and flipped the mesh c/v reinstalled keyway that i found on the ground... now ok what: flipper 2 ? what: product detect issues
why: part sticking in die.... had operato check his die release ..good
ran about 20 minutes and did it again ..
operator has been reset and run ... what: robot needs touched up
why: not putting part in trim press right
c/m: retaught robot trim press load position what: trim press issues and OK c/v issues
why: sensor issue on trim and getting jammed on ok c/v
c/m: cleaned sensor off to stop trim press faults and adjust c/v posiition what: LIQID METAL UPPER LIMIT ALARM
why: because upper limit had been met
c/m: none had 2ND SHIFT dh fire up and run what: OPERATOR requested new 1.0 ladel.
why: unknown
c/m: got ladel what: Vaccume alarms ( pump not coming on)
why: 3rd: coupler completly shredded. what: automatic delivery system pump bad
Why: will cycle in manual but not in auto
C/M: replaced pump everything is operating as intended what: broken saftey lock and key
c/m: replaced both saftey swich and safety key. what: ingot loader saftey latch wires exposed
c/m: reinstalled wireing to saftey lock on ingot loader door what: little scrap conveyor not moving what: operator called for bent robot arm
c/m: replaced robot arm.... what: operator door wont open
why: found door lock wired different that ive noticed before found 2 broken wire
terminations on the enter request reset button .. also replaced operator side door what: repeated hydraulic pump overloads / LINE PRESSURE FAULTS...
why: what: 2nd shift operator accidently broke selector switch (tie bar out/in)
why: accidently broke when a die change was being performed
c/m: replace switch and confirm operations
reoccur: in time what: 5YK baffle die, faulting at both trim presses
why: position
c/m: Touched up robot positioning at both trim presses for collision detect faults what: ACC faults
why: Nitrogen low not in spec running 3.2
c/m: Turned over to production to fill nitorgen to correct spec per standard what: Air leak coming from the bottom of the upper crucible.
why: sight glass fell off (under yellow box)
c/m: removed yellow box and put sight glass on. what: Air leak on robot
why: hole in air line
c/m: replaced air line what: Air leak on upper crucible lid
why: attrition
c/m: replace air line in box 4 above dog house. what: All 4 cavities part stuck in fixed side of die
why: unknown
c/m: Removed jammed parts from fixed side of die, Told DH to verify temperature of die up to operating temperature before production
c what: Aluminum build in cavity for moveable die.
c/m: called JR Otto to pull die. what: Aluminum wont pass K molds
Why: Aluminum leaking under filter Inclusions
c/m: Replace Lower Holding Crucible (Contaminated)
will it reoccur:
cycle time: what: Anchor OK carrier and tighten chains per Corey.
why: Bolted existing angle iron brackets to OK carriers frame, removed links from both chains to make adjusting plate adjustable(adjustment plate what: Axis 3 pin not moving. why: female hyd. fitting leaking and air in line. countermeasure: replaced fitting and line bleed channel 3. recurring: timing what: BLOW BACK
why: tip worn
C/M: replaced tip
REOCCER: yes what: Bad ladle probe
why: attrition
c/m: replaced with new style what: Big scrap c/v stopping
why: loose c/v triggering scrap detect sensor
c/m: adjusted tension for c/v until I couldnt adjust no more, relocated a tensioner bolt to get more tension on c/v. Straight what: Biscuit breaking off in die.
why: root cause unknown, plunger lube line was loose and turned
c/m: verified biscuit size was good, adjusted plunger lube line. Operator honed sleeve. what: Blow back
why: Worn sleeve
c/m: Replaced worn sleeve at 117198 shots, tip 10946. what: Broke airline
why: attrition
c/m: replaced air line and fitting from the main to the air bowl by the vacuum machine control box. what: Broken coil for upper crucible lid solenoid.
why: attrition
c/m: replaced solenoid. what: Broken coolant line fitting on movable die
why: attrition
c/m: non in inventory, took one from another die. what: Broken coolant line, moveable side die.
why: attrition
c/m: replaced several hoses and cut back existing hoses to control the leaks. what: Broken hydraulic hose for bottom slide core
why: excess hose dragging floor grate
c/m: replaced hydraulic hose what: Broken ladle
why: root cause unknown
c/m: cut bolts off new ladle and tack welded nuts what: Broken links in scrap c/v
why: attrition
c/m: replaced 4 rods 3 roller and several links what: Broken safety door switch, operator side. Damaged liquid tight,
Why: apparent collateral damage.
C/M: See below what: Broken selector switch for ladle fwd/back
why: attrition
c/m: replaced switch what: Broken slide core, upper right
why: attrition
c/m: what: Broken steel coolant line on fixed die
why: attrition
c/m: extracted broken threads, installed new pipe. what: Broken water pipe in collar that goes around the sleeve
why: attrition
c/m: extract broken pipe from fitting what: C positon pressure hole depth out of spec
why: squeeze pin on c position loose on cylinder, pin backed off allowing pin to depth to read to deep
c/m: removed move core Helper side, removed c pos what: Cavity 3/4 OK c/v not turning
why: Three plastic drive sprockets walked off the keys
c/m: disassembled, got sprockets back on keys. what: Cavity 3/4 ok c/v torn apart with damage to drive shaft
why: attrition
c/m: Passed to day shift. c/v was taken off of diecast 8 and put on D/C6 while the one from D/C6 was being repaired. what: Cavity 4 trim damage
why: cutter position in trim press
c/m: Removed cutters and cleaned repositioned cutters, verifiy shims behind cutters ok. what: Channel 1 counting up on squeeze master
why: initially thought it was a hydraulic leak but squeeze pin 1 was stuck in the "in " position.
c/m: confirmed that there was no hydraulic leaks by ins what: Channel 4 error
why: root cause unknown
c/m: cycled power to pinpoint cabinet what: Charge loader door safety switch loose causing improper contact with safety key what: Charge machine loader, bent lifting forks
why: Bucket slid off forks and hit door frame while going up
c/m: used porta power to bend forks back up. what: Clamping safety device limit switch error
why: broken bolts for cylinder coupler. what: Coolant leaking from quick connects on plunger shaft
why: attrition
c/m: replaced rubber seals what: Cooling water leaking from a fitting on moveable die, back side lower.
why: defective fitting
c/m: replaced fitting what: Cracked air bowl
why: attrition
c/m: replaced air bowl what: DH called and needed a ladle
why: ladle was cracked and leaking across top of crucible ring
c/m: gave a 1.0 ladle to DH to change. confirmed ladle travel path ok.
reoccur: in time what: DH called and said he hears an air leak coming from robot
why: air leak is coming from an air line, to the air bowl, on the spindle oil unit. cause is from wear over time
c/m: replace air line a what: DH called and said scrap conveyor 1 is jammed up
why: part of shot stuck in chain
c/m: removed shot piece from chain and watched conveyor move in auto for 5+ minutes with no jam/faults. turned b what: DH called stating trim press wont complete cycle
why: lower limit sensor not being made on trim press cylinder. loose set screws
c/m: adjusted sensor to be made when trim press is down. confirme what: DH requested a hydraulic filter change
why: filter life at 2000 hours
c/m: replaced filter and reset life
reoccur: next 2000 hours of runtime what: DH stated air blow on trim press not working/ very light air pressre
why: main shut off ball valves were not open completely.
c/m: Shutoff valve handles missing? (maybe countermeasure) Opened u what: Damage to operator side vacuum block and moveable die.
why: root cause unknown
c/m: removed operator side vacuum block,
and spacer, removed built up aluminum, stoned all surfaces, installed new what: Die pull for repair
why: Cracked upper slide core, metal build up in right cavity.
c/m: Pulled die, replaced upper slide core, replaced a cooling joint and several water lines. Removed molten m what: Die release pump not pumping
why: blue handle shut off valve inside cabinet shut off
c/m: cleaned filters and turned on valve. what: Die release pump quit working.
why: No oil in the oiler.
No check on the maintenance check on check sheet.
C/M Replaced pump.
reccur yes timing what: Fixed die not getting up to temp
why: possible dirty thermocouplers in die
c/m: verified cooling water valves were in the correct positions. Reset the 275 ton chiller. what: Fixed die not getting up to temp.
why: Root cause unknown
c/m: pull die to check thermo couplers, clean thermo couplers with scotch bright what: Fixed side thermocouple broke
why: Thermocouple wiring smashed in between die
c/m: Replaced broken thermocouple and ran wiring behind cooling lines. Wire tied lines to cooling lines to prevent e what: Follow up from 2nd, trim press flipping 3 actuator has broken guides causing the flapper not to actuate.
Why: Broken acuator
C/M: Took apart and fixed no spare parts put back together now ok what: Follow up from 2nd. Scrap c/v 1 jammed up, c/v motor NG.
why: attrition
c/m: Freed up C/V, installed motor and adjusted, extruded broken sprocket bolt. Installed all guards and covers that were what: Follow up from WO98599
c/m: removed left over aluminum from cavity, replaced known burnt water lines and did a water pressure test and found more bad water lines and loose fittings. Replaced mor what: Helper door limit switch error (LS2)
why: bent rocker arm on limit switch
c/m: straightened rocker arm, adjusted trip dog on helper door what: Helper door not moving
why: Mounting bracket for the cylinder broke off
c/m: Removed stationary and helper door, fabricate/weld bracket to helper door, reinstall doors. what: Holding crucible low temp alarm
why: root cause unknown
c/m: reset and refired holding and melting furnace. Tightened loose screw in thermocoupler. what: Holding crucible low temp/metal leak
why: root cause unknown
c/m: removed metal from probes, fired burner. what: Holding crucible misfire
why: root cause unknown
c/m: replaced relay AV2 for high presurre air, no change. Took the igniter cable from diecast 9 and put it on dc10, igniter fired. Put the ignite what: Holding crucible temp. not holding. Reading 815 degrees but aluminum melted.
why: thermocouple for holding crucible NG. Eratic readings.
c/m: Replaced holding crucible thermocouple. what: Holding crucible, upper limit probes and holder fell into crucible.
why: Accidental contact
c/m: 1st shift finished the repair what: Hole in Filter/ crucible cracked where it holds filter ng
WHY: unknown
C/M: replaced crucible, halfpipe
reoccer:yes what: Hood light not operating
why: defective switch
c/m: defective switch blew breaker #30, Replaced defective switch and verified operation of lights. ok what: Hydraulic leak coming from slide core fitting.
why: attrition
c/m: replaced with a new fitting what: Hydraulic leak in pipe on moveable die
why: Attrition
c/m: removed pipe to be welded what: Hydraulic leak on metal pipe in robot cage on fixed side by injection.
why: attrition
c/m: remove pipe, grind down existing weld and welded crack. what: Hydraulic leak, broken line robot side slide core.
why: attrition
c/m: DH replaced one from another die what: Hydraulic leak.
Why: Squeeze pin line on robot side developed a leak.
C/M: Replaced line.
R/O: Timing. what: Hydraulic pressure gauge by robot leaking oil
why: attrition
c/m: replaced gauge what: Ingot fell from loader and jammed the conveyor and bending the loader up. Pusher 1 now hits the loader.
Why: Ingot loader was just alittle to far from furnace
C/M: Took anchor bolts out pushed l what: Ingot loader crashed what: Ingot loader crashed
why: ingot fell under loader
c/m: weld metal where welds broke on the ingot holder what: Ingot loader dropping ingots when pushing into furnace
why: root cause unknown, noticed loader bouncing off cushion when loader would go up.
c/m: replaced loader up cushion, adjusted pusher 1 ad what: Ingot loader wont go up after furnace door opens
why: cracked air bowl
c/m: replaced air bowl what: Ingot loader would not master on after accidental push of emergency stop button.
c/m: reset fault at the safety control interface panel
c/m: what: Ingot loader, loader will not go all the way down.
why: root cause unknown
c/m: replaced solenoid, same issue. Put on solenoid back on. Greased linear bearings chiseled hardened metal off rear l what: Jam detect staying on for big scrap c/v.
why: attrition
c/m: replaced receiver and installed the bracket that fell off what: Ladle electrode malfunction fault
why: possible broken wires
c/m: replaced 2 copper connectors what: Ladle electrode malfunction fault
why: root cause unknown. Possible cable pinch at strap.
c/m: moved ladle forward and back several times with no fault, pulled cable through straps to eliminate what: Ladle issues, broken ladle.
why: Aluminum left in ladle
c/m: DH installed used ladle. what: Ladle not pouring at plunger rod why
why: squeeze master not in auto
c/m: turned to auto what: Ladle not stopping going forward when it should
Why: Ladle forward and back no good
C/M: Replaced motor
Recur: Possibly in time what: Ladle not turning down to fill ladle
why: lower ladle unit locked up
c/m: replaced lower ladle bearing unit and set the 90 what: Leaky coolant fitting for the plunger shaft
why: defective fitting
c/m: replaced fitting what: Leaky coolant line on top side movable die
why: attrition
c/m: replaced red plastic coolant line what: Leaky fitting for plunger lube line
what: attrition
c/m: replaced fitting and install different lube line that was already made. what: Leaky quick connect for coolant line for plunger shaft.
why: attrition
c/m: replaced quick connect what: Left scale issues
why: overflow tabs stuck between ramp and scale
c/m: removed overflow tabs to align ramp to scale what: Level detecting electrode missing
why: attrition
c/m: replaced electrode what: Loading machine lifter over load fault
why: Root cause unknown
c/m: 1. Reset O/L on contactor and fault was still present. 2. Cycled power, fault still present. 3. Pushed the buzzer stop and res what: Lower melting Temperature controller not operating
why: Main power wire to controller operation disconnected
c/m: Tested controller power only had one leg, traced wires back found S10 disconnect what: Lubrication malfunction
why: broken flexible lube line
c/m: replaced with non-inventory lube line what: Melting burner keeps shutting off
why: cable for upper limit probes for holding melted
c/m: replaced cable what: Melting burner not staying on
why: upper limit staying for holder crucible, molten metal damaged end of cable.
c/m: cut back cable, re terminated upper limit. what: Melting crucible burner not firing.
why: Upper limit probe wires melted together for holding crucible.
c/m: Made and replsced cable what: Melting crucible lid not closing
why: Limit switch for moving the crucible not made.
c/m: adjust the arm for the limit switch what: Melting furnace flameout
why: Root cause unknown
c/m: Replaced relay for gas valve (R13), replaced ignition rod- same, put back in inventory. Cleaned flame detect with scotch bright.
1st: Replac what: Melting furnace thermo coupler not reading
why: broken wire at thermo coupler terminal
c/m: re terminated wire what: Melting turn on/off constantly causing low aluminum
why: Melting thermocouple NG not reading temp properly
c/m: Replaced thermocouple and verified temperature reading. what: Metal leak alarm
why: from over flow from 2nd
c/m: scraped metal from under holding furnace, re fire blower and and burner what: Metal leak for holding
why: Overflow
c/m: recover metal leak procedures, chiseled metal leak detect probes, ran temporary external cable for upper limit detect. what: Metal leak, excessive amount
why: possible crack in crucible
c/m: chiseled out metal, ladled out crucible what: Missing screw for the air side on the BR type spray gun.
why: attrition
c/m: installed screw what: Mold heater has no power
why: 15amp breaker tripped inside control panel
c/m: Reset breaker, mold heater operating as it should what: Move core 2 faults
why: possible reed switch not currently faulting
c/m: Manually ran in move core 2 no faults return can not hook up tester unless faulting. turned back to production to run what: NG conveyor jammed up
why: hole in the conveyor allowing tabs to fall in the conveyor jamming it up
c/m: replaced conveyor belt what: OK conveyor getting stuck
c/m: jumped chain back to proper position retentioned. what: OK conveyor not advancing
why: motor shaft stripped out
c/m: replaced motor what: OK conveyor not dumping
why: guide wheels not attached to OK bucket due to broken spring clips
c/m: reinserted guide wheels and installed new spring clips what: OK cov, sensor not down all the way
why: sensor
CM: move sensor in the right spot what: Oiler for trim press plastic canister damaged
why: excess scrap from c/v built up and hit canister
c/m: replaced canister with a non inventory one. what: Ok c/v carrier getting stuck on damaged rail. Mounting bolts for rail broken off.
why: attrition
c/m: replaced rail with a non inventory rail from the warehouse. C/V is repaired but the excess s what: Ok c/v motor moving but the carrier is not.
why: loose set screws for drive sprocket
c/m: replaced set screws, one was stripped out and needed extracted. what: Ok c/v not moving, motor throwing the overload.
why: Motor NG, all mounting bolts loose for motor, gear box and chain adjustment plates. One set screw broken for drive sprocket and set screws l what: Ok c/v stuck at the top of the c/v.
why: drive chains stretched
c/m: adjusted tensioning plate to take slop out of chains. what: Ok carrier not moving
why: key missing from motor shaft
c/m: removed motor, installed key and put new set screws in. what: Ok carrier not moving
why: key missing from motor shaft, set screws fell out
c/m: removed motor and gearbox, installed key and replaced set screws with locking nuts what: Ok carrier not returning after dumping parts in auto operation. Also air blow on trim press not blowing all scrap out causing the robot to fault.
why: Ok c/v- bucket not making both advance sens what: Ok conveyor issue
why: unknown, saw on production white board
c/m: advanced and returned carrier several times-ok. Inspected rails, chain tension, set screws all seemed to good at this time. what: Ok conveyor jammed up at flip dog
why: tensioning was off/skipped a tooth on sprocket
c/m: tensioned both chains accordingly
c/m: what: P1 and S1 slide cores broke. why: While ejecting the parts the slide cores where still in the parts. CM: Changed P1 and S1 slide cores and both tappet pins. what: P1 slide core crack. Why: bad slide core. CM: changed slide core. what: P1 slide core spec issues
why: slide core chipped out on RPY die F-7
c/m: replaced P1 slide core what: P1 slide core spec issues on 5A2 P&M die F-32
why: slide core cracked
c/m: replaced P1 slide core what: P1 tappet pin broke
why: age/ wear
c/m: replaced tappet pin and fixed 2 leaking water fittings what: P2 cavity slide core crack over 10
why: crack
c/m: Replaced p2 cavity slide core, gave operator new spec. change paperwork. Old slide core on JR desk for inspection what: P2 slide core change
why: initial quality check after slide core had been changed NG
c/m: replaced slide core and gave NG slide core to quality what: P2 slide core has sodering on it. why: coating was probably bad on slide core. CC: changed P2 slide core. what: P2 slide core out of spec
why: P2 slide core cracked on 5A2 die F-32
c/m: replaced slide core what: P2 slide core spec problems
why: crack in the slide core
c/m: replaced P2 slide core on 5A2 die 30 what: Part stuck in moveable side
why: water turned off to machine
c/m: ejector pin in part stuck on ejector pin not allowing part to be removed, Replacing die what: Part stuck in the die during preheat shots
why: root cause unknown
c/m: assisted operator to remove part. what: Passed from 2nd, squeeze master hydraulic pump loud
why: root cause unknown
c/m: manually ran channels 1-4 in and out with no issues. Verified hydraulic fluid level was good. what: Plc low battery alarm
why: battery life
c/m: replaced battery, re soldered black lead to battery what: Pressure feeder device not ready error.
why: die lubrication automatic mixing machine turned off, unsure why.
c/m: turned machine on and fault went away. what: Product detect alarms and U/L robot crashed into punch press. what: Replace shot sensor
why: requested by "John".
c/m: replaced shot sensor and bushing what: Right cavity filled up with aluminum behind upper slide core.
c/m: support die pull. what: Right side cavity 100% filled with aluminum behind upper slide core causing issues with the upper slide core.
why: root cause unknown
c/m: Drilled, chiseled and dremeled metal out. what: Right weigh scale not working, capture span failed on screen.
why: weigh platform got knocked off its feet and cut cable in half.
c/m: cut cable back and terminated in box with the same fault. T what: Robot chuck sensor issues
why: broken wire at the connector, also connector was corroded.
c/m: replaced connector, re terminated sensor. what: Robot chuck sensor set screw stripped out
why: attrition
c/m: replaced sensor, recovered robot what: Robot chuck solenoid NG
why: attrition
c/m: replaced solenoid and trimmed back damaged hose. what: Robot faulting at die
why: shot dragging on die, shot jamming
c/m: Retaught PR5 to allow shot not to drag on sprue
will it reoccur: No
cycle time: unchanged what: Robot faults\
why: top arm broke bolt would not pickup shot
c/m: Removed broken bolt and tapped threads, installed new bolt with bushing. verified robot picking up part what: Robot paws broken off
why: root cause unknown
c/m: extracted broken bolts, put back together. what: Robot running NG program after die replacement what: Robot side vacuum manifold fill with aluminum
why: blown vacuum block
c/m: drilled out metal what: Robot would not home, servo 231 error
why: root cause unknown
c/m: Recovered robot what: S 2 slide core spec issues
why: chip in the slide core
c/m: replaced S2 slide core on 5BA p/s die f-12 what: S1 cavity ejector pin out of spec
why: ejector pin to long
c/m: ground end of ejector pin what: S1 slide core cracked
why: wear/heat
c/m: Replaced S1 slide core, quality sheet printed and located on operator table for inspection after production in resumed. what: S1 slide core out of spec. Why: bad slide core. C/M: replaced S1 slide core. what: S1 tappet pin broke. why: tool break. CC: replaced S1 tappet pin. what: SLide core stuck in part
why: Spray cartrage valve shut off not cleaning off die
c/m: Removed stuck slide core by heat, cleaned die and verified spray operation. what: Safety switch next to holding crucible not resetting
why: wires pulled from connector, defective switch
c/m: rewired connector, replaced switch. what: Scrap c/v issues (big scrap c/v) guard fell off
why: attrition
c/m: none, guard was repaired by a previous shift. Observed with c/v running with no issues. what: Secondary air pressure drop for melting furnace
c/m: reseated relays AV-O and AV-! in the Melkeeper control panel. what: Shot position sensor break alarms
why: buildup around shot position sensor
c/m: Removed shot position sensor and housing cleaned all debris and cleaned sensor, verified shot position sensor for what: Speed acc filling malfunction
why: pressure gauge was reading high on hydraulic
C/M: replaced hydraulic filter. what: Spray cartridge turn not getting a forward sensor light what: Sprue bushing water leak
why: Sprue bushing cracked
c/m: REmoved and retapped bushing lines still had leak, removed from die and tested (cracked around center step down. Replaced with new sprue what: Squeeze master, channel 1 not building pressure. Channel 1 filling up in the zero position.
why: root cause unknown
c/m: Operator tried a couple used hydraulic hose with no luck. I replaced with what: Squeeze master- channel four squeeze pins not moving
why: faulty directional flow valve
c/m: replaced valve what: Support for metal leek
why: possible cracked half pipe
c/m: policed and cleaned up molten metal. what: Temp A alarms
why: Temp A set point to low
c/m: adjusted temp A set point from 376 to 390 to allow temperature to rise to middle of tolerance. what: Tower internal metal failure.
Why: Last repair material did not hold up to the heat.
Countermeasure: Remove all inner metal and bottom plate from tower and replace with 309 Stainless steel fabri what: Trim damage cavity 2, cavity 1 and 2 lube/oil/porosity in parts
why: back cutter cavity 2 moved, cavity 1 and 2 spray/blow off
c/m: adjusted rear cutter cavity 2, concentration in spec, cleaned what: Trim press , upper air blow not working and parts sticking to upper die cavity 2.
why: spring loaded pusher for cavity 2 stuck in. Upper air blows unhooked with mismatched hose sizes.
c/m: repla what: Trim press OK carrier not getting a return light
why: plate below bucket for carrier advance sensor loose and got bent up
c/m: removed plate and straightened, reinstalled plate. what: Trim press cutter shaving the parts
why: root cause unknown
c/m: adjusted speed of pushers, adjusted cutter. what: Trim press down limit switch staying on (X021)
why: attrition
c/m: replaced sensor what: Trim press home light flashing, needs to be solid.
why: root cause unknown
c/m: looked up M15600 in program, to get a solid light auto needs selected and home button pushed. what: Trim press motor overload
why: Scraps stuck in scrap c/v 1.
c/m: freed up c/v, removed excess scrap what: Trim press part detect misaligned, full work fault.
why: vibration from trim press interfering with detect
c/m: adjusted sensor and tightened sensor mounting rods. what: Trim press unloader chuck not closing when picking the part.
why: metal build up around part
c/m: manually removed part and recovered mc. Operator cleaning die to prevent this. what: Trim press work detect out of alignment
why: mounting bolt backed out
c/m: aligned and tightened work detect, verified operation is good. what: Trim press would not Master On
why: PLC corrupted due to power being shut off loosing PLC program.
c/m: Cleared corrupted programs, Installed PLC from company shared, uploaded from diecast 1 PL what: Trim press would not cycle start
why: door safety switch by scrap c/v was open
c/m: closed safety switch and reset what: Trim press would not master on
why: PLC program corrupt
c/m: Hooked up to PLC, stated parameter was in correct, whole screen was yellow and missing several items from plc program. Cleared plc a what: Trim press would not master on
why: PLC program corrupt
c/m: Hooked up to PLC, stated parameter was in correct, whole screen was yellow and missing several items from plc program. Installed new what: Trim press, NG conveyor wire mesh belt badly damaged. Holes in mesh causing jam ups and parts building up causing the flippers to not work.
why: attrition
c/m: replaced mesh belt Passed to the n what: Trim press, ok c/v getting stuck on chute when returned.
why: root cause unknown
c/m: tightened bucket chains, moved c/v a bit further from chute. what: Trim press, part detect not making
why: mounting bracket loose
c/m: tightened down bracket, adjust part detect Lsx416 what: Trim press, part detect staying made
why: root cause unknown
c/m: adjusted part detect what: Trim press, robot leaving tree behind. Air blows not blowing tabs off die.
why: part detect not aligned
c/m: adjusted part detect and air blows. what: Trim press, turn table 2 not turning on. 2 blown fuses in cabinet
why: found motor leads U and W loose in terminal box
c/m: megged motor-ok, reinstalled motor leads and replaced fuses. what: Two black water lines broke on moveable side, by U/L robot.
why: rubbing on die moving
c/m: replaced water lines(used old fittings) what: U/L robot not going to home position
why: root cause unknown
c/m: recovered robot what: Unload and spray robot problems what: Unload robot servo 037 fault
why: root cause unknown
c/m: recover robot several times what: Unload robot stopped above scrap c/v.
why: root cause unknown
c/m: recovered robot. what: Unload robot stopped in dip tank
why: root cause unknown
c/m: recovered robot what: Unloader for the trim press crashed into the frame
why: root cause unknown
c/m: recovered unloader, observed in auto operation with no further issues. what: Upper crucible blower motor clogged filter
why: attrition
c/m: cut and installed filter, filter was found in MRO. what: Upper crucible reading over 2400 degrees on the exhaust gas temperature controller while the metal is hard.
why: defective thermocoupler
c/m: replaced thermocoupler. what: Upper limit staying on
why: overflow from 2nd.
c/m: replace cable and ec1 relay what: Upper limit staying on for holding crucible.
Why: 2 wires were crossed
C/M: Put 2 blacks side by side and 2 reds side by side together what: Upper limit staying on.
Why: Cable running from main box to Level probes no good
C/M: Replaced wires from power terminal to ladle probes about 1 hour what: Vacuum block stuck in die, robot side.
why: blow out
c/m: got vacuum block out. what: Was asked for support for tip and sleeve removal
why: tip stuck in sleeve
c/m: removed tip and sleeve through die side what: Water leak on cooling junction on moveable die side
why: defective quick connect fitting (one touch fitting)
c/m: replace fitting what: Weigh scale alarm, red alarm lights flashing rapidly
why: scrap conveyor jam detect on
c/m: adjustd jam detect what: Wires broke for holding crucible upper limit probes
why: attrition
c/m: cut cable back and re terminated wires to probes. what: Wires ripped out of safety switch by holding crucible
why: root cause unknown
c/m: re terminated wires to plug, secured seal tight to safety fence post. what: air bowl leaking before spindle 10 bowl
why: crack in bowl allowing air to escape
c/m: replaced air bowl after ball valve to spindle 10 unit what: air bowl leaking on robot side of DCM behind helper side door
why: cracked air bowl
c/m: replaced air bowl
reoccur: in time what: air leak
why: cracked air bowl
c/m: replaced air bowl what: air leak
why: cracked air bowl for the furnace door
c/m: replaced air bowl and filter what: air leak
why: main air bowl cracked
c/m: replaced air bowl what: air leak
why: supply air line to the robot NG
c/m: replaced air fitting what: air leak from crucible lid solenoid valve
why: operator dropped an ingot on it while loading crucible
c/m: replaced solenoid valve what: air leak on the spray wand
why: hole at the end of feed line to the spray wand
c/m: cut the end off hose and reattached what: air line leaking on chuck. also chuck sensor melted.
why: melted.
c/m: replaced air line and chuck sensor.
recur: timing. what: air on main to spray cartridge broke off. manifold bolts broke off mount.
why: wear.
c/m: replaced. had to drill out bolts for manifold block.
recur: timing what: air pressure drop
why: cracked air bowl
c/m: replaced air bowl what: air regulator leaking air. maintenance check no.19 out of spec. countermeasure: replaced regulator. cycle time n/c what: aluminum in op side vacuum manifold
why: op side block blew sucking aluminum in to the manifold
c/m: removed aluminum from manifold and checked operation what: aluminum in the vacuum manifold and blown vacuum block op side
why:
c/m: replaced in let filter and all clear vacuum hoses, cleaned vacuum filters and cut off damaged ends of the black hoses what: aluminum over flow
why: upper limit probes too short causing high aluminum level making it easier to overflow
c/m: replaced upper limit probes and set at 9 inches to lower the upper limit what: aluminum stuck in the sleeve
why: machine poored but didn't inject and aluminum got hard and wouldn't come out
c/m: replaced tip and sleeve what: aluminum stuck to squeeze pin 2
why: did not get a full ladle pour
c/m: removed aluminum from die/squeeze pin and started it back up, had operator bleed his squeeze master what: axis alarms
why: change over from breather baffles to 59B 1 RKR
c/m: adjusted pressure and flow on squeeze master what: back cutters in trim press, bolts snapped
why: crash in trim press during stamp
c/m: replaced one cutter. pulled snapped bolt from other cutter and reused. replaced all 4 bolts. ran out of time what: bad slide core. Why: spec problem. CM: changed slide core. what: bad slide cores. why: coating was removed from slide cores. CC: changed Slide cores #1 and #4 and replaced the tappet pins for life as well. what: basket size jumping around
why:
c/m: adjusted the ladle poor and changed badly worn tip and sleeve what: bent robot arm
why: large biscuit bent arm when pulling part out of the die
c/m: replaced arm and confirmed operation what: biscuit alarms
why: biscuit readings are less than 1mm on panel but not faulting robot. physically bigger than 1mm. checked the dryshot st and it was off from reference by 16mm
c/m: adjusted dry what: biscuit alarms high/low
why: ladle arm bearings locking up
c/m: Removed whole ladle arm for rebuild, rebuilt and installed passed to first for final assembly and adjustments what: biscuit size jumping
why: ladle pouring slow
c/m: adjusted fast pour from 35% to 40% and slow pour from 30% to 20% per plex what: biscuit size jumping from low to high
why: lower ladle unit locking up
c/m: replaced lower ladle unit and set all ladle timers back to plex setting what: biscuit size jumping in size
why: lower ladle arm locked up
C/M: replaced ladle lower unit what: biscuit size jumping large to small
why: plunger lube not spraying in the sleeve wearing it out prematurely (wash)
c/m: replaced tip and sleeve what: biscuit sticking to chuck claw
why: excessive wear and build up on chuck claws
c/m: replaced all 4 chuck claws
reoccur: no what: biscuit sticking to tip and excessive blow back
why: badly worn tip and sleeve
c/m replaced tip and sleeve and adjusted plunger lube tip
reoccur: yes in time what: biscuit thickness issues
why: suspect ladel bearing are dragging or semi locking up
C/M: REPLACED LOWER LADEL UNIT what: blow back
why: tip and sleeve worn
c/m: replaced tip and sleeve what: blow back
why: cracked screw bushing.
c/m: replaced tip. 54,000 shots of tip
recur: timing what: blow by
why: wear (44,740)shots.
c/m: replaced tip.
recur: timing. what: blow by. (51,000 shots)
why: wash out on sleeve.
c/m: replace tip and sleeve.
r/c: yes timing. what: blow by. pc malifuntion alarm
why: wear. when pulling plunger wasn't returned.
c/m: replaced tip (23278 shots).
recur: yes timing what: blow out
why: build up on the die
c/m: cleaned die what: blow out
why: undetermined
c/m: cleaned die and vacuum block holder of aluminum changed vacuum block and blue and black hoses chill block shim and die cooling lines what: blow out op side die F-7
why: flashing build up around op side slide core
c/m: cleaned die around slide core, replaced robot side vacuum block, and repaired op side vacuum hose what: blow out robot side
why: possible wrong shim behind chill block on robot side
c/m: cleaned die and replaced .050 shim for .100 shim behind the chill block what: blow out robot side 59B 1rkr die f-16
c/m: possible dirty die
c/m: cleaned die what: blowing both vacuum blocks
why; possibly water in the spray cartridge air blow
c/m: switched hoses from v2 to v1 changed filters in v1 and v3 and drained air line to the spray cartridge what: blowing op side vacuum block what: blowing op side vacuum blocks
why: vacuum filter dirty
c/m: cleaned filters and replaced op side clear hose what: blowing vac blocks on operator side of die
why: DH asked for new filter, old one was dirty
c/m: replaced vac filter for operator side what: blowing vacuum blocks in pre heats
why: possible hole in black air line going to the block
c/m: cut end off black line on rb side what: blowing vacuum blocks operator side only
why: buildup in canister filters
c/m: cleaned filters and reinstalled
reoccur: timing what: blown op side vacuum blocks
why: bad vacuum hose o-ring on op side
c/m: replaced o-ring checked hoses, oil and filters all ok what: blown vacuum block op side
why: possible hole in black line
c/m: cut end off black hose checked filters and die release what: blown vacuum blocks
why: possible die release pump NG
c/m: adjusted spray tip, cleaned filters, switched cav3 and 4s squeeze pin hoses to the correct cavity (3 was on 4 and 4 was on 3) and chan what: blown vacuum blocks op side
why: air leak from loose fitting on op side tank solenoid valve
c/m: diluted die release to 100:1 replaced o-ring and found small hole in blue air line not allowing what: blowout RB side
why: possible worn chill block. chill block had a wave on the top side
c/m: replaced chill block on Rb side and cleaned all aluminum off of the die what: blowout on robot side
why: possibly dirty die
c/m: cleaned die what: blowouts op side. 59B 1 rkr die F-15
why: chill block not allowing die to fully seal
c/m: spot checked die. removed shim from behind op side chill block and removed clog from die release pump an what: bottom op side slide core stuck
why: flashing build up around slide core
c/m: removed build up and polished housing along with replacing bottom side op cooling joint (leaking) what: broken air bowl inside robot cage
why: attrition
c/m: replaced air bowl what: broken bracket on rear yellow door for locking and setting the limit switch for the hydraulics.
why: attrition
c/m: removed door, grind/ weld bracket back into place, reinstall door. verified it what: broken cutter front left side of trimpress
why: cutter was old snapped in half broke bolt off in trimpress also
c/m: removed broken bolt, repaired threads and replaced broken cutter
reoccur: tim what: broken ladle
why: cracked
c/m: replacment ladle given to operator what: broken ladle
why: probe alarm with aluminum in cup, cracked after remelt
cm: replaced broken ladle what: broken ladle
why: unknown
c/m: replaced ladle what: broken ladle cup
why: unknown
c/m: replace ladle cup what: broken slide core. Why: slide core failed. CC: replaced slide core. what: broken wire on high aluminum probes
why: wire broke
c/m: Reterminated wire for high aluminum probe and verified operation for high aluminum fault working ok. turned over to production what: broken wires for upper limit for holding crucible
why: attrition
c/m: re terminated with ring connectors what: burr on cavity #4 slide core. Why: chip in slide core. CC: replaced #4 slide core. what: burr on roller groove. Why: chip in slide core. CM: Change slide core #1. what: c/v jammed
why: worn out conveyor pieces ,bent rods broken flytes
c/m: replaced and fixed what: cable for half pipe door came undone
why: defective cable clamp
c/m: reinstalled 1 clamp out of two what: casting pressure high
why: accumulator pressure high out of range.
c/m: 250 ton accumulator should read 6.0-7.0 per standard. was reading 8.5 purged accumulator down to 6.8 within tolerable ran what: cav. #1 trim damage
why: worn cav. #1 cutter
c/m: replaced cutter and had operator verify trim height what: cav. 4 tappet too deep. 13.65mm spec is 13.00mm to 13.40mm
why: possible air in the squeeze pin lines
c/m: cleaned tappet pin. removed frayed hose cover from between squeeze pin fittings allowin what: cav. P1 slide core spec problem. why: slide core was warn. c/m: replaced slide core p1. what: cav.2 scraping coming out of the die
why: buildup along the edge of cav.2
c/m: cleaned die what: cav.2 tappet pins too sallow
why: flow on cav.2 squeeze pin set high
c/m: adjusted flow to match the other cavities and had operator confirm parts were in spec what: cav.3 (bottom, rb. side) slide core leaking water
why: bad o-ring in slide core housing
c/m: replaced o-ring what: cav.3 sticking to the die
why: possible build up on pin hole
c/m: cleaned die and adjusted spray point what: cavities jumping on squeeze master spec. why: air in lines. countermeasure: put straight fittings for direct hyd. fluid to cylinders. recur: no what: cavity 1 slide core broke
why: unknown
c/m: replaced cavity 1 slide core, confirmation sheet printed and gave to operator for completion what: cavity 2 trim damage
why: overflow tab off trim stuck in between guides.
c/m: Removed overflow tab and verified trim damage ok. adjusted air blow to remove tab getting left behind. what: cavity 2,3,and 4 over 700.0mm on squeeze master
why: unknown
c/m: shutdown squeeze master and rebooted system, rebleed lines and stroked machine. All cavities in spec and reading properly. what: cavity 3 and 4 trim damage
why:robot positioning off
c/m: replaced cutters (timpress work order #61235) and adjusted robot positions24 and 25 and had operator confirm parts what: cavity 3 trim damage
why: tree breaking coming out of die causing to be to deep
c/m: Cleaned die and operator rebleed squeezemaster what: cavity 3 trim damage
why:Upper punch causing dent in top of part, punch wear
c/m: Replaced worn punch cavity 3, polished sides of new punch to clear off burr buildup. adjusted rear cutter cavity what: cavity 4 axis alarms
why: air in line
c/m: Cleaned die and squeeze pins, Line bleed all cavities, rebleed using squeeze master. all cavities in spec turned over to production. what: cavity 4 bottom slide core bad as per quality. why: bad slide core. CC: changed cavity 4 bottom slide core. what: cavity 4 tappet depth to deep (out of spec)
why: cavity 4 tappet pin stretched allowing overall length to be NG
c/m: Removed cavity 4 slide core and replaced tappet pin. what: cavity 4 trim damage
why: cavity 4 rear cutter moved position
c/m: Removed and cleaned area for cavity 4 rear cutter, reset cutter what: cavity 4 trim damage
why: large overflow tab stuck in side of trim die
c/m: removed and checked air blow to clean off die. what: change slide core 5ba S1
why: quality contacted E/S asking us to change slide core S1 due to illegible lettering after parts get shot blasted
c/m: replace slide core S1. had to replace 3 o-rings what: changing over to 1 rkr no cooling joint or plumbing for cooling joint
c/m:added cooling joint and all plumbing what: channel 4 on squeeze master leaking by internally.
why: unknown.
c/m: replaced solenoid.
r/c: timing. what: charge loader lifter overload
why: root cause unknown
c/m: reset overload, verified loading what: charge loader returning too far not allowing the forks to accept the loading bucket
why: loose lower limit switch
c/m: adjusted lower limit switch up what: check die for blow outs per JRO
why: looking for signs of blow outs
c/m: looked at die OK what: check die for possible blow out per JRO
why: been having blow outs
c/m: looked at die OK what: checking anchors in floor for movement.
why: two anchors have stripped nuts.
c/m: double nutted. floor marked with yellow and green paint marked to check for movement. (has ran 3.5 hrs. no move what: chip conveyor jammed up.
why: wear
c/m: fixed some of the broken chain links
recur: yes. what: chipped cutters on scrap cutter. countermeasure: replace upper and lower cutters. recur: time. what: collision detect alarm when pulling shot out of the trim press
why: robot pulling part out crooked
c/m: touched up robot positions 63 and 64 what: collision detect alarms when pulling parts out of the trim press
why: robot position off
c/m: tightened side clamp air line bracket, bent tab shoot back in position and touched up robot positio what: collision detect in trimpress
why: robot holding shot hitting cylinder at trimpress
c/m: touched up trim press set position
reoccur: no what: cooling joint for sleeve broke off.
why:
c/m: rethread installed new cooling joint.
recur: timing what: cooling joint for sleeve leaking
why: cooling joint was bent
c/m: replaced ng cooling joint and re-bent copper line going to it due to wear
reoccur: timing
cycle time unchanged what: cooling joint leaking on tip and plunger
why: broken
c/m: replaced broken cooling joint
reoccur: timing what: cooling joint was leaking water.
why: cracked
c/m: replaced
recur: timing what: countermeasure for 59B/RPY Trim-die parts hanging up causing quality issues. what: cove core 2 faults
why: slide core 2 stuck in die
c/m: Turned mold heater up, heated part with torch to get slide core to return position.
Used torch to heat die raising moveable side temp. Use what: cover for robot is mangled
why: robot crashed
C/M: reshaped the guard and remounted it. All is well. what: crack in ladle
why: wear over time
c/m: gave operator replacement ladle. confirmed ladle travel path ok
reoccur: in time what: cracked cutter in 1-3. why: maybe from double stack part. counter: replace cutter. recur: no
This was last replaced on 1-25-2017 same m/c what: cracked ladel head
why: attrition
c/m: replaced ladel what: cracked ladle
why: wear
c/m: replaced ladle what: cracked ladle
why: wear/age
c/m: replaced ladle what: cracked slide core
c/m: replaced what: cracked slide core, helper bottom 5BA P part
why: possibly age, heat, cycle count or other issue
c/m: replaced slide core helper bottom 5BA P part die #12 what: cycle time over
why: cause unknown
c/m: nothing what: cycle time over
why: unknown, ladle would not return after fault. PLC did not have G562 ladle level position to allow ladle to return from sleeve.
c/m: verified operation of invertor telling lad what: cycle time overs what: cycle time overs
why: ladle sitting too long before going into the aluminum
c/m: adjusted mid way stop. cycle time Ok what: cycle time overs
why: water pressure was falling off faulting the mold heater
c/m: switched filters from the chiller what: damage around the tappet area of cav.3 and 4
why: scratches in the die (59B die F-14) making it look like trim damage
c/m: production changing the die what: damage to parts coming from trim press
why: 5ba p1 cavity press block hitting part causing damage on lettering
c/m: plunger was locked up. removed and cleaned off rust. free floats now but did n what: die blew out/ aluminum covering die
why: bottom slide cores stuck excess aluminum
c/m: Cleaned die removed excess aluminum, got bottom slide cores unstuck. cleaned and reset die height what: die cleaning
why: roughness out of spec
c/m: cleaned BC die f-11 what: die cleaning
why: soldering
c/m: cleaned die what: die cleaning
why: soldering build up
c/m: cleaned die what: die cleaning
why: soldering
c/m: cleaned die what: die lock malfunction
why: slide core no closing properly
c/m: cleaned debris from cav.4 slide core and reset die lock what: die loosing die lock, change die to see if die was issue. what: die not closing all the way and robot faults
why: robot was in step not allowing it to move and die height not set correctly
c/m: took robot out of step and showed operator how to set die height what: die not wanting to open after shot
why: low on hydraulic fluid
c/m: filled main hydraulic tank what: die open/close cylinder leaking hydraulic fluid behind block when die opens/closes
why: o-ring in block was shredded/
c/m: welded block by where the pipe is welded to it / grinded and stoned e what: die release pump ng, low level control relay bad
why: relay went bad not telling it to add water. pump running dry
c/m: replaced pump, replaced relay with new inventory part what: die release pump pressure higher than spec. spec .35-.5mpa reading .8mpa
why: gauge NG
c/m: replaced gauge with non-invantory pump pressure at .4mpa what: die will not open
why: fault then manually cant open die.
c/m: found tie bar selector switch in between positions not reading off position. Moved selector switch to off, opened die and elected what: die wouldn't close
why: hook cylinder would not release to allow die to shut
c/m: replaced hook cylinder and verified operation of die ok turned over to production to bleed squeeze master what: dip tank not cycling water
why: thermocouple not reading correctly
c/m: replaced thermocouple what: door lid on upper crucible. ret. senor ng.
why: ret. senor melted.
c/m: replaced x56 sensor.
r/c: timing what: door lock wont reset
why: wires came out
c/m: terminated wires what: dropped ingot
why: ingot dropped on loader causing jam up
c/m: Removed dropped ingot and straitened bent paddles. turned over to production what: dropping P1 part coming out of the die
why: part possibly sticking to squeeze pin
c/m: cleaned and waxed squeeze pin along with robot side vacuum block and clear hose what: dropping cav.2 and 4
why: shot sticking to the tip
c/m: replaced both vacuum blocks checked die release concentration and spray points. adjusted plunger lube spray tip and replaced plunger tip what: dropping cav.4
why: cav.4 sticking to the die
c/m: used spray map to adjusted spray points and adjusted ejectors from 30mm to 15mm what: dropping cav.4 coming out of the die
why: shot breaking when ejecting
c/m: checked die release concentration adjusted spray points and adjusted spray from .3 to .5, bled squeeze master cleaned a what: dropping part on cavity 4
why:
c/m: what: dropping robot side trees rb. side (trial die 6B2-wp die F-11)
why:
c/m: adjusted spray points what: during change over slide core hose wouldn't go on
why: pressure build up in the fitting
c/m: relieved pressure and installed slide core hose what: email from kent ,noticed a couple trim damage parts
WHY: 2 over flow cutters missing (broke off lost in scrap bin) and we noticed that the wrong air blows installed
C/M: replaced missing overfl what: ex. temp. cont.
why: tip burnt.
c/m: replaced thermocoupler.
recur: no. what: excessive blow back
why: plunger tip wore
c/m: replaced plunger tip and adjusted plunger lube tip what: excessive blow back clogging spray tip
why: plunger tip worn out
c/m: replaced plunger tip and adjusted and verified plunger spray what: excessive flashing around P1 slide core
why: P1 slide core worn
c/m: replaced P1 slide core what: exhaust gas temp reading pegs high then low
why: found terminal inside thermalcouple disconnected
c/m: reterminated connection what: exhaust temp gauge not reading correctly
why: thermo coupler NG
c/m: replaced thermo coupler what: exhaust temperature was not reading properly
why: thermocouple in lid NG. temperature wouldnt get past 860 while smelting was fired up.
c/m: replaced thermocouple in lid. confirmed temperature r what: exhaust thermo couple reading incorrectly
why: thermocouple NG
c/m: replaced exhaust temp thermocouple what: filter change time
why: hydraulic filter at life 2000 hours
c/m: replaced hydraulic filter and reset life timer what: filter replacement
why: filter at 2000 hours
c/m: Replaced hydraulic filter and reset to 0 hours what: fixed side of die running to high on temp. why: on fixed side not opening. countermeasure: replace solenoid on fixed side. recur: no what: fixed side temperature problems
why: thermo couple wire broken
c/n: replaced thermo couple what: flame coming around the half pipe door
why: air fuel ratio off
c/m: adjusted air ratio on holding crucible what: flame out holding crucible
why: aluminum dropped over the spark plug
c/m: removed drpped aluminum from grounding out spark plug, replaced damaged photo eye. Verified operation of flame for holdi what: flame out on holding crucible
why: ignition wire was pulled off the igniter from end of shift shutdown/ COP
c/m: re-connected wire and confirmed operations temp was down to 1058 degrees what: flame out on melting crucible
why: air/fuel ratio off, set screw on air loose allowing valve to close on pilot
c/m: adjusted air on pilot back to 7. confirmed operation of pilot and melting on u what: flameout faults for melting furnace
why: root cause unknown
c/m: reset and refired may times, finally took off and stayed fired. what: flapper no 3 not opening or closing.
why: cylinder off mount. missing snap ring.
c/m: remount cylinder and replaced new snap ring.
recur: timing. what: flashing operator side
why: damaged slide core
c/m: replaced slide core
reoccur: no what: flashing why: wear on tip and sleeve 16,884 shots. countermeasure: replaced tip and sleeve. recur: time what: flow line aluminum buildup by chill block robot side
why: air alignment, die buildup
c/m: air adjustment set to 8.5 per plex set points, adjusted air line for flow line spot on part, cleaned bu what: follow up from WO99291, trim press scrap chute damaged causing scrap to not fall and build up. Blown water hose in the DCM.
why: attrition
c/m: removed chute to bend to get correct angle X's 4. what: furnace change pm, replace coupler when change is done and used roll of wool
c/m: replaced coupler, used wool on new furnace/door what: furnace door drifting up losing start position and turning off burner
why: excess chain slack
c/m: tightened chain. what: guide roller on ingot loader door fell off (left side)
why:?
c/m: find roller and spacer and replaced.
r/c: no what: half of the operator panel doesn't work. Thinking it was the I/O board we changed it out , but still receiving the same problems
why: what: half pipe door
why: cable snapped
c/m: replaced cable what: having issues with the smelting lid open and close
why: air valve is not shifting
c/m what: helper auto side door close limit switch failure
why: loose bracket on door and the helper door close LS2 was flipped the wrong way
c/m: tightened bracket on helper door. flipped ls2 to its corr what: helper door alarm
why: loose bolt holding limit switch rail
c/m: replaced bolt holding limit switch rail and confirmed open/close limit switches what: helper door bouncing off return limit switch
why: root cause unknown
c/m: adjusted the the return speed control, adjusted return side limit switch trip dog. what: helper door close limit faults
WHY: limit switch 2 sticking causing faults
C/M: replaced limit switch 2
reoccur: UNKNOWN but ran last 4 hrs no problems what: helper door cylinder bracket broke
why: attrition
c/m: welded and reinstalled bracket what: helper door faults
why: bracket attaching door to cylinder broke off
c/m: Removed bracket, welded and reinstalled. adjusted door cylinder to allow close and open operations what: helper door faults
why: main bracket on helper door fell off not making contact with door limit switches
c/m: Reatched main bracket on helper door and verified operation of door and correct limi what: helper door malfunction
why: limit switch #2 stuck on possibly to debris after blow out (cop)
c/m: cleaned debris from around switch and confirmed operation what: helper door slamming
c/m: adjust cushions on cylinder what: helper door slamming shut
why: door cylinder NG
c/m: replaced cylinder what: helper door wont close, tip and sleeve sound NG
why: Robot not at home position not allowing helper door to operate, tip and sleeve noise due to high pressure pump not turned on so water was not what: helper door wont shut
why: robot did not have home light
c/m: moved robot to home position and verified door movement what: helper side door broken, needs rewelded
why: door bent, spot has been rewelded multiple times
c/m: cut piece of angle iron and welded it around broken area to give it more support as well as fil what: helper side door faults
why: helper side door slow to get return position to allow robot to load
c/m: removed air lines and drained air from cylinder, unhooked cylinder to verify door operation what: helper side door issues. conduit holding electric wiring on top of door fell apart
why: no lock nut. bad threads on conduit
c/m: cleaned up threads on conduit. replaced lock nut on conduit.
reoc what: high speed shot alarms
why: low nitrogen and ladle pour setting
c/m: added nitrogen to specified amount and adjusted all the pour settings per plex what: high speed shot issues
why: discovered optional shot screen settings deviated from plex document numbers, plunger lube also not spraying well
c/m: set optional shot options back to what plex doc what: high temp alarms. why: not enough cooling water. counter measure: pull deck plate and adjust flow. (was at 23 changed to 15) recur: possible what: high trim on cavity P1
why: die is chipped out where runner meets part cavity P1
c/m: nothing i can do without changing die. previous shifts were filing trim on cavity P1. passed info on to TL. what: holding crucible flame out
why: ignition rod shorting out
c/m: cleaned aluminum off ignition rod and wire what: holding crucible misfire what: holding misfire
why: loose igniter wire
c/m: connected wire and confirmed operation what: holding temp inconsistent
why: thermalcouple ng
c/m: replaced thermalcouple what: holding temp. reading inconsistently
why: thermocouple NG
c/m: replaced thermocouple what: hyd. filter out of spec. why: clogged. countermeasure: replace filter. recur: time. what: hyd. leak at manifold block.
why: o-ring failed under solenoid stack.
r/c: not oem O-rings for valves.
c/m: replaced O-rings.
r/c: yes. ordered the oem flat type.
cycle time: no change. what: hyd. line leaking. countermeasure: removed line welded up. recur: no what: hyd.manifold body leaking. what: hydraulic bracket loose
why: came loose from closing/opening
c/m: Replaced all bolts and lock washers to hydraulic bracket what: hydraulic filter change alarm
why: age/wear
c/m: replaced hydraulic filter what: hydraulic filter change up
why: at hours of operation for filter change
c/m: Replace Main hydraulic system filter what: hydraulic filter replacement
why: filter time up at 2000 hours
c/m: replaced filter and reset time, verified no leaks turned over to production what: hydraulic filter replacement
why: toscast filter warning
c/m: replaced filter and reset what: hydraulic filter time up
why: filter at 2000 hours
c/m: replaced and reset hydraulic filter timer what: hydraulic filter time up
why: time up for filter replacement at 2000hours
c/m: Replaced hydraulic filter and reset hours what: hydraulic leak
why: Robot side move slide core 2 advance position line leaking
c/m: Removed hose, removed leaking fitting Reapplied tape on fittings and reinstalled, verified no leaks. what: hydraulic leak
why: attrition
c/m: added hydraulic fluid to tank, ran in auto to look for leak what: hydraulic leak
why: flex cable leaking
c/m: replace flex cable what: hydraulic leak at the trim press valve stack
why: valve stack manifold cracked
c/m: replaced manifold what: hydraulic leak from robot side slide core IN hose
why: hydraulic hose NG
c/m: replaced slide core hose what: hydraulic leak on the squeeze master
why: squeeze master pressure and return lines leaking due to age/wear
c/m: replaced both hoses and checked for other leaks what: hydraulic leak trim press
why: leaking hoses and valves and O-rings
c/m: changed out 2 hydraulic hoses, and replaced 2 leaking valves and o rings. also replaced chiller
reoccur: not for seen. what: hydraulic oil leak
why: loose fitting
c/m: took off fittings and re taped them what: hydraulic pump not coming on
why: broken 24v wire to ladle switch
c/m: re-terminated wire what: hydraulic pump on squeeze master shut off
why: overload tripped
c/m: Reset overload and operator bleeding squeezemastr what: hydraulic temp high
why: 50 ton chiller running at 90 degrees, chiller not operating has low ambient temp. what: ingot loader crash
why: unknown
c/m: replaced 3 broken paddles
reoccur: possibly what: ingot loader crashed double stacked. why: ingots missed limit switch. countermeasure: replaced bent ingot loading paddles and ingot loader lift bent back down. recur: in time. what: ingot loader crashed.
why: bent flites allowing inget to tip
c/m: replaced bent flites. hand loaded m/c to keep running production.
recur: yes what: ingot loader crashed.
why: flites were bent. loader platform broke on outside and middle.
c/m: bent back into place and welded broken parts.
recur: yes timing. what: ingot loader crashed.
why: unknown.
c/m: removed all bent cradles and replaced.
r/c: maybe what: ingot loader door safety lock wont reset
why: wires came disconnected from device
c/m: reterminated wires and reinstalled what: ingot loader faults
why: ingot loader loading tray bent due to igot fell in front pushing metal cover back under loader while coming down
c/m: removed ingot, fixed cover behind furnace. bent loa what: ingot loader faults when moving forward
why: unknow cause
c/m: passed on what: ingot loader insert plate bent up
why: ingot caught top of the side lip and bent up when conveyor was advancing
c/m: bent insert plate back and confirmed operation what: ingot loader not loading , lid wont open
rootcause: Pressure for lift cylinder not adequate
countermeasure: Adjusted lift cylinder pressure
reoccur: No what: ingot loader not loading ingots correctly
why: possible loose flight causing ingot to not load on the loader correctly
c/m: tightened loose flight what: ingot loader not moving
WHY: conveyer motor wires smashed (dropped ingot)
C/M: replaced motor wires what: ingot loader not moving
why: vent hood position switch lever was moved, so it didn't think hood was over upper crucible. would not allow anything to move
c/m: adjusted lever on limit switch
reoc what: ingot loader not wanting to dump
why: the upper ingot level sensor NG
c/m: replaced sensor what: ingot loader not working
why: air line fitting broke off to cylinder for pusher forward on ingot loader. unsure of how it was broken
c/m: replaced fitting. confirmed ingot loader operations in m what: ingot loader problems
why: ingot fell and bent the flights
c/m: bent 14 flights bake into place and replaced 2 flights what: ingot loader safety door problems
why: holes stripped out of safety latch bracket
c/m: made new bracket for safety latch
recur: what: ingot loader safety gate not closing
why: bolts holding safety latch fell out
c/m: replaced bolts and added lock washers what: ingot loading outside row paddles bent
why: ingot fell during loading and hit all the paddles
c/m: removed and replaced all bent paddles
reoccur: time what: injection rod blew apart
why: unknown cause what: injection stroke abnormal fault, water leak and broken ladle
why: injector lost home position. broken return water hose on the injection rod
c/m: re zeroed injection rod and replaced water hose what: inspection table needs light
Why: so operators can inspect the parts properly
C/M: installed inspection table light what: keeps blowing op side vacuum blocks
why: moister in vacuum tanks
c/m: replaced inlet air filter and checked all other filters, trimmed black hose to the vacuum blocks adjusted spray cartridge (s what: ladel electrode faults
why: broken wire
c/m: reterminated wire what: ladel electrode malfunction
c/m: replaced wire harness what: ladel wont move
why: unknown cause
c/m: hand cranked ladel and then was freed up to move what: ladle arm wont move
Why: Lower unit froze up
C/M: Replaced lower unit
Recur: Possibly in time what: ladle bouncing as goes into aluminum
why: buildup on short probe allowing contact to aluminum
c/m: Cleaned buildup and verified wiring on probe ok what: ladle bouncing in the aluminum
why: tip for ladle probe missing
c/m: replaced tip with a new one what: ladle cracked and leaking across top of crucible ring
why: wear over time
c/m: gave ladle to operator to replace what: ladle electro alarms.
why: normal wear.
r/c: movement of ladle arm.
c/m: replace ladle cable.
r/c: yes timing what: ladle electrode break
why: broken wire by the terminal
c/m: terminated wire and gave wire bundle some slack what: ladle electrode break
why: possible loose connection at the probe
c/m: tightened connections what: ladle electrode break fault, arm wont move.
why: excessive metal built up on electrodes
c/m: removed metal, arm move in and out. what: ladle electrode break faults
why: electrode line out of holder,
c/m: reconnected terminals and tightened all probes what: ladle electrode break faults
why: ground wire on ladle electrode bar broke
c/m: Reterminated ground wire for ladle electrode bar, verified operation what: ladle electrode faults
Why: Wire broke
Counter measure: replaced wire
R/C: Yes
Cycle time: unchanged what: ladle electrode faults
why: broken insulator for electrode
c/m: replaced electrode unit with a rebuilt one
reoccur: no what: ladle electrode malfunction
Why; aluminum build up on bulb
C/M: replaced with new
reccur: yes what: ladle electrode malfunction
why: wires pulled out of electrode probes
c/m: re-terminated wires and reconnected to probes what: ladle electrode wire break
why: attrition
c/m: replaced ladle connector tubing. what: ladle electron faults. why: bad wiring flashing build up. countermeasure: replaced wiring. recur: time what: ladle fwd limit switch faults
why: ladle position to far foward hitting sleeve when machine would pour causing to come off limit switch occasionally.
c/m: adjusted fwd limit for ladle to allow what: ladle hit tie bar cover when going in to pour
why: bearings locking up on lower unit
c/m: replaced lower unit and ladle what: ladle issues
why: lower ladle unit locked up and quit moving
C/M: replaced lower ladle unit. what: ladle limit switch malfunction
why: short in X060 wire
c/m: replaced wire and replaced broken ladle what: ladle malfunction error
why: metal across probes
c/m: removed metal from probes. what: ladle operation
why: probe wires broken
c/m: Replaced probe wires and probes, passed to 1st for final
REOOCER yes timing what: ladle over poring sleeve
why: sleeve turned to one side slightly, side of ladle broken allowing excess aluminum to flow out front causing overpour
c/m: replaced ladle what: ladle pour not moving
why: Root cause unknown
c/m: can manually move the ladle by turning the motor shaft but will not move with the switch. possible electrical issue. what: ladle problems
why; grounding probe and metering probe touching allowing contact of probes
c/m: Turned and tightened probes to allow no contact of probes during operation what: ladle replacement
why: ladle cracked
c/m: gave dh 1kg ladle what: ladle temperature probe not working
why: ladle wire broken
C:M/ fixed broken ladle wire what: ladle would not dip into crucible
why: insulator on measuring probe missing allowing contact to ground causing probe to read incorrectly
c/m: replaced ladling probe unit and verified operation what: ladle would not operate
why: pour unit binding up after pouring into sleeve.
c/m: Manually moved ladle back to 90 position, removed covers and tightened upper and lower chains to allow position what: ladle would not operate
why: safety door at crucible needed reset
c/m: looked inside door at ladle invertors, both had error, checked safety plc crucible safety switch not reading properly. Open what: ladle wouldn't move
why: wires got pulled out of crucible safety gate
c/m: rewired safety switch and mounted differently to stop from happening again what: large scrap conveyor locking up
why: possible wear block on bottom outside not round causing chain to bind
c/m:Replaced several cotter pins on outside. what: leaking airbowl
c/m: replaced air bowl what: leaking spray valves 3
why: debris
c/m: replaced 3 valves
reoccur: yes timing what: leaky coolant line for plunger shaft
why: defective fitting
c/m: replaced fitting, trimmed line back. what: left scale not reading correctly
why: tabs under the scale
c/m: removed tabs and re-zeroed scale what: lid to upper crucible wont close/open
why: open/close solenoid valve is busted
c/m:Replaced broken solenoid valve for crucible lid open/close verified operation ok what: light curtain on back side of the ingot loader not resting
why: possibly due to shut down
c/m: cycled the power to the safety unit to reset the light curtain what: limit switch bad
why: end of life
C/M: reset faults, fixed safter door switch, cleaned up limit switch because it still had continuity and everything worked as intended. what: line filter chock alarm on squeeze master
why: in line filter clogged
c/m: replaced in line filter what: loose ladle probe
why: loosened up over time/use
c/m: positioned and tightened probe. operated ladle several times to confirm function
reoccur: in time
cnt: unaffected what: low aluminum, upper will not melt
why: metal level upper limit, aluminum under probe across metal bracket
c/m: Cleaned off extra aluminum, upper melting what: low high speed alarms
why: shop position speed off
c/m: adjusted injection point 5 speed from .46 to .45 and FML end from .79 to .80 per plex settings what: lower crucible aluminum hardened over the weekend
why: bad igniter box
c/m: replaced lower crucible and halfpipe
reoccur: in time what: lower crucible probe too low
why: set screw in collar was loose allowing the probe to drop too low
c/m: adjusted probe within range according to sheet posted on machine what: lower crucible temp high
why: controller/PLC communication
c/m: Hooked up to PLC x30/x31 operation for burner on/off, tighted conections on both PLC and controller. adjusted set points to verify what: lower crucible upper limit set to high
why: upper limit probe NG (too short)
c/m: replaced upper limit probe and set at 9 in. what: lower ladel unit bad bearings
c/m: replaced lower ladel unit
c/m: 3rd- pour position was not lined up. Took lower ladle unit off and realigned chains. what: lower ladle arm locked up
Passed to next shift. what: lower ladle stuck at the sleeve
why: Root cause unknown
c/m: put crucible cover and protective blankets over crucible, manually turned ladle motor shaft until ladle moved in the up/down position what: lower left product sensor fell apart from housing
why: attrition, vibration
c/m: extension block for product detect missing, fabricated new block and reinstalled sensor back into housing. adjust what: lower right product detect not working
C/M: REPLACED SENSOR what: machine check #20 die release pump pressure out of spec
why: pressure gauge NG
c/m: replaced gauge what: machine wouldn't start due to injection rod not being home
why: shot injection sensor not reading properly
c/m: replaced shot injection sensor what: main hose to fixed side of die leaking water
why: bad o-ring in quick connect fitting
c/m: replaced o-ring and checked for other leaks. OK what: main hyd. line leaking.
why: o-ring failed.
c/m: replaced o-ring.
c/t: n/c what: main hydraulic filter change
why: 2000 hr life
c/m: change and recycle filter what: main water line to the moveable side leaking
why: o ring in the fitting NG
c/m: replaced fitting from hard line to hose and checked for other leaks OK what: making noise when injecting
why: tip and sleeve NG due to clogged spray tip
c/m: un-clogged spray tip and replaced tip and sleeve what: mark on cavity 4
why: Upper block on cavity 4 trim press had build up causing mark
c/m: cleaned upper block and polished removing buildup causing mark what: melted switches on operation panel. why: half pipe plugged up got to hot. countermeasure: replace push buttons and switches.
Reoccurrence: This shouldn't occur unless operator doesn't check half what: melting burner flame out
why: spark plug ignitor covering ripped allowing spark to not spark in correct position
c/m: replaced ignitor spark plug and confirmed operation what: melting crucible thermo coupler not reading
why: thermo coupler NG
c/m: replaced thermo coupler and verified temp. OK what: melting crucible upper limit probe faults
why: loose connection
c/m: tighten screw for connectors what: melting flam out
why: damaged igniter insulator causing igniter to short out
c/m: replaced igniter insolate what: melting furnace high burn not kicking on
why: ingot loader not in home position
c/m: returned ingot loader to home position what: melting furnace not firing
why: holding metal leak probe wires loose
c/m: tightened probe wire screws what: melting furnace problems. constantly kicking on and off
why: lower melting thermo coupler not reading correctly
c/m: replaced lower thermo coupler what: melting furnaceindicates low temp -30.0
why: unknown
c/m: shut upper lid and heated it up what: melting pot temp problems
why: broken thermo-coupler
c/m: replaced thermo-coupler
reoccur: yes in time what: metal leak
why: crucible cracked up by "spout" under dog house. dog house was also cracked all the way through
c/m: replace holding crucible and dog house
reoccur: in time what: metal leak
why: root cause unknown
c/m: scrape/chisel metal out what: metal leak
why: unknown cause overfill ran out backside
c/m: heated up and cleaned out fixed probes what: metal leak at crucible
why: attrition
c/m: was requested to trim metal leak probe above solidified metal so the furnace could be fired up what: metal leak from 3rd
WHY: overflow
C/M: had to replaced 1 metal leak detect probe due to being cut from hard alum what: metal leak in holding crucible
why: aluminum over fill
c/m: removed excess metal from behind door and removed metal from metal leak probes what: metal leak probes not working properly
why: probes lost conductivity due to age
c/m: replaced metal leak detect probes and confirmed operation what: missing screw valve on spray nozzle
why: root cause unknown
c/m: replaced screw valve what: mist collector filter (machine check 11C) out of spec
why: filter clogged
c/m: replaced mist collector filter what: mist collector 12A gauge out of spec
why: filter NG
c/m: replaced 12A filter what: mist collector filter gauge out of spec machine check 12D
why: filter clogged
c/m: replaced filter what: mist collector filters out range.
c/m: replaced filters.
no down time. what: mist collector stage 3 replacement
why: filter life
c/m: replaced 2 stage 3 hepa filters what: mist collector tripping contact overload.
Why: Motor is drawing to many amps on start up.
R/C: Motor is bad.
C/M: Replaced motor.
R/O: Timing what: mold heater motor contactor replacement
why: motor contactor no working properly
c/m: replaced heater motor contactor with non-inventory what: mold heater not powering up
why: e-stop was pressed witch trips the main breaker inside unit
c/m: reset the main breaker what: mold heater pressure to process out of spec @120psi should be between 80-100 psi
why: gauge NG reading 40 psi with no pressure.
c/m: replaced gauge pressure at 90psi what: molten metal leak. why: over flow of molten metal by half pipe.(detect rods at lower door) countermeasure: cut rod and removed molten metal. replaced with new. recur: no. what: molten metal leaking out of side door.
why: Not taking care of jack hammering when needed. Floor should be slanted but from not jack hammering floor is level on the inside.
C/M: Jack hammered s what: molten metal upper limit faults.
Why: Bare wire touching causing it to fault.
C/M: Ran all new wires and put heat wrap around new wires.
Recur: No what: motor contactor replacement
why: motor contactor for the heating element not functioning properly
c/m: replaced motor contactor with non inventory what: motor over load
why: right side turn table not spinning due to loose locking nut
c/m: tightened shaft locking nut what: motor overload on scrap press
why: small scrap c/v jammed tripped overload
c/m: reset overload, turned scrap c/v in reverse to removed jammed part and cleaned out c/v. verified operation turned what: motor overloads on the trim press
why: over flow tabs built up in the scrap conveyor
c/m: removed rear cover and removed tabs what: motor overloads on the trim press
why: over-flow tab stuck in scrap conveyor #1
c/m: ran conveyor backwards and removed tab what: movable side temp problems on 59B die F-16
why: thermocouple wire pinched between die and backing plate
c/m: replaced thermocouple what: move core 2 faults
why: after change over the top lead switch wire got pinched in the die when shutting on 5A2 P&M die F-32
c/m: replaced top lead switch and re-routed wire to avoid getting pin what: move core 2 faults
why: cav.3 slide core moving very slow causing fault/ cylinder NG
c/m: replaced cylinder and confirmed operation what: move core 2 faults
why: op. side lead switch NG
c/m: replaced lead switch what: move core 2 faults
why: small piece of debris not allowing the slide core to go In all the way
c/m: removed debris and cleaned the die and confirmed operation what: move core 2 faults (59b die f-11)
why: op side lead switch not reading when core is IN
c/m: tested both lead switches, op side NG, lead switch not in stock. production changing the die what: move core 2 not getting IN light
why: op side lead switch on 6A0 M die NG
c/m: replaced lead switch what: move core 2 stuck in robot side parts
why: squeeze pin stuck inside parts
c/m: adjusted temp up to get die temp high, manually moved move core and got squeeze pin to release. cleaned squeeze pin what: moveable slide core faults
why: Robot side reed sensor in hydraulic cylinder NG
c/m: Removed cylinder and plate, installed new reed sensor and reattached. Confirmed operation of reed sensor turn what: moving side of die leaking water profusely
why: 2 cracked slide cores
c/m: replaced OB and HT slide cores
reoccur: in time what: need ladle
why: full of aluminum from past week
c/m: replaced ladle what: no hydraulic pressure from squeeze master pump
why: hydraulic pump NG
c/m: replaced pump what: not faulting for metal leak (machine down, operator doing checks and notified us of issue)
why: broken wire in flexible conduit from machine to panel
c/m: replaced all 4 wires in conduit with wi what: oiler canister for trim press got filled with contaminated oil after being replaced.
c/m: removed and cleaned canister, added oil (nuto h46) what: ok c/v 1 not operating
why: table shaft broke
c/m: Removed and installed new table shaft, verified operation of table
will it reoccur; timing
cycle time: unchanged what: ok carrier faulting out, jamming up
why: chain stretched out allowing it to jump teeth, chain uneven
c/m: replaced ok carrier with unit from warehouse with new motor and chains
reoccur: in time what: ok conv guide fell off and was getting jammed
why: wear
c/m: put plate back on and jumped a couple links what: ok conveyor bucket alarming while returned
why: ok bucket conveyor advance sensor staying on
c/m: replaced sensor
reoccur: no what: ok conveyor getting stuck in advance position
why: possibly the left chain had too much slack in it
c/m: tightened left chain to match the right one what: ok conveyor getting stuck on the way back down
why: too much slack in the chain
c/m: adjusted chain tension what: ok conveyor getting stuck on way down
why: top inside rail bent up due to broken bolt
c/m: replaced bolt what: ok conveyor guide plates worn out.
why: guide plates made out of soft material.
c/m: made new guide plates.
r/c: yes timing what: ok conveyor hanging up
why: top guide rail worn out and catching ok basket
c/m: replaced top rail with non-inventory rail
reoccur: yes in time what: ok conveyor jam
why: chain skipped a tooth
c/m: jumped chain and adjusted slack what: ok conveyor jamming
why: guide rail for top plate worn
c/m: replaced guide plate on right side due to wear. Verified operation turned over to productin what: ok conveyor jamming
why: slack in right chain pulling it unevenly
c/m: adjusted chain what: ok conveyor jamming going up
why: right side chain jumped a tooth
c/m: put chain back and tightened the slack in the chain what: ok conveyor ng
why: guide plate fell off
c/m: put plate back on what: ok conveyor not getting its home light
why: possibly dirty sensor after blow outs
c/m: cleaned sensor what: ok conveyor not goi ng to top
why: jammed up
c/m adjusted chain tension what: ok conveyor not moving
why: key missing from motor shaft
c/m: removed motor and gearbox, installed key. what: ok conveyor not working
why: busted shaft on motor
c/m: replaced shaft what: ok conveyor rails wear out.
why: normal wear.
c/m: replaced rails with stainless steel type.
r/c: timing. what: ok conveyor sticking on way to return
why: chains out of adjustment
c/m: adjusted chains so they were even what: ok conveyor to table jammed, broke chain belt that carries parts
why:belt worn/bent got caught and ripped itself apart
c/m: replaced belt with new one
reoccur: in time what: ok cv stopping not returning
why: Brake not releasing in motor allowing to return
c/m: replaced motor and verified operation turned over to production. what: ok parts getting kicked out onto NG conveyor
why: what: ok table 2 not turning
why: clutch slipping allowing table not to turn with parts
c/m: tightened clutch and verified operation what: ok unload conveyer ng. why: wear on rails. countermeasure : replaced with rebuilt unit. recur:time what: okay converyor sensor bracket broke off.
why: wear.
c/m: replaced bracket with a new one.
recur: no what: okay conveyor hanging up and moving slow.
why: unknown cause.
c/m: cleaned checked chain tension.
recur: timing what: okay conveyor not getting a advance light.
why: guide plate on right side worn.
c/m: replaced guide plate and adjusted chains.
r/c: yes timing. what: okay conveyor stuck.
why: one chain really tight.
c/m: adjusted chains
recur: timing what: okay conveyor wouldn't move. part jammed at bottom of tub.
why: key fell out of gear box.
c/m: removed gear box and put key way in and locked set screw.
recur: timing what: only getting cav. 3&4s on the table
why: parts jamming cav.1&2 flippers from advancing
c/m: pulled trim press and removed jammed parts what: op door wont lock
why: safety switch key broken
c/m: replaced safety switch key what: op side vacuum blocks blowing
why: blue hose not connected at the manifold
c/m: trimmed black hoses checked filters and concentration and re-attached blue hose at the manifold what: operator asked about filter in Absolent mist collector unit reading high
c/m: changed filters in mist collector (11c tag on gauge) what: operator called and said they have no power to mold heater, operator door safety switch not functioning, and squeeze pins not operating in auto
why: breaker tripped on mold heater. operators wer what: operator called because they couldnt get upper lid to open and AL01 alarms on exhaust temp controller
why: upper stack wasnt pushed back all the way making limit switch. exhaust thermocouple was what: operator called for an excess error.
could find no alarm made on robot pendent under fault log... only thing i was able to find was a broken mtor connector on J3
Had operator start machine and what: operator called for cavity 2 going to scrap conveyor while all other cavities are going to ok conveyor
why: solenoid never engages. had to pull trim press. flipper 1 never switches state. should what: operator called for lot mark spec issues. out of spec on negative side
why: digital indicator was set up wrong. giving negative readings when should have been positive. somebody must have hit th what: operator called for metal leak
why: after melting out upper crucible, pulled stack back and crucible was cracked above spout. having operator run lower crucible out and scrape the upper crucible what: operator called for noisey trim press hydraulic tank
why: had operator confirm oil level. suction filter was ng
c/m: replaced suction filter
reoccur: in time
cnt: unaffected what: operator called for product detect lights not working
why: product detect sensors are working correctly but the wiring to the product detect lights were ripped out of terminals. not sure how. mo what: operator called for spray cassette drifting down when in auto, faulting machine for robot fault
why: spray cartridge drifts down about an inch and is losing upper limit sensor on spray cassette what: operator called for water leak
Why: fitting in die was broken causing a leak
C/M: replaced fitting on die and now back in production what: operator called saying ladle wont move
why: holding crucible safety door switch wont make on safety panel. wire 1 was pulled out of safety gate latch terminal
c/m: put wire 1 back in its proper what: operator called saying they couldnt dump scrap in semi-auto but could dump scrap in manual
why: damper close limit switch was always engaged on crucible panel, even when damper was open
c/m: dis what: operator called stating they cant get spray cartridge home light to start machine up
why: up end sensor for spray cartridge cylinder would not light up. stuck off. tried using magnet and still w what: operator called, stating the ok conveyor bucket is getting stuck when returning
why: excessive slack in chain
c/m: adjusted tension to chain for ok conveyor. confirmed operation before turning o what: operator changing vacuum block said it was stuck
why: unknown told no details on what happened prior to page
c/m: removed block turned back over to production
reoccur: possible what: operator claimed machine was faulting/ killing hydraulic pump
why: unknown
c/m: Checked safety doors, checked side side covers, installed bolt on machine side side cover. Turned over to producti what: operator could not get trim press to master on or get the squeeze master hydraulic pump to start up. also had emergency stop faults
why: squeeze master issues were related to injection cover not what: operator found water leak from from fixed side die
why: sprue bushing was ng
c/m: replaced sprue bushing
reoccur: timing what: operator had robot fault and used buttons on side of trim press gate to return robot home. robot ran into helper side door. OVC fault on pendant.
why: buttons on trim press gate does not work wh what: operator had water leak
why: spray cartage valve leaking by
c/m: replaced leaking valve and verified no leak after replacment what: operator having axis 1 alarms
why: axis 1 would intermittenly jump up out of range. stroke would keep climbing on axis 1 even when valves were closed. noticed valve nut was down to far keeping v what: operator is unable to get green auto start button to light on operator panel for full auto running
c/m: TOOK ROBOT OUT OF STEP PROGRAM..... what: operator knocked upper limit probe mount into holding crucible
why: operator accidently knocked it in when cleaning slag from crucible. <-- this pulled wires out of terminals and everything is c what: operator on 2nd called and said quality shut machine down due to area 1 trim on cavity 2 being too deep
why: had operator get me 10 shots onto ng conveyor. noticed runner to part, on cavity 2, w what: operator said spray cartridge is leaking from line
why: bad spray valve
c/m: replaced spray valve and confirmed leak fixed
reoccur: in time
cnt: unaffected what: operator side slide core leaking water
why: crack in water line piping into die
c/m: replaced section of pipe with new from die maintenance area
reoccur: possibly what: operator stated robot would not home
why:crashed into trim press/ extra shot in trim press
c/m: opened helper side door and used homne program to send robot home. Cleaned out trim press what: operator top tappet pin bent
why: operator noticed it and paged E/S
c/m: replaced tappet pin on operator top side as well as the operator top and helper top slide cores while we had access to th what: operator tried to recover robot and had robot out of cycle. when I recovered robot, it was not getting home position light
why: robot faulted at trim press and robot home limit switch was loose what: over flow tab staying trim die. also causing the robot to fault at scrap cutter. why: not enough air blows. countermeasure: added a air blow to the left side of trim die. recur: no. what: over pour
why: possible slow pour setting off
c/m: tightened lock nut on electro bar to fix ladle electro bar malfunction and turned sleeve and adjusted slow pour from 30% to 20% per plex to sto what: part detect sensor broken, servo 37 fault. squeeze master fault.
why: part detect sensor was broken and fan in servo drive stopped spinning. then squeeze master faulted out causing die not to op what: part request for lot mark pins what: parts request for lot mark pins what: parts sticking to the plunger tip
why: plunger tip NG
c/m: replaced tip and adjusted plunger spray tip what: parts table 2 stopped turning. why: chain come off sprocket. countermeasure: replaced table with rebuilt one. recur: time. what: pass on from 2nd, die making noise while in operation
why: plunger shaft water off
c/m: Turned water on to plunger shaft what: passed on that a wheel on the tower was bad and tower would not move forward all the way
why:: found a piece of aluminum on the lid tat would not allow the tower to slide to its home position
c/ what: passed on to 3rd that operator safety door switch was broken
why: door was slammed shut with bent key, breaking the switch
c/m: replaced switch. straightened key out. confirmed switch operation
what: passed on water leak at diecast 3
why: sleeve cooling joint leaking. joint bent and broke at threads. this will be 3rd one replaced on this machine in last 2 days
c/m: replaced sleeve cooling jo what: phantom metal leak
why: possible corrosion in metal leak probes
c/m: cleaned corrosion off of left probe what: plug gauge no good on go. Why: bad slide core. CM: changed P1 slide core. what: plunger lube leak back by sleeve
why: loose elbow fitting on plunger lube line
c/m: tighten fittings. verified leak gone. plunger tip in good positioning. collar and sleeve in good positioning
r what: plunger lube not spraying correctly
why: spray tip loose
c/m: tightened spray tip and adjusted what: plunger lube not working
why: air pressure set to high
c/m: clean out pick up tube, adjust air pressure what: plunger lube pump ng. countermeasure: replaced pump. recur: time what: plunger tip life
WHY: tip had 26,257 shots
C/M: replaced plumger tip what: porosity
why: Sprue bushing leaking 6A0-S part
c/m: replaced sprue bushing what: porosity cavity 2
why: spray cartage leaking, temperature running on low side
c/m: replaced NG valve on spray cartage, no leaks. Adjusted temperatures to allow die to run mid range on monitor. o what: porosity cavity P1
why: spray points off location, op side vacuum block turned off at valve
c/m:adjusted spray points for P1. Turned vacuum block valve on for operator side, verified operation o what: porosity in all cavities
why: leaking spray valves
c/m: replaced 5 valves checked spray points and cleaned plunger lube and flashing from around tip and sleeve. what: porosity in all cavities
why: vacuum issues and spray point issues
c/m: put a .010 shim behind robot side chill block replaced inlet filter and cleaned the canister filters adjusted spray and bl what: porosity in cav.2
why: bent squeeze pin and leaking squeeze cylinder
c/m: replaced both squeeze pin and top operator side cylinder cavity 2 from die F-11 Per M. Hoffman. what: porosity in cavity 1 and 2
why: leaking spray cartridge
c/m: replaced 4 leaking spray valves what: position configure change alarm when sending the robot home using the side buttons and pendent
why: possibly the robot lost its positioning and didn't know where it was at
c/m: used pendant to j what: primary and power melted in conduit melted together. R/C: Aluminum leaked on conduit.
C/M: Replaced and rerouted conduit, replaced wires. Reoccur: no. what: product detect faults
why: #4 product detect sensor not reading part properly
c/m: adjusted sensor and touched up robot position 16 what: product detect faults
why: product detect sensor NG
c/m: replaced sensors what: product detect issues
why: sensor for product detect got bumped
c/m: retaught all positions
reoccur: possibly what: product detect not seeing all cavities
why: top right product detect sensor for cavity 2 was loose. out of position
c/m: adjust loose product detect sensor to see part and tighten in place. conf what: product detect sensors not staying adjusted
why: mounting bolts inside the sensor housing was loose on cav.2, 3 and 4 possibly due to adjusting with the sensor clamps still gight
c/m: tightened what: pump overload
WHY: pump life
C/M: replaced pump and changed the oil what: pump overloadon squeeze master
why: unknown/ bleeding squeeze master at time of fault
c/m: reset and bled squeeze master. turned over to production what: refractory fell out of side door, needs re-patched
Why: ?
C/M: Tear out old existing patch and Put new in
Recur: In time what: remelt bin rear wheel broke
why: wheel severely worn down
c/m: replaced both back wheels with new ones
reoccur: in time what: replaced thermal coupler
(no down time running as normal- forgot to clock out) what: reported hydraulic leak
why: small hydraulic puddle on top by squeezae master lines
c/m: inspected lines for leaks none found, puddle very small by lines looks like amound due to removal and ins what: request for a 1.0 ladle what: request for a ladle what: request for a ladle
why: broken
c/m: replaced ladle what: request ladle
why: ladle arm issues, cup had aluminum in it that cooled
c/m: gave operator new ladle cup what: request tor sprue bushing what: right scale not reading correctly
why: tabs built up under the scale
c/m: cleaned tabs from under the scale and recalibrated and confirmed operation what: robot alarming at scrap press
why: at trim press shot was getting moved during operation in robot hand causing it to fault at scrap press
c/m: touched up trim position and scrap press positions
what: robot collision detect ant the trim press
why:
c/m: replaced missing cav.4 (block 5) and 2 (block 1)overflow blocks. touched up robot positions 25 and 26 what: robot collision detect faults.
why: program errors
countermeasure : checked plunger lube concentration good. checked robot pos. all seemed to be ok. moved trim up a little bit. Made program ch what: robot collision detect in the trim press
why: robot hitting guide pin in the trim press
c/m: touched up positions 58 and 59 what: robot collision detect removing part from trim press
why: trim press part clamp not returning due to robot not setting part in the trim press correctly
c/m: touched up positions 59 and 60 to set what: robot collision faults
why: robot not removing parts from trim press properly
c/m: touched up pr64 when robot removed part from trim press
reoccur: no what: robot collision faults at trim press. why: hitting on trim press. countermeasure: touch-up robot at trim press. recur:no what: robot crash into water tank
why: teaching robot on new model an they hit tank
c/m replaced robot cable what: robot crashed in the trim press
why: small biscuit caused the shot to move
c/m: recovered robot what: robot crashed on large biscuit at die.
why: biscuit to large and hit chuck.
c/m: touch up robot points at trim press and take out.
r/c: no what: robot crashing at mid point
why: undetermined
c/m: touched up lines 236 and 237 for mid way drop off point what: robot crashing at mid way drop
why: part not setting on alignment pins properly
c/m: cleaned debris off chuck fingers and touched up robot lines 237 (p93) and 238 (p54) what: robot crashing at the trim press
why: shot falling apart leaving tabs in the trim press
c/m: adjusted spray points and spray and blow timers per plex settings. what: robot double stacked in trim press
why: scrap left behind
c/m: removed scrap and recovered trim press. what: robot dropping parts
why: broken bolt on robot chuck arm
c/m: drilled out and removed broken bolt from chuck block (did not have new) replaced bolt along with both trim press part clamp
reoccur: what: robot dropping parts
why: broken claw bolt broken
c/m: replaced shoulder bolt and mounting block along with part pusher return air line on trim press what: robot dropping shot at product detect
why: plunger lube tip bracket broken
c/m: repaired bracket and replaced plunger lube tip along with replacing bad chuck sensor on the robot what: robot fault
why: chuck sensor NG
c/m: replaced chuck sensor what: robot fault at trim
why: part sitting wrong onto stationary causing collision detect
c/m: Touched up part positioning at stationary for part to sit on jig what: robot faulting at trim press
why: lots of build up on runners not allowing shot to sit in trim press flat
c/m: die is being ran to life per craig. touched up p24 and p25 to allow shot to sit fla what: robot faults
why: chuck hand staying closed never opening
c/m: replaced ng sensor up to box
reoccur: no what: robot faults
why: looked like robot was crashed at the re-grab position before trim press
c/m: straightened out a bent re-grab pin and had to teach robot at re-grab
reoccur: in time
cnt: unaffec what: robot faults
why: loose connection on chuck open sensor
c/m: tightened connection. then found the trim press part pusher not returning causing collision detect. adjusted pusher switch and confir what: robot faults
why: shot slipping when coming out of die and faults at trim press. ejector pins limit was set at 47 when they shouldve been set at 28.
c/m: changed ejector limit back to 28. craig what: robot faults at trim press
why: positon/ part catching on trim press
c/m: adjusted position 25/26 at trim press what: robot faults.
why: chuck sensor ng.
c/m: replaced chuck sensor on robot.(xo11).
r/c: no. what: robot faults. robot wont go into die to pick up shot.
WHY: x41 stuck on relay no good
C/M: replaced RY2 relay what: robot getting collision detect when in trim press
why: no soft float at the trim press causing collision detect when trimming
c/m: added a soft float after position 26 (line 252) through trim cy what: robot leaving shot in trim press randomly
why: after the double clamp the chuck fingers wasn't grabbing the biscuit
c/m: touched up robot position 24 what: robot leaving shots in the trim press
why: cry092 relay bad
C/M: replaced relay
REOCCER: yes timing what: robot move error excess faults
why: trim press part detect sensor out of adjustment
c/m: adjusted part detect sensor what: robot move excess fault
why: undetermined
c/m: changed robot program from type 06 rpy mid to type 04 rpy mid what: robot move faults
why: cav.2 part sticking to the top guide pins on the trim press causing shot not to get trimmed and causing the move fault
c/m: straitened and cleaned guide pin what: robot not getting its home light and collision detects in the trim press
why: at home limit switch not made
c/m: adjusted limit switch along with adjusting cav.3 product detect sensor, and touch what: robot not moving from the product detect sensors
why: possibly the previous fault was not cleared from the pendent
c/m: reset the robot using the pendant and monitored what: robot not returning home
why: possibly robot lost positioning
c/m: used pendant to return robot to home position. what: robot not returning home
why: robot hit the door when operator hit the go home button for the robot
c/m: used pendant to return the robot home what: robot pulling shot out of the trim press before it trims
why: possibly dirty trim press part detect sensor causing the robot to pull the shot out too soon
c/m: cleaned sensors what: robot will not go into auto running
why: Type not set for robot
c/m: Verified parts running and set type with push button on robot control panel once set robot able to run correct program and go what: robot wont move
why: helper door not open all the way
c/m: opened helper door to get it open light what: safety clamping device fault
why: x505 staying on limit switch fault when closing
c/m: hooked up to plc and seen x505 flickering. replaced sensor x505 what: safety door frame fell apart. countermeasure: remount frame back up. recur: yes needs supports and extra brackets what: safety door melted. countermeasure: replace door. what: safety door switch bad (operator side)
WHY: electric switch bad
C/M: replaced door switch
REOCCER: YES TIMING what: safety gate switch by crucible not resetting
why: wire shorting what: safety gate switch for upper crucible loose
why: loose bolt
c/m: tightened loose bolt what: safety hook not coming out
why: operator error, air got turned off
c/m: turned air on what: safety latch broken on ingot loader
why: wear
c/m: Replaced safety latch and holder on ingot loader door what: safety switch for charging loader door broke off mounting plate
why: stripped out T-rail nuts
c/m: removed damaged t-rail nuts, replaced with larger t-rail nuts what: scrap c/v jammed up bending the guards, upper limit probe wire broke at terminal what: scrap conveyer 1 jammed
WHY: overflow stuck in chain link
C/M: broke overflow piece out of link
reoccer: yes timing what: scrap conveyer 2 jamming
WHY: missing cotter pins
C/M: replaced cotter pins on 5 different links
reoccur: yes timing what: scrap conveyer jamming
why: missing cotter keys
cm: replaced 15 cotter keys and 1 master link plate what: scrap conveyor #1 motor overload and vacuum problems op side
why: conveyor; tab stuck in chain. vacuum; dirty vacuum filters and black vacuum hose pinched in the back tip and sleeve cover.
c/m: what: scrap conveyor 1 jammed
why: over flow tab stuck in the chain
c/m: removed tab what: scrap conveyor 1 jammed up
why: excess broken pieces of sprew/gate stuck in chain links and sprocket
c/m: removed c/v unit from machine, extracted pieces of sprew/gate from chain links and sproc what: scrap conveyor 1 jamming up
why: bad roller
C/M: Replaced roller and cotter pins
Recur: Yes in time what: scrap conveyor 1 locked up. why: scraps from trim press jammed in chain. countermeasure: replace with rebuilt conveyor. recur: time. what: scrap conveyor alarms
why: x99 on scrap press damaged not seeing reflector
c/m: Replaced x99 what: scrap conveyor faults /overload
why: part jammed in conveyor side
c/m: Removed conveyor and removed jammed part, reinstalled and verify operation what: scrap conveyor jam up
why: Cotter key missing allowing roller to flip and jam conveyor.
c/m: Removed damaged rollers and replaced, installed cotter keys on shafts and verify no missing keys in what: scrap conveyor jammed
why: a piece of scrap stuck in the chain
c/m: pulled conveyor and removed debris what: scrap conveyor jammed
why: broken link
c/m: replaced broken link and rod and 15 cotter pins what: scrap conveyor jamming
why: missing cotter keys
c/m: replaced 16 missing cotter keys, 2 chain links and 1 pin what: scrap conveyor jamming up
why: broken link in the chain jamming on the rails
c/m: replaced link and cotter pin what: scrap conveyor jamming up
why: missing cotter pins
c/m: pushed 10 connecting pins back in and replaced the missing cotter pins what: scrap conveyor jamming up
why: over flow tabs built up on the inside of the scrap conveyor
c/m: removed over flow tabs and confirmed operation what: scrap conveyor not working what: scrap conveyor problems
Why: missing cotter pin
C/M: replaced missing cotter pin. what: scrap conveyor scale not working properly.
why: advance and return sensors were out of place
C/M: adjusted advance and return sensors now working properly. what: scrap cv not operating
why: manual override cover knocked off
c/m: Straitened manual override box cover and reattached. verified operation what: scrap press guide bearing ng.
why. bearings fell out of sleeve.
countermeasure: replace bearings.
recur: timing. what: scrape on the part
why: soldering buildup on the die
c/m: cleaned the die what: scratch on the part
why: nick in the die causing scratch on the part when the robot pulls part out of the die
c/m: cleaned aluminum off of the nick. still a light scratch on the part. nothing what: screen on squeeze master blank
why: No power to screen, 24v power supply NG
c/m: replaced DrU1 24v power supply in squeeze master, set 24v output and verified screen operation what: secondary hole too deep on water passage die F-10
why: tack weld holding the squeeze cylinder adaptor broke causing it to un screw making the hole too deep
c/m: re-welded the cylinder adaptor an what: secondary pressure hole out of spec/fluctuating
why: squeeze master needed bled out
c/m: bled the squeeze master out a couple of times
reoccurr: possibly what: servo037 (IMSTP input) alarm on the robot
why: die cast machine in die change mode
c/m: took out of die change mode and reset robot what: sheet metal under tip/sleeve area bent
why: scraping out with tool pulled metal back allowing water lines to catch
c/m: Removed plate and strained, reinstalled and installed bolts to hold plate what: shot malfunction alarms..
why: Shot detect sensor ng.
c/m: Replaced shot detect sensor, origin reset the shot stroke and verified 0.0 position.
Reoccur, timing what: shot position sensor faults
why: shot positioning sensor dirty
c/m: removed sensor and cleaned area, cleaned sensor and reinstalled. verified returning to zero position what: shot position sensor wire break alarms
why: debris on the shot sensor
c/m: cleaned debris off the sensor. when we tried to run the die height was off due to the backing plate losing its origin. what: shot position sensor/wiring fault
why: attrition c/m: replaced shot sensor. what: shot position wire break alarms
why: debris on the shot sensor
c/m: cleaned sensor what: shot sensor not reading correctly
why: sensor NG
c/m: replaced shot sensor and re-zeroed what: shot sensor wire break alarm
why: debris on the shot sensor
c/m: cleaned debris off shot sensor and re-zeroed what: shot sticking 2 tip
WHY: tip loose and plunger lube spray out of position
C/M: replaced plunger tip and adjusted spray
REOCCER: yes timing what: shot sticking to tip
why: wear
c/m: replaced tip and verified lube what: shot stuck in die
why: Mov core 2 not reading it is return so ejector will not eject part.
c/m: Found mov core 2 wiring not connected. Re connected and verified operation and reading moveable c what: shot wont home. Keeps climbing by 5mm each time you inject and return what: shots sticking to the tip and low high speed shot alarms
why: tip and sleeve worn
c/m: replaced tip and sleeve what: side door chunked out
why: Build up from operators scraping leaving aluminum on face then trying to knock off and it breaks off in chunks
c/m: patched furnace by side door
Recur: In time what: sleeve cooling joint leaking water
why: cooling joint broken
c/m: replaced cooling joint what: slide core malfunction what: slide core move 2 faults
why: root cause unknown
c/m: swapped upper and operator side reed switches from another die, tightened hydraulic coupler. what: slide core replacment, cavity 2
why: buildup in roller groove QA deem out of spec
c/m: Replaced cavity 2 op top side slide core, verified no leaks after install. printed confirmation paperwork what: slide core spec cav. S2 5BA P&S Die F-9 chunking out part
why: slide core had a burr
c/m: replaced slide core what: slide core spec issue
why: chip and crack in 5BA die F13 slide core S-2
c/m: replaced s_2 slide core what: slide core spec issues
why: slide core had a crack
c/m: replaced cav. S2 slide core what: slide core spec problems
why: chunk in the slide core causing a burr
c/m: replaced slide core cavity P1 on 5BA P&S die 9 what: slide core spec problems
why: cracked slide cores
cm: replaced P1 and P2 slide cores on 5A2 die F-32 what: slide top core sticking
why: possible dirty die release filter
c/m: cleaned filter and checked concentration what: small amount of plunger lube leaking when lube in injected
why: fitting worn
c/m: Replaced worn fitting and verified lube ok
turned over to operator for production what: small biscuit size
why: aluminum built up around the ladle collar not allowing it to pour properly
c/m: removed aluminum around ladle and adjusted the pour what: sodering / Ingot loader not operating
why: buildup on slide core, cleaned. LS NG for identifying ingot in position
c/m: cleaned buildup. Replaced LS33 on ingot loader, verified loading operation what: soldering on cavity 2
why: buildup in die
c/m: die cleaning on cavity 2 what: soldering on parts, leaking hose
why: soldering common on parts, hose had a laceration causing leak (yellow zipties on fitting, water line running above helper door)
c/m: cleaned die with alclea what: solenoid to the furnace head door broken. why: loading ingots countermeasure: replaced. recur: no what: spec on cavity 4 bottom slide core out
why: aluminum buildup on part due to NG slide core
c/m: replaced cavity 4 bottom slide core, quality sheet printed and turned over to production what: spray cartage leaking water
why: valve for spray NG wear
c/m: replaced worn valve and verified no leaks what: spray cartridge
why: unknown
c/m: wait and see what: spray cartridge base pedestal mounting bolts broken. 3 out of 4.
why: vibration, bolts loosened then broke off.
c/m: drilled broken bolts out and replaced.
r/c: possible with time. what: spray cartridge issue
why: air blow not coming on, electrical socket broken on solenoid.
C/M: Replace valve and replaced plug what: spray cartridge leak
why: bad valve on block causing it to leak through cartridge
c/m: replaced bad valve after testing without cartridge to see where it was leaking from what: spray cartridge leaking
why: 2 spray valves NG
c/m: replaced 2 spray valves what: spray cartridge leaking
why: spray valve NG
c/m: replaced 2 spray valves what: spray cartridge leaking
why: spray valve NG
c/m: replaced 3 spray valves what: spray cartridge leaking
why: valve ng
c/m: replaced valve what: spray cartridge not spraying die release
why: bad die release pump
c/m: replaced pump what: spray cartridge not working in full auto( manual ok)
why: unknown
rootcause: unknown
countermeasure: none
reoccur: unknown what: spray cartridge wont get home pos
why: x40 sensor dead
c/m: replaced sensor what: spray lube bracket came loose.
why:
c/m: adjusted and tightened up. replaced fitting on plunger tip.
recur: timing what: spray tip clogged
why: over pour causing aluminum to pour on the spray tip
c/m: replaced spray tip, adjusted spray and turned sleeve to stop the over pour what: spray tip collar out of adjustment
why: attrition
c/m: adjusted spray to injector what: sprue bushing leaking
why: crack in weld
c/m: replaced sprue bushing what: sprue bushing leaking
why: sprue bushing NG
c/m: replaced sprue bushing on RPY die F-30 also replaced tip and sleeve due to excessive blow back. confirmed plunger spray working correctly. what: sprue bushing leaking water. Why: Cracked sprue bushing. CM: changed sprue bushing. what: sprue bushing was leaking
why: it had a crack letting water leak out
c/m: replaced sprue bushing
reoccur: in time what: squeeze master channel 1 not returning.(After die change)
Why: Valve not shifting.
R/C: Valve is bad.
C/M: Replaced valve.
R/O: Timing.
Cycle Time: NO Change what: squeeze master pump wouldn't power on
why: breaker tripped on inside
c/m: reset breaker what: squeeze master very noisy.
why: filter in ng range.
c/m: replaced filters and cleaned suction filter.
recur: timing what: squeeze pin cavity 2 spec
why: Cavity 2 squeeze pin cylinder NG, not holding correct pressure allowing oil to blow by within cylinder
c/m: DH to replace die, Cavity 2 bleed and stroked, stroke what: squeeze pins not returning
why: pressure adjusted to low after change over from 1rkr to breather baffle
c/m: switched manifold hoses to correspond with the correct cavity. line bled and adjuste what: squeezemaster issues (wont run axis faults)
found a leak in die hydraulic line - replaced fitting passed on to DH and 3rd what: stage 1 hepa filter out of spec
why: filter reading high
c/m: Replaced both stage 1 hepa filters, all in spec what: steel hydraulic pipe leak
why: attrition
c/m: removed pipe fortigwelding what: temp C low temp alarms (movable side)
why: possible trial of mold heater @155 degrees and water valves open
c/m: monitored and noticed it took 20 extra shots for the movable side to heat up. run what: temp issues B and D
why: thermocouple hooked up incorrectly
c/m: Removed A and B thermocouple and swapped connections. C and D thermocouple and swapped connections. After reconnected temperatur what: testing of operators switches. why: melted from Crucible spout being clogged up.(wo 19744) countermeasure: changed wiring on spray equipment switch. removed 2 switches from die-cast 6 for ladle what: the scrap press fell apart.
why: vibration.
c/m: re-tapped main mounting bolt put a little bolt in.
r/c: timing. what: thermo coupler melted on cuisible.
why: worn.
c/m: replaced
recur: no what: tie bar sensors melted. operator said it caught on fire.
why: unknown. heavy amount of die lube could cause fire.
c/m: replaced sensors "NON INVENTORY SENSOR" what: tip and sleeve life (93,802 shots)
countermeasure: changed tip and sleeve
why: life.
r/c: timing what: tip and sleeve.
why: worn sleeve. change-over 59b tensioner to 59b rocker. (8033 shots).
c/m: new tip and sleeve.
r/c: yes timing. what: tip making noise when injecting
why: no lube from spray tip. tip had been clogged
c/m: replaced tip and sleeve and confirmed plunger lube what: tool life on tip and sleeve.
why: life.
c/m: replaced.
r/c: yes.
TOOL LIFE: 98,516 what: top slide core hydraulic hose leaking
why: wear
c/m: replaced hose with non-inventory what: touch up robot for model trial 6A0 m parts.
why: not touched up after j1 axis motor replacement.
countermeasure: run the program and touch up.
r/c: yes until all parts on ran on m/c what: tower lid wont close
why: tower wires not plugged in all the way
c/m: plugged in wires and adjusted air flow to the cylinder what: tower lid wont open
why: tower forward limit switch not made due to the tower wiring bending limit switch arm
c/m: straitened arm and re-routed wiring what: tower not getting forward limit
why: welds broke on the stop plate
c/m: cleaned and welded bracket back on what: trim damage what: trim damage
why: burr on the punch
c/m: cleaned burr what: trim damage
why: robot chuck finger loose
c/m: tightened chuck finger, cleaned cutter and touched up robot positions 59 and 60. found broken bolts on inside cutter. removed trim die to repair br what: trim damage
why: worn cutter guide
c/m: replaced
reoccur: yes - time what: trim damage
why: worn out cutter
c/m: replaced cav #4 tappet cutter and cleaned build up off all other cutters what: trim damage
Why: Overflow pieces being left on die
C/M: Switched out air blow to only bottom of die
Recur: Possibly in time what: trim damage
why: robot tooling end bent
c/m: replaced tooling arm on robot, re-teaching set down position in trim press
reoccur: timing
cnt: unaffected what: trim damage ----
why: unknown cause at this tme
dh took over while i was at lunch and resolved problem what: trim damage cav. #1
why: worn out cutter
c/m: replaced cav. #1 cutter trim die #1 what: trim damage cav. 1 (5BA M die 2)
why: cutter worn
c/m: replaced cutter and touched up robot position 43 and 44 what: trim damage cav. 2 and 3
why: build up on cutters
c/m: cleaned cutters what: trim damage cav. 2 and 3
why: buildup on cutters
c/m: cleaned cutters what: trim damage cav. 2 and 4
why: build up on the cutters
c/m: cleaned cutters what: trim damage cav. 4 vacuum side
why: buildup on cutter
c/m: cleaned buildup on cutter and checked for damage. OK what: trim damage cav. P1
why: worn cutter cav.1(5A2 trim die 2
c/m: replaced cutter and touched robot positions 262 and 261 what: trim damage cav. P1 and S2 5BA Die F-13
why: build up of material on the tree connecting the part
c/m: production changed die what: trim damage cav.1
why: robot position off
c/m: cleaned cutter and touched up robot position 26 and 27 and had quality confirm parts what: trim damage cav.1
why: build up on cutter
c/m: cleaned cutter what: trim damage cav.1
why: undetermined
c/m: changed out trim press and cleaned die and lower slide cores what: trim damage cav.1 tappet area
why: worn cutter (59B 1rkr trim die 2)
c/m: replaced cutter what: trim damage cav.2
why: build up on the cutter
c/m: cleaned cutter what: trim damage cav.2
why: tab cutter out of adjustment
c/m: cleaned build up off cutter and adjusted what: trim damage cav.2
why: worn 26L cutter
c/m: replaced cutter and touched up robot positions P25 and 26 what: trim damage cav.2 (trim die 2)
why: build up on cutter
c/m: cleaned cutter what: trim damage cav.2 (trim die 3)
why: build up on cutter
c/m: cleaned over flow cutter what: trim damage cav.2 tappet area
why: change over
c/m: cleaned cutters and touched up robot positions 25 and 26. then getting robot collision detects and re-touched up position 26. operator confir what: trim damage cav.3
why: build up on cutter
c/m: cleaned build up off of cutter what: trim damage cav.3
why: build up on cutter
c/m: cleaned cutter and adjusted the air blow to remove overflow tabs from trim press what: trim damage cav.3
why: loose cutter
c/m: cleaned cutter and added missing lock washers what: trim damage cav.3
why: robot not setting shot strait into the trim press
c/m: cleaned cav.3 cutter and adjusted robot position 24 and 25. what: trim damage cav.3 and 4 tappet area
why: possible debris on inside tappet cutters
c/m: cleaned cutters and had quality confirm parts what: trim damage cav.3 tappet area
why: robot positioning
c/m: touched up robot position 25 and 26 what: trim damage cav.4 and 1 over flow tab (trim die 3)
why: build up on cutter
c/m: cleaned all 4 cutters and touched up robot positions 24 and 25 what: trim damage cave 1 and 2 around the tappet
why: worn out cutters
c/m: replaced tappet cutters on cav. 1 and 2 on trim die #2 what: trim damage cave#3 (rpy/5Ba trim die 2)
why: cutter wear
c/m: replaced cav. #3 cutter and confirmed trim what: trim damage cavity 1
why: cutter contacting shaft area of part causing mark
c/m: removed cutters and guides and cleaned, reseated guides and cutters. Ran test parts by hand ok. ran in full auto what: trim damage cavity 1
why: cutter moved
c/m: removed cutter. cleaned burrs on cutter. cleaned cutter cavity. placed cutter and stamped a few shots to confirm trim damage was gone
reoccur: in time what: trim damage cavity 1
why: upper die burr on cavity leaving dent on top of part
c/m: Removed burr build up and turned over to production what: trim damage cavity 1 and AL01 alarm on melting crucible on temp controller
why: AL01 alarms coming from a bad thermocouple in melting furnace. trim damage coming from burr on cutter and broken s what: trim damage cavity 1(die #2)
why: Rear cutter moving in trim press
c/m: Rear cutter damaged allowing to move In trim press, removed rear cutter from die #3 for cavity 1. part quality ok after re what: trim damage cavity 2
why: burr on cutter for cavity 2
c/m: removed burr with stone and stamped 5 shots with no trim damage
reoccur: in time what: trim damage cavity 2 and 3
why: rear cutter in trim die #2 59B one rocker
cm: Pulled and cleaned cavity 2 and 3 for rear cutter reseated, verified by operator trim ok what: trim damage from viborater and robot dropping parts
why: loose bolts on the clamp arm of the robot
c/m: replaced bolt and added lock washer on clamp arm to stop it from loosening and replaced da what: trim damage on P1 and S1 tappet area (5BA trim die 2)
why: build up on the cutters
c/m: cleaned cutters what: trim damage on S1
why: buildup on cutter and robot position off
c/m: adjusted robot position 24 and 25 and cleaned cutter what: trim damage on cav. 2
why: worn cutter
c/m: replaced 26L cutter what: trim damage on cav. 3
why: build up on the cutter
c/m: cleaned debris off cutter what: trim damage on cav. 3. along with tabs getting stuck on cav. 3
why: broken guide on trim press #1 along with broken bolt
c/m: changed out trim press #2 with trim press #1. had to replace missing what: trim damage on cavity 1 (trim die #3)
why: tab cutter worn out
c/m: replaced cutter on cavity 1 what: trim damage on cavity 2
why: unknown
c/m: cleaned cutter, cavity, and shim what: trim damage on cavity 3 what: trim damage on cavity 3
why: worn out cutter
c/m: replaced cutter what: trim damage on m2
Why- Support block that sits opposite of the cutter where the trim height was occurring was not tight on the part, allowing it to move during trimming.
C/M- Tightened support b what: trim damage on the top of the part
why: punch leaving a mark on the top of cav.#1
c/m: cleaned punch and cutters what: trim damage to parts what: trim die breaking off pieces
why: trim die set too low
c/m: adjusted height of trim die what: trim height issues on cav.1 6A0 M
why: shot not sitting in the trim press correctly
c/m: changed trim press and touched up robot positions 25 and 26. had operator confirm trim height what: trim height ng. on M1 and M2 cavity. Also had vacuum issues.
Why- Vacuum block wasn't in die properly causing shots to bend. Also the whole operator side of the spray cartridge wasn't spraying what: trim height on p-1 and p-2. Why: cutter needed adjusted. countermeasure: removed rounded out bolts and adjusted. recur: no what: trim height out of spec on cav.3 tappet area
why: worn cutter
c/m: replaced cutter and missing shims (A6: .10 and A8: .20) what: trim issue/ punch
not always knocking off the trim at punch .. retaught robot positions 3 x then it leaves a piece of trim and faults what: trim press (59B chain tens) crashed
why: broken guides
c/m: replaced broken cav. #1 inside guide along with broken cav. #4 inside guide and broken bolt and cav. #4 damaged punch what: trim press alarming out with no indication light
why: possible dirty scrap press part detect sensor
c/m: cleaned scrap press sensor what: trim press clamp solenoid valve replacement
why: from work order #62650. used valve to repair DC #5
c/m: replaced valve with non-inventory what: trim press cylinder bleeding down during cycle
why:
c/m: replaced adv/ret solenoids for trim press, replaced dcv valve feeding hydraulic fluid thru block to trim press and scrap press cylinders what: trim press damage cavity 4
why: cutters damaging part
c/m: adjusted cutters
reoccur: timing what: trim press damage to cavity 1 up near tappet
why: burr on cavity 1 push block
c/m: trim press plunger ok. cutters ok. robot ok at trim press. removed burr and ran a few shots, no longer mark on what: trim press double stacking
why: cross sensor not reading part
c/m: adjusted sensor what: trim press drifting down loosing home position
why: trim press cylinder leaking by
c/m: replaced trim press cylinder and verified operation what: trim press drifting down losing start position
why: return sensor was on the edge of being made, possibly losing return sensor
c/m: adjusted return sensor lsx020 what: trim press faulting
why: product detect sensor reading part
c/m: cleaned sensor and area confirmed location and verified will catch part/no part operation. turned over to production what: trim press faulting
why: door open/ safety sensor on flashing at fault, Found air blow Y06E causing 24V short allowing contactors to chatter.
c/m: chatter from MS1 contactors, unsure of cause. what: trim press faulting while in auto start condition
why: trim press sensor reflector NG not allowing sensor to read properly
c/m: replaced reflector and verified operation of sensor what: trim press faulting/alarming
why: scrap press sensor x99 thinks part left in press
c/m: Replaced NG reflector on sensor x99 to allow sensor to operate correctly what: trim press faults
why: Cavity 2 sticking in top of die
c/m: Removed cavity 2 upper press, cleaned and replaced both locate pins. Reinstalled and verified operation. Top front right trim press sl what: trim press hard line leaking
why: hard line worn out from not bolted to floor moving around wore hole in line
c/m: replaced hard line with flexable and replaced fittings what: trim press hydraulic cylinder leaking fluid on the parts
why: seals in the cylinder NG
c/m: replaced cylinder what: trim press hydraulic pump leaking
why: seals worn out
c/m: replaced pump what: trim press hydraulic pump making noise and no pressure
why: bad hydraulic pump
c/m: replaced pump and filter what: trim press issues
why: relief holes plugged with aluminum debris
c/m: removed tri blocks from die and drilled out aluminum debris and re installed blocks what: trim press issues
why: cutter getting excessive buildup
c/m: replaced cutter, info in W059429 what: trim press loading issues
why: cavity 3 getting trim damage
c/n: touched up robot position into trim press, adjusted cavity 3 guide to get rid of mark
reoccur: possibly what: trim press not going down far enough. why: lock nut came loose. counter measure: adjusted and retightened lock nut. recur: possible. what: trim press stuck down
why: suck part in cav. #4 due to broken cutter
c/m: replaced cav. 4 broken tab cutter and damaged inside guide what: trim press will not operate
why: CP3 breaker trim/ interior light
c/m: Reset breaker and verified light operation. Reset PLC to clear latches. Machine running in auto what: trim press wont clamp
why: solenoid valve not switching.
c/m: what: trim press wont master on
why: trim press was cycled off for over a week, plc battery NG allowing program to be lost
c/m: replaced plc battery, uploaded program into machine. what: trim press wouldn't cycle
why: bad down cycle relay
c/m: replaced relay what: turn table is not moving
why: turn table shaft was broken and sprocket was ate up.
C/M: replaced broken shaft and sprocket with new. what: turn table not moving
why: motor dead and gear box seized.
C/M: replaced motor and gearbox what: turn table one not spinning
why: loose motor bolts allowing drive chain to come off the drive gear
c/m: re-installed chain and tightened motor bolts what: turntable 2 not turning
why: gear head locked up
c/m: replaced two gear heads and motor what: unload not advancing or returning
why: operator error what: unloader not getting chuck light
why: root cause unknown possible part mislocation unloader was found misaligned
c/m: loosened up unloader mounting bolts and straightened unloading unit what: unloading conveyor jammed will not turn
why: conveyor off track on back side
c/m: Adjusted chain to get back on track and verified operation what: upper crucible lid falling apart
why: welds broke/ steel movement allowing guard to become unattached
c/m: removed upper crucible lid and rewelded. Reattached lid and turned over to production f what: upper crucible loading sensor not allowing ingots to load
why: sensor error on loading sensor
c/m: unplugged and terminated plug for sensor, sensor reading properly after retermination. what: upper crucible molten metal leak
why: spout cracked what: upper limit probe holding block broken
why: age/wear
made new block and confirmed operation what: upper limit probes not working
why: probes too short
c/m: replaced probes what: upper limit probes too short
why: wear
c/m: replaced both probes what: upper thermocouple reading
why: coupling pulled out of housing exposing bare wire to ground out on machine
c/m: Reterminated coupling and wiring to thermocouple, reading correctly now what: vacuum air supply shortage
why: air was shut off to the vacuum unit for extended shut down
c/m: turned air on to the vacuum unit what: vacuum alarms
why: vacuum settings
c/m: adjusted vacuum settings per plex what: vacuum block stuck in die
why: spot in operator side fixed die where the block was catching, looks like it was crashed or closed on something at one point in time
c/m: tried cleaning up area to what: vacuum faults
whY: vacuum pump not building pressure, coupler broken. Oil over full in pump
c/m: Replaced broken coupler and motor side gear due to crack. Drained oil in pump to correct amount what: vacuum faults
why: root cause unknown
c/m: cleaned aluminum out of hoses, cleaned out connector joint for hoses what: vacuum faults when die was opening
why: the biscuit was large holding the injection at the vacuum turn on point @220mm. then when the die would open the vacuum would fault out
c/m: turned shot w what: vacuum inlet filter clogged
why: wear
c/m: replaced filter what: vacuum issues
why: changeover problems
rootcause: improper training on die changes and machine setup
countermeasure : removed aluminum - matched settings to plex
reoccur: yes , lack of training what: vacuum issues
why: plunger tip damaged allowing vacuum issues.
c/m: replaced tip and all vacuum lines to die. Verified water on for tip due to water being off. Tip replaced with extra tip/rod l what: vacuum low speed air pressure line leaking, faulting out vacuum pump
why: wear on the hose caused multiple holes
c/m: replaced hose and air fitting
reoccur: possibly what: vacuum no.1 abnormal reach to the tank faults
why: vacuum not recovering in time
c/m: replaced inlet air filter and both vacuum ejectors what: vacuum press faults
why: possibly a hole in OP side clear hose
c/m: replaced clear hose going to the vacuum block what: vacuum problems
why: dirty filter
c/m: cleaned filter what: vacuum problems
why: low pressure. air was shut off to vacuum unit
c/m: opened air valve to vacuum unit and confirmed operation
reoccur: possibly if operators forget to turn air valves back
cnt: what: vacuum problems
why: vacuum recovery time over
c/m: replaced inlet filter and checked others. OK what: vacuum problems operator side.
why: unknown.
c/m: put all setting to plex, on squeeze master.
r/c: unknown. what: vacuum problems.
why: dirty vacuum ejectors.
r/c: war.
r/c: yes. what: vacuum problems.
why : blow back.
countermeasure: changed tip and adjusted operator side spray points.
recur: yes what: vacuum too low alarm during start up
why: possible improper shut down of vacuum unit
c/m: cycled power manually checked operation of vacuum pump and turned to auto what: vacuum trouble
Why: ?
C/M: replaced blocks when die maintenance got here
Recur: In time what: vacuum trouble
why: Robot side line filled with aluminum into line filter
c/m: removed line fiter and cleaned housing of aluminum what: vacuum trouble
why: pump worn not allowing correct pressure
c/m: changed vacuum pump
reoccur: yes timing what: was asked for a ladle by operator
why: changed over, did not have ladle available to them
c/m: gave operator a ladle for their changeover what: was helping steve change slide core when i noticed one of the product detect sensors was hanging on the ground
why: unknown. operator has no idea how it happened
c/m: remounted product detect se what: water hose on moveable die fell off
why: hose clamp failure
c/m: replaced hose clamps what: water leak
why: what: water leak
why: Cooling joint into sleeve broke
c/m: Replaced cooling joint in sleep and fittings. Verify no leak after replacement. Turned over to production what: water leak
why: bad fitting on fixed, rb side of the die
c/m: replaced fittings and water lines what: water leak
why: bad fittings on the water line to slide core P2
c/m: replaced both fittings and confirmed water leak disappeared
reoccur: no
cnt: unaffected what: water leak
why: bottom cooling joint lines on 6A0 m die 6
c/m: replaced leaking cooling lines and checked for other leaks. OK what: water leak
why: broken cooling joint
c/m: replaced cooling joint what: water leak
why: broken sleeve cooling joint
c/m: replaced broken cooling joint
reoccur: yes in time what: water leak
why: cooling joint fitting ng
c/m: replaced fitting what: water leak
why: cooling joint for the sleeve leaking
c/m: replaced cooling joint what: water leak
why: cooling joint sw31 leaking on robot side moveable core
c/m: Removed cylinder and cooling joints, installed new seals on SW31
will it reoccur: timing
cycle time: unchanged what: water leak
why: coupler was leaking
C:M/ replaced coupler and is now running what: water leak
why: crack in the sprue bushing
c/m: replaced sprue bushing
reoccur: yes in time what: water leak
why: crack in the sprue bushing
c/m: replaced sprue bushing on 6A0 M die F-4 what: water leak
why: cracked sprue bushing
c/m: pulled half of die and replaced sprue bushing
reoccur: yes what: water leak
why: fitting feeding water to the upper slide core leaking
c/m: re-taped and tightened water fitting what: water leak
why: movable side bottom water line fitting NG
c/m: replaced water fitting what: water leak
why: movable side main water hose had hole in it
c/m: replaced hose what: water leak
why: o-ring on the main return line on the fixed side NG
c/m: replaced o-ring in the fitting what: water leak
why: spray cartage valve stuck open
c/m: replaced stuck valve and verified operation ok. turned over to production. what: water leak
why: sprue bushing NG
c/m: replaced sprue bushing (6A0 M die F-6) what: water leak
why: sprue bushing leaking
c/m: replaced sprue bushing and checked for other leaks. OK what: water leak
why: sprue bushing leaking/ threads NG
c/m: replaced sprue bushing what: water leak
why: squeeze pin cylinder shaft became misaligned causing coupler to bind and bolts came out
c/m- realign cylinder shaft, install new water fittings and hoses on squeeze pin what: water leak
why: water line running down to the sprue bushing had a hole in it due to blow out
c/m: replaced water line what: water leak
why: plugger tip water lines caught sheet metal while advancing
c/m: replaced male and female ends in plugger tip and lines. Verified no leaks, atachhed water lines so can not rub o what: water leak
why: plunger rod internal rod/seal leaking
c/m: replaced internal rod with now seal. Verified no leak what: water leak Upper slide core
why: on going issue on upper squeeze pin turning allowing water joint to break causing water leak and porosity in parts.
c/m: Removed and replaced squeeze pin and b what: water leak and broken ladle
why: cracked sprue bushing 5ba m die 5. broken 1kg ladle
c/m: replaced sprue bushing and ladle
reoccur: yes timing what: water leak at plunger rod and sleeve
c/m: tightened rod and sleeve what: water leak at plunger shaft.
c/m: replaced fittings on cooling line.
recur: timing what: water leak at sleeve
why: return water line had hole allowing water leak
c/m: replaced line, a lot buildup around sleeve, cleaned and verified ladle pouring what: water leak at tip
why: o ring on internal fitting leaking
c/m: replaced oring on internal fitting of tip rod what: water leak by the tip and sleeve
why: fitting NG
c/m: replaced fitting on the cooling joint what: water leak coming from bottom of die
r/c: sprue bushing ng
c/m: replaced sprue bushing
reoccur: timing what: water leak from cooling joint movable side
why: age/wear
c/m: replaced fitting with non-inventory what: water leak from fixed lower cooling joint fitting
why: fitting NG
c/m: replaced fitting what: water leak from fixed side of the die
why: sprue bushing cracked on RPY P and S die F-7
c/m: pressure tested and found a crack. replaced sprue bushing what: water leak from fixed side of the die
why: the sprue bushing cracked
c/m: replaced the sprue bushing on 6A0 P die 3 what: water leak from spray cartridge
why: spray valves NG
c/m: replaced 2 spray valves what: water leak from the moveable die, back side of the slide core
why: attrition
c/m: Taka X rayed parts and said it was ok to run, he wants an IPP made. what: water leak from the sprue bushing. why: cracked sprue bushing. CC: replaced sprue bushing. what: water leak from under fixed side of the die
why: fitting loose
c/m: applied thread tape and tightened what: water leak in the op side cooling joint lines
why: blow out
c/m: replaced op side cooling joint lines and cleaned aluminum build up on the die. After getting die back together still had water le what: water leak movable side of die
why: cooling joints going into top helper side slide core ng
c/m: replaced cooling joints
reoccur: no what: water leak moveable side
why: water line NG leaking behind die
c/m: Removed hydraulic manifold and replaced NG water line turned over to production after no water leak what: water leak on die
why: cooling hose got between die when doing preheat shots
c/m: Replaced busted water line, ran line so could not get in between die what: water leak on drain box. why: water leaking around Plexiglas of box. countermeasure: re-silicone around edges of Plexiglas. recur: in time what: water leak on fixed side. why: cracked sprue bushing. CC: replaced sprue bushing. what: water leak on main return line on movable side
why: hole in the line
c/m: cut end off where hole was and reconnected what: water leak on main water hose to fixed side die
why: loose female fitting on hose and debris in fitting
c/m: cleaned and tightened fitting. confirmed leak gone after machine was in auto run
reoc what: water leak on sleeve. at cooling joint of sleeve.
why: being hit by tip.
c/m: put a slight bend in new cooling joint.
r/c: yes if build up of blow by. what: water leak on slide core number 1. why: cracked slide core. cm: changed slide core and o-rings on cooling joints. what: water leak on sprue bushing. why. cracked sprue bushing. CC: Replaced sprue bushing. what: water leak on the bottom water hose robot side fixed half
why: worn o-ring
c/m: replaced fitting what: water leak on the lower movable side supply water line
why: wear
c/m: made and replaced copper cooling line and checked for leaks what: water leak on the movable side of the die
why: worn o-rings on water fittings
c/m: replaced main return line o-ring and bottom supply fitting and checked for other leaks what: water leak on the upper RB side slide core
why: slide core cracked
c/m: replaced slide core and cooling joint on RPY die F-7 what: water leak on upper slide core (wp die f-7)
why: cooling joint
c/m: replaced upper squeeze pin and cooling joint and inlet hose. what: water leak top slide core. Why: Broken water fitting. CM: changed water fitting. all good now. what: water leak upper slide core
why: bad water line fitting on squeeze pin for upper slide core
c/m: pulled and tore down cylinder. replaced fitting, water line, and squeeze pin due to wear what: water leak, metal leak and squeeze master issues.
why: water leak- quick connect for the plunger shaft leaking. metal leak-overflow.
c/m: replaced quick connect, bled lines for squeeze master. D what: water leak/ porosity
why: sprue bushing leaking
c/m: replaced sprue bushing on RPY die #2 what: water leaking from bottom of fixed die
why: sprue bushing ng
c/m: replaced sprue bushing
reoccur: timing what: water leaking from fixed op side, side cooling lines
why: small blow out melted the lines
c/m: cleaned die and replaced cooling lines. checked for other leaks. OK what: water leaks on RPY M die F-8
why: bad fittings
c/m: replaced OP and RB top slide core cooling joint fittings and movable side main supply fitting o-ring what: water pressure gauge on die release pump not working check 15
why: gauge NG
c/m: replaced gauge what:" broken tee-bolt
c/m: replaced
reoccur: no what:Melting furnace thermocoupler faulting out.
Cause: extreme heat,normal wear
countermeasure: replaced with new one
reoccur: likely in time. what:air leak from air bowl
why: cracked
c/m: replaced air bowl what:replaced 2000 hr filter
WHy:hour alarm went off
C/M: replaced filter
recur:yes what; AUTO DOOR LOCK NOT WORKING AS ADVERTISED
why: UNKNOWN REASON
C/M: CYCLED MAIN POWER what; ladel wont move in and out or pour
why: lower unit locked up
cm: replaced with rebuilt unit what; scrap c/v overload
why: weight scale or something had it off
c/m: reset overload ran parts off using the contacts M/c3 then machne was able to run what; sodering cavity 1
why: buildup cavity 1
c/m: removed sodering cavity 1 what; water leak fixed side
why: hole in cooling line
c/m: replaced hose on fixed side and checked for leak ok what= tappet pin going though part
C/M= replace pin when setting shot scrap in scrap press the shot scrap would bounce around and would get out of position to where cutters could not cut it or the left over pieces would be left behind in the press why: upper limit probe worn down too short so they have been replaced, replaced wiring.do to length of wire. why? Ladle electrode malfunction faults
why happen? Ladle probe terminal bolt hitting ladle arm causing probe to short out
countermeasure? Turned probe 180 degrees and tightened down
Reoccurrence? No why? Operator crashed robot into helper door
why happen? Operator used r/b teach pendant to home r/b, r/b ran into door during homing.
countermeasure? Jogged r/b in joint to remove r/b from helper d why? die release tank overflowed
why happen? float came off bracket allowing bypass hose to spray out of tank, shorted 24v power supply
countermeasure? Reinstalled float to bracket and tightened, zip wo vacuum blocks blown on operator side this shift. worked on nitrogen project ( with LARGER HYDRAULICS) but there was a problem with threads on fill valve where the hose connects so SAM is getting more material to finish job worn, dropping parts worn, spec issues
