Erecting machine audit FP-4’s

• Audit Title

• Document No.

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

• Personnel

1.0 - BLANK HOPPER ( FP- 4)

• 1.1 All components , present and tight

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 1.2-Hopper central, position, blank fit

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 1.3-stack retainers operation, position

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 1.4- Photoeye operation, position and condition of hopper

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

2.0 - VACUUM PULL DOWN

• 2.1 - Cups and hoses, condition, position, operation

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 2.2 -vacuum pull down arms, position, condition, timing, lube

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 2.3 - Vacuum release valve condition, timing, operation

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 2.4 Vacuum pump and filters condition, operation, cleanliness

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

3.0 - FLAP FOLDERS

• 3.1 - Drive arms condition, tight , timing , in & out position

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 3.2 - Rack and pinion Rod Ends condition, operation, lubrication

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 3.3 - Splines and shafts condition, operation, lubrication

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 3.4 -mount arms condition, in line

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 3.5- Flap guides condition, tight, straight

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

4.0 - BLANK PUSHER FEED

• 4.2 - Pusher chain condition, tension and lubrication

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 4.1 -Ensure back dead centre is 0+/-4 on encoder position

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 4.3- Pusher drive pin and traveller condition and lube

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 4.4 -Pusher carriage condition, wear and lubrication

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

5.0 - HOTMELT

• 5.1 - Glue pattern , position, size<br><br><br>

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 5.2 - Glue tank condition, charring, overflow, damage, operation

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 5.3 - Guns and hoses, tight, leaks, abrasion, position, guiding

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 5.4 - Photoeye condition, position, sensitivity

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

6.0 -CORNERPOST AND LAMINATION

• 6.1 - Column folders& cylinders operation, condition, leaks, timing

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 6.2 - Column presses condition, set up, lube, 2nd hole shortened angles

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 6.3 - Column presses cylinder operation, leaks, position, timing

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 6.4- Laminators rack and pinion operation, condition, lube, position

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 6.5- Laminator cylinders & air timer operation, condition, leaks, timing

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 6.6- Fingers condition, position, operation, leaks, timing

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 6.7 - Blue feed wheels operation , condition, glue build up

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 6.8 - Bed and Leaf springs condition, position, glue buildup

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

7.0 - FORMING

• 7.1 -Blank position, guiding, movement, & rebound stops

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 7.2 -Mandrel Rack & Pinion condition, Lube, grease points fitted

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 7.3 - chamber, central, wear, operational, all parts present and tight

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 7.4 -Roll over Rack and pinion operation, condition & lubrication

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 7.5-Mould presses condition, operation, speed, mounts and timing

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 7.6 -Claws condition, operation, speed, mounts and timing

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 7.7- Expulsors condition, operation, lube, guides, bearings

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

8.0 -DRIVE SYSTEMS

• 8.1 - Drive Belt condition, tension, over load limit switch setting

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 8.2 - Chains condition tension, lube, overload limit switch setting

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 8.3 - Nylon cams wear, cam follower, Mount & Lubrication

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 8.4 -Gear wheels condition, lubrication, grease point fitted

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 8.5 - Hand oilers operation, leaks, oil level

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

9.0 - STACKER

• 9.1 - Belt condition, tension, tracking and lubrication

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 9.2 - Elevator cylinder operation, condition, air leaks, lubrication & latches

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 9.3 - Stack eject cylinder operation, condition, airleaks and Lube

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 9.4 - Electrical cAbinet, controls and PE operation , condition and cleanliness

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

10.0 -ELECTRICAL

• 10.1 - Elect cabinet, tidy, clean, locked, main switch lock fitted

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 10.2 - Contactors, operation, condition

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 10.3 - Push buttons, operation, condition, labelled

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 10.4 -Wiring, condition, tidy, fastened, tagged

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 10.5 - motor & VSD operation , condition, settings, speed

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 10.6 - P.L.C battery condition

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 10.7 - Screen operator interface operation, condition, all pages working

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 10.8 - Hot melt time clock, setting, operation

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

11.0 Pneumatics

• 11.1 - Cylinders, valves and tubes condition, operation, air leaks

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 11.2 - Air supply unit condition, operation, gauges and auto drains

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 11.3 - Pressure switch operation check, low pressure and happy settings

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 11.4 -Pressure settings all regulators ( record values)

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

12.0 - SAFETY

• 12.1 -Emergency stops condition, operation and labelled

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 12.2 - Guard safety switches operation, condition

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 12.3 - Top FORMING chamber guard condition, operation, correct lift kit

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 12.4- All fixed guards in place , secure

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 12.5 - All warnings and labels in place, readable

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 12.6- Lightening, adequate, turned on

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 12.7 - Clean And safe work area around m/c . PPE available and cond

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 12.8 - Only trained operators operating machine

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

13.0 - GENERAL

• 13.1 - machine cleanliness condition, over, under, deck, glue overspray

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 13.2 - Machine feet and jacking screws condition, present and tight

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 13.3 - Mounts and fastening present , tight bolts

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 13.4- Timing of VAC cups, Mandrel and Pneumatics( rectify if necessary)

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 13.5- Wind adjusters operation , condition , chain tension, lubrication

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 13.6- Wind DIAL counters equal actual measurements

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 13.7- Set up sheet and change over procedures available, correct

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 13.8 - Manual and holder , fitted, condition

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 13.9- MEX I.D tag fitted on all components

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

• 13.10 - Product reject rate square, parallel, damage free, all glue bonded

  0- failed

  0.2- severe wear

  0.5- some wear

  0.9- slight wear

  1- OK

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