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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Eugene Raman
Erecting machine audit FP-4’s
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