Title Page

  • Description of equipment

  • Serial Numbers

  • Conducted on

  • Prepared by

  • Location

  • This document should be used in conjunction with an assessment of the equipment’s compliance with the Provision and Use of Work Equipment (PUWER) regulations 1998

  • PROTOCAL AND PROCEDURE AGREEEMENT

  • Client Representative

  • Supplier Representative

Machine Suitability for FAT

  • To determine that the equipment is complete including all ancillary equipment and change parts.

  • Visual inspection against the technical specifications including any agreed changes.

  • Check the physical dimensions including guards against the layout drawing.

  • All guarding in place and properly fastened.

  • HMI screen in correct local language.

Machine Suitability for end use

  • To verify that the machine can be run in the customer-required position and has all the components in place as outlined in the machine specification.

  • A. Check the physical dimensions including guards against the layout drawing.

  • B. Check all machine components on the machine comply with relevant electrical/mechanical specifications.

  • Operation through Main screen.

  • Variables are easy to understand and clearly describe their function.

  • All peripheral alarms function properly

  • Pushbuttons around machine function properly.

  • Product size screen contains all change settings and changeparts.

  • Recipes loaded in the HMI

General Appearance

  • To verify the machine meets the minimum standard of appearance required.

  • To be completed at the beginning of the trials:
    A. Examine the whole machine for scratches, damage or cracks
    B. Gland contact points are smooth and burr free.
    C. Inspect all bolts including domed nuts.

  • Equipment is clean.

  • All guarding in place and properly fastened.

  • Gauges are visible, accessible and properly mounted.

  • No sharp edges and smooth welds.

  • No visible damage on frame, guarding and other components.

  • Gearboxes and motors are properly mounted, no signs of leakage.

  • All changeover settings have rulers or scales including indicator for proper setting.

  • No trip points around the machine

  • No outsticking components / machine parts in workway of operator

  • All format parts are identified with proper identification

Electrical check

  • Verification of all electrical wiring & components meets Clients electrical standards and codes of practice.

  • Using Regulatory standards and any variants agreed. Check all electrical components wiring and ancillary equipment and mountings.

  • Each input and output must be correctly wired, with no spare I/O being wired to devices. The action of each input/outputs must correspond with the schedules. All spare wires terminated.
    • All components comply with agreed standard.
    • All wiring is suitably protected and routed.
    • All protection is to the agreed IP rating.
    • All sensors are suitably mounted.
    • Control panel is built and constructed to agreed specification.
    • All earth straps are in place and secure.

  • Panels are clean and free from debris and any metal filings.

  • Wires properly connected and installed.

  • Wires and terminals clearly marked and identified.

  • Note down voltage marking on identification tag: V, Hz.

  • All components identified corresponding to schematics.

  • Electrical schematics are provided in the cabinet.

  • All doors are clearly marked and identified (check display vs actual door numbering.

Mechanical check

  • To verify that all mechanical components meet Clients mechanical standards and codes of practice.

  • Using the Clients mechanical standards and any variation agreed check all mechanical components for compliance secure fixing and correct positioning

  • All components comply to standards.

  • All components are fit for purpose.

  • All bearings are either sealed for life or centrally lubricated as agreed.

  • All bearings to be agreed and gear boxes to be filled to the correct level with the agreed lubricants.

  • All serviceable items to be easily accessible for maintenance.

  • All pneumatic / hydro filter and top up bottles to be easily accessible.

Machine guarding, unlock & safety devices

  • Machine guarding is suitable and that all interlock and safety devices function as agreed, and indicate correctly.

  • Test should be carried out with no product.
    1) Complete PUWER.
    2) Activate the E-stop,
    3) Check and record message on the panel.
    4) Check operation of the safety unit
    5) Pull the e-stop out
    6) Check operation of the safety unit
    7) Attempt to restart machine in each operating mode

  • E-stop, switch on machine, randomly activate an emergency stop. Machine stops, all drives switch of, pneumatics go to safe state, message on display.

  • Unlock e-stop, reset alarm and restart machine, machine starts reliable

  • Doors are locked during normal operation

  • Activate door “door open request” machine stops before opening doors

  • Close door command works reliable, machine will not start when not properly closed.

  • Main power switch available.

  • Hotmelt unit is safely mounted, no change of injury of operator

  • Air supply can be locked out

  • Air dump valve works reliable

  • Machine is according to CE covered.

  • All dangerous points are covered or protected and protecting the operators against injury.

Signage and Labelling

  • To verify the machine has adequate signage
    This includes,
    A. Earth labels
    B. CE labels
    C. Machine identification plate
    D. E-Stop labels
    E. Warning labels
    F. Wire Identification
    G. Sensors, Actuators, Pipe work
    H. Lamps, Beacons
    I. Machine asset plate

  • All appropriate warning signs are on the machine in the correct local language.

  • All buttons labelled and in correct language.

Dry Tests

  • To ensure machine functions smoothly.
    - Operate machine at low speed
    - Run machine at full speed including any over speed
    - Check for vibration or excessive noise

  • Machine starts in sequence.

Machine running

  • To ensure that the machine operates as per the tender and specification document

  • A – Demonstrate the machine functionality
    B – Check that the machine functions properly at agreed maximum and minimum speeds
    C – Demonstrate that change over can be achieved within agreed times
    D – Ensure that all machine controls are easily accessible
    E - Witness all formats running.
    F – Ensure that whilst machine is running it is free, smooth and free from vibration

  • Packs are positioned correctly in SmartTrack.

  • Packs are correctly picked up.

  • Pick up head holds packs correctly during flight.

  • Packs are correctly placed in case (see product tests for more details).

  • Cases are correctly taken from magazine.

  • Casesblanks are folded correctly and glued properly.

  • Cases are square (measure diagonals).

  • After filling cases are closed correctly.

  • During erecting, filling and closing cases are not damaged.

Recovery from Power Failure

  • To verify that the system recovers in a controlled fail-safe manner after a power failure.

  • A - Run machine.
    B -Run the machine as normal, and turn the power off while the machine is running.
    Turn the power back on again the machine should not restart.
    C - Repeat tests (A) and (B), but with the machine stationary.
    D - Restart machine.
    E - Repeat the above action to check machine functionality.

  • Machine should power up as normal with no faults.

Documentation

  • To verify that all required documented is in place.

  • To sight and review the following files
    1. All parameter and register settings logged onto program, Disk and hard copy placed in Manual
    2. 3 copies (plus USB/CD version) of the electrical / pneumatic drawings checked and modified if necessary.
    3. Program backed up on disk.
    4. 3 copies (plus USB/CD version) Machine manuals, (operation and maintenance) in correct language. (English)
    5. Second copy of Tech file supplied. Tech files signed by manufacturer’s rep.
    6. CE marked and a certificate of conformity. Noise and EMC test certificates included
    7. Replacement parts list.

  • Hard and soft copy of manuals provided.

  • Program backed up.

  • Recommended spare parts list.

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