Fill Level Audit

• Audit Title

• Document No.

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

• Personnel

• The purpose of this checklist is to act as a guide in determining if any anomalies exist on the line or in the FT-50 equipment itself that limits the performance of the system.

• While making the check of the systems, have the available maintenance personnel accompany you.

• These checks will be an excellent opportunity to do training as well as exchanging information.

• In most cases, anomalies can be immediately corrected as you find them.

• Do not make any changes or corrections unless you have consulted with the customer.

• MACHINE SN:

• SOURCE SN:

• LINE NUMBER:

• Software Version:

• Machine Type:

• Bottle or Can

  Bottle

  Can

• Does the customer have any known or existing problems?

  Yes

  No

  N/A

Conveyors

• Is the conveyor braced so that it does not move under the Inspection head?

  Yes

  No

  N/A

• Is the conveyor level, not running at an angle through the Inspection zone?

  Yes

  No

  N/A

• Is the chain in good condition?

  Yes

  No

  N/A

• Are there any new and old sections of chain mixed together?

  Yes

  No

  N/A

• Are the containers on the conveyor stable (no erratic movement?)

  Yes

  No

  N/A

• Conveyor material

  Plastic

  Stainless Steel

• Conveyor type

  Magnetic Rex 1.5

  Magnetic Rex 1.0

  Standard Rex 1.5 in

  Rex 1.0

  Matt top belt

• Measure 10 conveyor links and note the value

Physical Installation

• The inspection Head should be level and properly braced

• Is the Inspection Head level over the conveyor - should be parallel to the container fluid.

  Yes

  No

  N/A

• Is the Inspection Head braced so that it does not move? (If it is not properly braced then the Inspection Head could move and cause false rejects.)

  Yes

  No

  N/A

Conveyor Guide Rails

• Guide rails should be adjusted properly to guide containers in a non-staggered path through the Inspection tunnel and rejection zone.

• Do the guide rails guide the containers through the center of the inspection tunnel with no slippage on the conveyor?

  Yes

  No

  N/A

• Is the customer aware that if changeovers occur only the rails across from the rejector should be adjusted. This ensures that the containers are in the same location in regards to the rejector (1/8" from the rejector pad).

• Are the containers 1/8" from the rejector pad?

  Yes

  No

  N/A

Rejector

• Rejector Type

  Select Proline Proline II Intermediate Slat Servotec I Servotec II

  • Proline
  • Proline II
  • Intermediate
  • Slat
  • Servotec I
  • Servotec II

• Any Loose hardware found?

  Yes

  No

  N/A

• Rejector pad in good condition?

  Yes

  No

  N/A

• Rejector pad retainer clip in place?

  Yes

  No

  N/A

• Rejector mounted properly? (not loose, correct pad distance -1/8" from the containers)

  Yes

  No

  N/A

• Rejector rail opening correctly sized for the line speed? <br>

  Yes

  No

  N/A

• should be a minimum 8" add an inch for each 100 containers per minute. Example 1500 cpm = 15 inch opening

• Is the rejector timing correct (use white grease)

  Yes

  No

  N/A

• Do containers backup into the rejection zone?

  Yes

  No

  N/A

• The air controls should be clean and adjusted correctly. Oil (if required - original Proline) should be the proper type and viscosity.

• Are the air controls for the rejector adjusted approximately 60 to 80 psi.

  Yes

  No

  N/A

• Are the air controls correct for the rejector being used?

  Yes

  No

  N/A

• Is oil used for the rejector? (Proline, Slat only)

  Yes

  No

  N/A

• Is the oil 5 wt, non-detergent, food-grade oil. (Proline, Slat only)

  Yes

  No

  N/A

• Rejector Options

• Backup sensor installed?

  Yes

  No

  N/A

• Reject verification installed?

  Yes

  No

  N/A

• Reject verification functional?

  Yes

  No

  N/A

• Reject performance monitoring installed?

  Yes

  No

  N/A

Inspection Trigger

• What trigger raising mechanism installed? (If old dovetail-style, recommend upgrade to new raising mechanism)

  Dovetail

  linear bearing

• Trigger Configuration

  Centerline

  Upstream

• Trigger type

  Glass Fiber Optic

  Plastic Fiber Optic

  Banner Optics

• Trigger clean?

  Yes

  No

  N/A

• Any damage found with the trigger?

  Yes

  No

  N/A

• Does the plant have a cleaning procedure in place?

  Yes

  No

  N/A

Inspection Head

• Inspection head properly sealed?

  Yes

  No

  N/A

• Air purge installed and functional?

  Yes

  No

  N/A

• "Yellow" indicator lamp functional?

  Yes

  No

  N/A

• "Yellow" indicator lense damaged?

  Yes

  No

  N/A

• "Red" indicator lamp functional? ( Auto Shutter versions only)

  Yes

  No

  N/A

• "Red" indicator lense damaged? ( Auto Shutter versions only)

  Yes

  No

  N/A

• "Green" indicator lamp functional? ( Auto Shutter versions only)

  Yes

  No

  N/A

• "Green" indicator lense damaged? ( Auto Shutter versions only)

  Yes

  No

  N/A

• Encoder Installed?

  Yes

  No

  N/A

• Encoder Coupling in good condition?

  Yes

  No

  N/A

• Encoder Shared with another unit?

  Yes

  No

  N/A

• Encoder Properly Calibrated?

  Yes

  No

  N/A

PLC - I/O Power Junction Box

• PLC - I/O Power Junction Box installed?

  Yes

  No

  N/A

• Relays used?

  Yes

  No

  N/A

• Using Modbus?

  Yes

  No

  N/A

• IDC Serial interface?

  Yes

  No

  N/A

Line Dynamics - Product Info

• Container Size during Visit?

• Number of Container types?

  Select 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

  • 1
  • 2
  • 3
  • 4
  • 5
  • 6
  • 7
  • 8
  • 9
  • 10
  • 11
  • 12
  • 13
  • 14
  • 15
  • 16
  • 17
  • 18
  • 19
  • 20

• Head Heights?

• Notes

Machine Parameters

• Button #1 - Fill Level Settings

• Gamma Counts - Full Container

• Gamma Counts - Empty Container

• Gamma Threshold

• Look time gate

• Button #4 - Rejector Settings

• Rejector Pulse Width

• Reaction Delay

• Inspection Trig to C/L Rej (Value - Should be within ±10mm of measured distance)

• Inspection Trig to C/L Rej (measured distance)

• Button #5 System Settings

• Time Width of container

• Container Width at Trigger

• Maximum Container diameter

• Encoder Calibration Value

• Pre-Scaler Value

• Gamma Sample Cut-off Limit

• Additional Service Required?

  Yes

  No

  N/A

• Does the plant have spare parts inventory? (If yes list)

  Yes

  No

  N/A

Plant Contact Information

• Plant Manager.

  Yes

  No

  N/A

• Maintenance Manager

  Yes

  No

  N/A

• Production Manager.

  Yes

  No

  N/A

• Quality Manager

Signatures

• Service Engineer Signature

  Sign

• Maintenance Manager Signature

  Sign

• From 1 - 10 give overall impression of the inspection equipment (1 = poor - 10 = excelent)