Loader Machine Audit

• Audit Title

• Document No.

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

• Personnel

Over all Machine Inspection

• All safety devices are present and in good working condition. EX: e-stop's, door switches, main power disconnects, air dump valve and air disconnects.

  Yes

  No

  N/A

• All machine functions work properly. EX: auto run, forced run, cycle index, and cycle stop.

  Yes

  No

  N/A

• All external cabling and conduit is in good condition.

  Yes

  No

  N/A

• All wiring in panel is in good condition and working properly.

  Yes

  No

  N/A

• All touch safe guards are installed in electrical panels. If not recommend purchasing them.

  Yes

  No

  N/A

• All machine guard panels are in proper place.

  Yes

  No

  N/A

• No forces on PLC.

  Yes

  No

  N/A

• All documentation is updated and located inside electrical panel or in maintenance shop.

  Yes

  No

  N/A

• Change over sheet is updated and out by machine.

  Yes

  No

  N/A

Timing Screw

• Timing screw drive belt tension correct.

  Yes

  No

  N/A

• Timing Screw speed correct? running at speed and not pulling gaps.

  Yes

  No

  N/A

• Timing Screws change parts in good condition.

  Yes

  No

  N/A

• Guarding and safety circuit in good working condition.

  Yes

  No

  N/A

Diverters

• Diverter Change parts in good condition.

  Yes

  No

  N/A

• Diverter Operation correct. EX: not slamming from side to side, Stroke as centered as possible, timing is correct

  Yes

  No

  N/A

In-feed

• Infeed change parts in good condition

  Yes

  No

  N/A

• Infeed top rack level and set up correctly.

  Yes

  No

  N/A

• Infeed top rack jacks work correctly

  Yes

  No

  N/A

• Infeed Belts in good condition

  Yes

  No

  N/A

• Low speed and High speed drive sprockets in good condition and engaging belts correctly.

  Yes

  No

  N/A

• Infeed photo eyes are set up and working correctly. EX: Product at Gate and High Prime and infeed full. Timing for all correct.

  Yes

  No

  N/A

• Infeed bearings in good working condition

  Yes

  No

  N/A

• Low speed infeed Temp

  Safe

  At Risk

  N/A

• Low speed motor amp draw.

  Safe

  At Risk

  N/A

• HIgh speed Motor temps

  Safe

  At Risk

  N/A

• High Speed Amp Draw

  Safe

  At Risk

  N/A

• Pin assembly functioning properly.

  Yes

  No

  N/A

• PIn assembly bearings and pneumatics in good condition.

  Yes

  No

  N/A

• Product stop functioning properly.

  Yes

  No

  N/A

• Product stop Bearings and pneumatics in good condition.

  Yes

  No

  N/A

• Clear to pick and Clear to move photo eyes are set up and functioning correctly.

  Yes

  No

  N/A

Main load cell

• Transfer Belt in good condition.

  Yes

  No

  N/A

• Transfer X axis Bearings and shafts in good condition.

  Yes

  No

  N/A

• Transfer Z axis bearings and rails in good working condition.

  Yes

  No

  N/A

• All Servo cable connections in good condition. No corrosion or damage.

  Yes

  No

  N/A

• All homing and over travel sensors are in good working condition.

  Yes

  No

  N/A

• pickup head in good condition.

  Yes

  No

  N/A

• all taught positions, accels, decels and dwells are correct for product being ran.

  Yes

  No

  N/A

• axis position sensor is set up and working correctly.

  Yes

  No

  N/A

• Suction Cups in Good condition.

  Yes

  No

  N/A

• Mechanical pick up head in good condition.

  Yes

  No

  N/A

• Separator screw/belt and protective boot are in good working condition.

  Yes

  No

  N/A

• Separator/Rotate Positions are correct.

  Yes

  No

  N/A

• A axis servo motor temp.

  Yes

  No

  N/A

• A axis motor amp draw.

  Yes

  No

  N/A

• B axis servo motor temp.

  Yes

  No

  N/A

• B axis motor amp draw.

  Yes

  No

  N/A

• Separator motor temp.

  Yes

  No

  N/A

• Separator axis motor amp draw.

  Yes

  No

  N/A

• Rotate axis motor temp.

  Yes

  No

  N/A

• Rotate axis motor amp draw.

  Yes

  No

  N/A

Top and Bottom Pad Magazines

• Bottom pad magazine functioning properly.

  Yes

  No

  N/A

• Bottom pad cylinder in good working condition.

  Yes

  No

  N/A

• Bottom pad suction cups and ventures in good condition.

  Yes

  No

  N/A

• Board lay down eyes working properly.

  Yes

  No

  N/A

• Top pad magazine functioning properly.

  Yes

  No

  N/A

• Top pad cylinder in good working condition.

  Yes

  No

  N/A

• Top pad suction cups and ventures in good condition.

  Yes

  No

  N/A

• Top pad 'package present' eye working properly and timing correct.

  Yes

  No

  N/A

Glue Assy.

• Glue tank, hose and head temps are in correct range. No over or under bonding occurring.

  Yes

  No

  N/A

• Glue tank air pressure is in correct range.

  Yes

  No

  N/A

• Glue head is correct height off of index.

  Yes

  No

  N/A

• Glue placement is correct for all sizes.

  Yes

  No

  N/A

• Glue tank in good working condition. No charring in tank, tank relatively clean, no broken pieces.

  Yes

  No

  N/A

• Glue hoses in good condition.

  Yes

  No

  N/A

• Glue head in good condition, all modules and nozzles working correctly.

  Yes

  No

  N/A

Index

• Index chain tension is correct.

  Yes

  No

  N/A

• Index chain is lubricated properly.

  Yes

  No

  N/A

• Index flight bars are square and in good condition.

  Yes

  No

  N/A

• Index bed is in good condition.

  Yes

  No

  N/A

• Index registration sensor is working correctly.

  Yes

  No

  N/A

• index motor is in good condition and drive belt is tensioned properly.

  Yes

  No

  N/A

• taper locks and drive sprockets are in good condition

  Yes

  No

  N/A

• Index motor temp

  Safe

  At Risk

  N/A

• Index motor amp draw

  Yes

  No

  N/A

Stacker

• Stacker is functioning properly.

  Yes

  No

  N/A

• Stacker pickup head is level.

  Yes

  No

  N/A

• Bearing rails and drive mechanism(pneumatics or servo) are in good working condtion.

  Yes

  No

  N/A

• Suction cups or mechanical head are in good condition.

  Yes

  No

  N/A

• Position and timing are set up correctly.

  Yes

  No

  N/A

Jump Station

• Jump station is functioning properly.

  Yes

  No

  N/A

• Belts and rollers in good condition.

  Yes

  No

  N/A

• Chain and sprockets in good condition.

  Yes

  No

  N/A

• Lift station is in good working condition.

  Yes

  No

  N/A

• Jump station speed is correct, product pushed on to jump station and correct gap when leaving.

  Yes

  No

  N/A

Auxiliary Conveyors

• Belt is in good condition and belt tension is correct.

  Yes

  No

  N/A

• Drive sprockets are in good condition.

  Yes

  No

  N/A

• Transfers and pop out rollers are functioning properly.

  Yes

  No

  N/A

Upgrades and retro fits available

• Guarding update(for old machines)

  Yes

  No

  N/A

• Electrical panel touch safe gaurds.

  Yes

  No

  N/A

• New door safety switch upgrade.- new sensaguard door switches to eliminate nuisance trips that have been seen with the sipha version.

  Yes

  No

  N/A

• Touch screen cover.- protects touch screen with hinged lexan cover

  Yes

  No

  N/A

• Index pad control upgrade kit.- Helps control pad placement up through the glue section.

  Yes

  No

  N/A

• Loader flight bar upgrade kit- Taller Flight bars to accommodate warped corrugate and also flight bar connection point is floating (less drag).

  Yes

  No

  N/A

• Glue Stitching conversion kit- eliminates excess glue where it is not coming in contact with cup. Huge Glue savings

  Yes

  No

  N/A

• Infeed top rack adjustment jack upgrade.- kit provides all new jacks and shafts. Jacks have sealed bearings which is more susceptible to wash down

  Yes

  No

  N/A

• Rotary diverter upgrade.

  Yes

  No

  N/A

• Bimba air cylinder diverter upgrade- replace old obsolete air cylinder with Bimba air cylinder-requires new clevis mount and cylinder.

  Yes

  No

  N/A

• Pin assembly upgrade kit. - Replaces large air cylinder with brakes and shocks, with top rack mounted cylinder that adjust with top rack for change over

  Yes

  No

  N/A

• Mechanical Pick up head upgrade.

  Yes

  No

  N/A

• Pickup head vacuum conversion. - Kit provides venture style pick up heads instead of vacuum pump- stronger hold on cup.

  Yes

  No

  N/A

• Top pad placer.

  Yes

  No

  N/A

• Magazine (top and bottom) cylinder bushing kit. - Revised mount to eliminate the clevis mount area from getting worn out. Just replace bushing.

  Yes

  No

  N/A

• Stacker (air or servo)

  Yes

  No

  N/A

• Air stacker shock upgrade kit- eliminates rubber bumpers and replaces them with shocks for smoother operation

  Yes

  No

  N/A

• Timing screw quick change kit.- Provides a quick change coupler for quicker change over.

  Yes

  No

  N/A

• Transfer Station green belt conversion kit. - Adds a couple green grip belts to jump station to eliminate skewed packages

  Yes

  No

  N/A

• Lift transfer station kit.- Replace current skate roller Shuttleworth JS with newer style to eliminate downtime and replacement costs

  Yes

  No

  N/A

• Vision Systems.- can detect no lid, partial lid, lid not on correctly, bad foil, hole in foil, no foil, etc.

  Yes

  No

  N/A

Additional Services Available

• Formal training

  Yes

  No

  N/A

• Regular PM scheduling

  Yes

  No

  N/A

Spares

• spare kit level purchased? what level?

  Yes

  No

  N/A

• servo spares available?

  Yes

  No

  N/A

• Suction Cups in spares (1 Set)

  Yes

  No

  N/A

• Photo eyes and cables in spares? (1 of each eye and 1 of longest cable)

  Yes

  No

  N/A

• Infeed bearings

  Yes

  No

  N/A

• Pad placer bushings and Cylinders.

  Yes

  No

  N/A

Recommended spare parts

• Infeed section.

  Yes

  No

  N/A

• Load Cell.

  Yes

  No

  N/A

• Servo system.

  Yes

  No

  N/A

• Pad placers.

  Yes

  No

  N/A

Plant Contact Iformation

• Plant Manager.

  Yes

  No

  N/A

• Maintenance Engineer.

  Yes

  No

  N/A

• Production Manager.

  Yes

  No

  N/A

Signatures

• Auditors Signature

  Sign

• Maintenance Engineer Signature

  Sign