K28 Operation and QA Checks

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Questions and Answers

What material is used to make the clips, and how much glass is loaded into it?

PPGF-CLP with 50% glass

PPGF-CLP with 10% glass

PPGF-CLP with 25% glass (correct)

PPGF-CLP with no glass loading

What action must be taken if the machine is down for more than 3 minutes?

Continue production as usual

Notify the quality manager

Decrease the temperature of the machine

Back the barrel off and purge (correct)

Which bag color corresponds to the part number 200105-3?

Black

Red

Green

Blue (correct)

What must be done with the clips after they cool for 2 hours?

Use a go/no-go gauge to check their fit Signup and view all the answers

What should be communicated in a huddle report if clips are tight on the go side of the gauge?

A process change must be made Signup and view all the answers

What is the correct procedure if a bag of clips is found not to meet the required quantity?

Notify the production manager Signup and view all the answers

Which part number has the highest number of clips per bag?

200105-3 (IM1530) Signup and view all the answers

How should the scale be calibrated before testing bags?

Enter the number of clips and press 'Tare' Signup and view all the answers

What is the purpose of the divider roller when preparing a bag?

It keeps the two sides of the film separated. Signup and view all the answers

What should you do if the bagger alarms out due to a failure to grip?

Press the circular blue reset icon. Signup and view all the answers

Which tool is suggested to aid in pushing the bag through the bagger?

A screwdriver. Signup and view all the answers

What should be done with burn marks on the clips?

Clean the mold using a scotchbrite pad. Signup and view all the answers

Which action is necessary after placing extra clips in the bagger?

Cycle the bagger using the black button on the controller. Signup and view all the answers

Where is the lockout point for the press located?

On the back of the injection just below the press controller. Signup and view all the answers

What is one of the common issues when using the bagging machine?

The bagger alarming out due to failure to grip. Signup and view all the answers

What happens after pressing the start button on the controller when the bag is through?

The bag is cut and an empty bag is prepared. Signup and view all the answers

What should be done first if a nozzle gets clogged or freezes off during operation?

Use a small pick heated with a torch to clear the cavity. Signup and view all the answers

What is the appropriate temperature to set the nozzle to after attempting to unfreeze it with straight PP and high heat for 20 shots?

400 degrees Signup and view all the answers

Which step is involved in changing the bag on the bagger?

Slide the blue strap off the shaft to empty the roll. Signup and view all the answers

What might indicate that parts are being rejected during production due to a frozen cavity?

The part sensor does not make vacuum. Signup and view all the answers

After replacing the empty roll in the bagger, what is the last step to secure it?

Tighten the stop down in place by rotating the lever. Signup and view all the answers

What should be done if the nozzle remains frozen after multiple attempts to thaw it?

Call Process Engineering or Tooling. Signup and view all the answers

What happens if a frozen cavity is deselected from the EOAT I/O page?

It may allow continued production without alarming the robot. Signup and view all the answers

What should be monitored for signs of part rejection when running with a frozen cavity?

The press during production. Signup and view all the answers

What should you do if the press is rejecting multiple shots in a row?

Contact process engineering before taking any action. Signup and view all the answers

What action should be avoided when the press is experiencing frequent rejections?

Both A and B. Signup and view all the answers

When is the appropriate time to clean the mold?

Every Sunday night. Signup and view all the answers

What is the first thing to do if the press keeps rejecting shots after purging the mold?

Perform an ash test in the lab. Signup and view all the answers

What is required before entering the area between the platens during maintenance?

Lock out the press. Signup and view all the answers

What could be a reason for the press rejecting shots repeatedly?

The mold and nozzles are filled with glass. Signup and view all the answers

What should be used to clean all vents and cavities of the mold?

Mold cleaner and scotchbrite. Signup and view all the answers

What should you inspect for while greasing the wear plates?

Tightness and any leaks. Signup and view all the answers

What does a yellow stack light indicate?

An alert or warning condition exists. Signup and view all the answers

What should be checked after 10-15 shots in a row are being rejected?

Inspect for a frozen cavity. Signup and view all the answers

What action is necessary when changing jobs on the HMI?

Ensure the conveyor is clear of parts. Signup and view all the answers

How does the system ensure a bag is added to a box?

By detecting a seal signal from the bagger. Signup and view all the answers

What must be done before manually adding bags to a box?

Check the current bag count. Signup and view all the answers

What does the HMI allow you to do from the Home Page?

Start the robot and reset any faults. Signup and view all the answers

Why is adjusting the bag count particularly important?

It can lead to inventory inaccuracies. Signup and view all the answers

What is the primary function of the 'I/O Monitor' on the HMI?

To access various I/O pages. Signup and view all the answers

Study Notes

K28 Operation

K28 uses a 16-cavity mold to produce IMCLIP, which is used on all IM & CM Tanks.
There are six different part numbers:
- 200105-1 (IM1060) - 68 clips/bag - Clear
- 200105-2 (IM540) - 44 clips/bag - Green
- 200105-3 (IM1530) - 86 clips/bag - Blue
- 200105-4 (CM1060) - 64 clips/bag - Red
- 200105-5 (IM1250) - 72 clips/bag - Black
- 200105-6 (IM300) - 36 clips/bag – Yellow
Clips are made from PPGF-CLP, which is virgin material loaded with 25% glass, containing 98% PPGF-CLP and 2% Orange Colorant.
If the machine is down for more than 3 minutes, the barrel must be backed off and purged to avoid degraded material entering the mold.

QA Checks

Production is required to conduct a mid-shift QA check on the clips and bag quantity.
Use the "Quality Shot" button to eject the next shot into the reject bin.
Do not grab a part off the conveyor as it will mess up the clip count for the next bag.
Use the go/no-go gauge to check the clips after they have cooled for two hours.
The clip should easily fit on the “go” side and should not fit on the “no-go” side.
If the clips are tight on the “go” side, communicate this in a huddle report so a process change can be made.
Ensure the correct number of clips per bag by comparing a production bag to a control bag using the scale.
Production is required to perform these checks separate of any checks done by QA.

Alarms

The stack light for the K28 system has three modes: green, yellow, and red
The blender and press have separate alarms and stack lights.
The most common alarm is the iQ Controls alarm, which does not stop the machine, but triggers an audible alarm.
The iQ Controls alarm means the pressure profile for a good part was not met within a certain tolerance.
If parts are being rejected for 10-15 shots in a row, check for a frozen cavity and refer to sections 5 and 12 of this document.

Automation HMI

The HMI system is intuitive and only key screens are covered here.
From the Home Page, you can start the robot, home the robot, reset faults, change jobs, or create a quality shot.
When changing the job, ensure the conveyor is clear of any parts.
The robot requires you to hit the “Start” button when coming out of downtime.
The Box Out screen shows the bag count in each gaylord/tote and allows you to adjust the number of bags.
You can select the “I/O Monitor” on the navigation menu to access information on the bagger, robot, EOAT, and IMM.
Use the EOAT menu to deselect and turn off the vacuum for a specific cavity.

Frozen Cavity

Frozen cavities can occur due to the glass-filled material and small nozzle size.
To clear a frozen cavity use a heated pick to remove the plastic blockage.
If the pick does not clear the cavity, fill the barrel with virgin PP from K20/K21, increase the heat on the frozen nozzle to 520 degrees, and run plastic through the mold until the parts look like the specified part.
If the nozzle has unfrozen, reintroduce the PPGF-CLP and resume production.
If the nozzle remains frozen after 20 shots of straight PP and high heat, reduce the nozzle heat to 400 degrees, deselect the cavity on the EOAT I/O page, and continue production.
Monitor the press as running with a frozen cavity may cause pressure compliance issues.
If problems persist, stop the press, back off the barrel, and purge.

Bag Changes

To change bags, release the handle on the lower right side of the bagger.
Pull up the blue strap and slide it off the shaft to remove the empty roll.
Place a new roll onto the shaft and slide it against the stop.
Slide the other stop onto the shaft to sandwich the roll in between the two stops and tighten the stop by rotating the lever.
Feed the bag into the bagger as shown in the diagram.
Place the divider roller into the bag to keep the sides of the film separated.
Press the start button on the bagger controller to cut the bag.

Common Issues

Failure to grip – The bagger will alarm out and require a reset.
Hit the circular blue reset icon on the bagger HMI.
Hit the "drop bag" icon.
Hit the "continue" icon.
The bagger will try to re-feed the bag.

Rebagging Clips

Clips can be rebagged if there are extra from QA rejects or a broken seal.
Stop the press, put the clips into the bagger, press the black button on the controller to cycle the bagger, and press the start button on the robot.

Burn Marks

Burn marks may occur on the clips.
While not a reject condition, burn marks can be removed by using a scotchbrite pad and mold cleaner.
Focus on cleaning the vents and corners where the burn marks occur.

LOTO Point

The lockout point for the press is located on the back of the injection unit, just below the press controller.
LOTO is required when entering the press area.

Pressure Compliance Rejections

The press may automatically reject parts if the iQ controls sense that the injection pressures are out of tolerance.
Rejections for a couple shots are not a concern. However, 10-15 shots in a row indicate an issue.
Do not make any process changes.
The issue could be due to mold and nozzle buildup or glass content out of specifications.
Purge the mold and barrel with straight PP.
If the problem persists, get an ash test done on the material, drain the hopper, and use a different batch of material.
If the problem continues, stop the press and contact process engineering.

Mold Cleaning

The press must be stopped and the mold cleaned every Sunday night.
Use mold cleaner and a scotchbrite pad to clean the vents and cavities.
Grease the wear plates with general purpose grease and check for tightness.
Inspect the tool for leaks.
Refer to the Mold Maintenance section in the SOC book for more information.

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Description

This quiz covers the K28 operation for producing IMCLIP, including the different part numbers and material composition. It also addresses the necessary QA checks required for production, emphasizing the procedures to follow during and post-production. Test your knowledge on best practices for maintaining product quality and machine efficiency.