K28 Operation Quality System Work Instruction PDF

**Quality System\ Work Instruction** WI No: 710.15 Issue Date: 2/15/24 Revision No. 2 Page 1 Document Owner: Production Manager Approval: Operations Manager Subject: K28 Operation Section 1: General Information ============================== 1. K28 will run a 16-cavity mold that produces t...

**Quality System\ Work Instruction** WI No: 710.15 Issue Date: 2/15/24 Revision No. 2 Page 1 Document Owner: Production Manager Approval: Operations Manager Subject: K28 Operation Section 1: General Information ============================== 1. K28 will run a 16-cavity mold that produces the IMCLIP used on all IM & CM Tanks. 2. There are four different clip part numbers. **[P/N]** **[Clips/Bag]** **[Bag Color]** ----------------------- ----------------------------- ----------------------------- 200105-1 (IM1060) 68 Clear 200105-2 (IM540) 44 Green 200105-3 (IM1530) 86 Blue 200105-4 (CM1060) 64 Red **200105-5 (IM1250)** 72 **Black** 200105-6 (IM300) 36 Yellow 3. The clips will be made from PPGF-CLP, which is virgin material loaded with 25% glass. Loading is 98% PPGF-CLP & 2% Orange Colorant. 4. **If machine is down for more than 3min at any time you must back the barrel off and purge. Failure to do so can result in degraded material getting into mold....which is bad.** Section 2: QA Checks ==================== 1. Production is required to conduct a mid-shift QA check on the clips and bag qty. Press the Quality Shot button shown below. This will cause the machine to eject the next shot into the reject bin. **DO NOT JUST GRAB A PART OFF CONVEYOR....THAT WILL MESS UP THE CLIP COUNT FOR THE NEXT BAG.**  2. Grab a couple clips and set them off to the side to cool for 2hrs. After the two hours use the go/no-go gauge to ensure the clips are passing. The clip should easily fit on the go side, and **[not]** fit on the no-go side. **If the clips are tight on the go side, there is no need to scrap anything, but this must be communicated in a huddle report so a process change can be made.** 3. You must also ensure that the number of clips per bag is correct. Grab a bag out of one of the gaylords and bring it to the scale. First, place the control bag that has 64 clips in it on the scale. Press the 'Func' button, enter the number of clips that are in the bag, then press the 'Tare' button to calibrate scale to pieces. Now place the bag being tested on the scale to see how many clips are in the bag.  **NOTE: Production is required to perform these checks separate of any checks done by QA. Document checks on your mid shift QA checks.** Section 3: Alarms ================= 1. The stack light for the system has three modes: green, yellow, & red 2. Note that the blender and press have their own alarms and stack lights. The most common alarm on this particular press will be an iQ Controls alarm. This will not stop the machine but will trigger an audible alarm. This means that the pressure profile that we know makes a good part was not met within a certain tolerance. This OK. Do not make changes or rereference the compliance curve w/o talking to process engineering first. If parts are being rejected for 10-15 shots in a row check for a frozen cavity and reference sections 5 and 12 of this document. Section 4: Automation HMI ========================= 1. The HMI for the system is fairly intuitive. This work instruction will not cover all screens, only the most important ones. 2. Home Page: From here you can start the robot, home the robot, reset any faults, change jobs, or create a quality shot. When changing the job make sure the conveyor is clear of any parts to avoid creating any miscounts. **NOTE: The robot will require you to hit the 'Start' button when coming out of a downtime event (you can also do this at the teach pendant by press controller). See the QA Check section for info about the Quality Shot feature.**  3. Box Out: Using the menu of the left side of screen, press 'Box Out' and then 'Gaylord Status' to display the Box Out Screen. This will show you how many bags are in each gaylord/tote. You can also adjust the number of bags in each gaylord/tote.  **NOTE: Be careful when adjusting bag count. There is a standard number that should go into each box. If that number is off it will drive inventory inaccuracies.** It is also good to note that the system looks for a signal from the bagger that a seal was made AND a signal from a sensor on the conveyor before it will automatically add a bag to a box. It will only ever add 1 at a time. So, if multiple bags are on conveyor for some reason you will need to manually add the number of bags above 1 to the corresponding box. 4. I/O Monitor & EOAT: You can access several I/O pages by selecting the 'I/O Monitor' button on the navigation menu. You can access information on the bagger, robot, EOAT, and IMM. The most important menu here is the EOAT menu shown below.   From here you can deselect and turn off the vacuum for a specific cavity. This is required if we ever freeze off a cavity in the mold and want to keep running without alarming out the robot (see Section 5). Section 5: Frozen Cavity ======================== 1. Since the material is glass filled and the orifice size for the nozzles is only 2mm, they can get clogged or freeze off. 2. When this happens the part sensor on the EOAT will not make vacuum and the system will alarm out. To unfreeze or clear the cavity get a small pick. Heat the pick with a torch and gently insert the pick into the frozen cavity to clear the plastic. 3. If this does not unfreeze the cavity, pull back the feed throat and fill barrel with virgin PP from K20/K21. Turn heats on frozen nozzle up to 520deg. Run plastic through mold for several cycles, rejecting the parts, until they look like the part show here. 4. If nozzle has broken free reintroduce the PPGF-CLP back into the machine and resume production. 5. If the nozzle is still frozen after 20 shots of straight PP and high heat, reduce heat on nozzle back to 400deg and deselect the cavity from the EOAT I/O page on the automation HMI and try running production. There is a chance that running with a cavity frozen off may cause the pressure compliance to reject the parts. So, monitor the press. If this does happen it's time to call Process Engineering or Tooling to come, look at it. Stop press, back off barrel and purge. Section 6: Bag Changes ====================== 1. Release the handle on the lower right side of the bagger below where the roll sits on.  2. Pull up the blue strap and slide it off shaft. This will allow you to remove the shaft and empty roll from the bagger. 3. You will then be able to remove the empty roll from the machine and replace it with new roll. 4. Place a new roll onto shaft and slide it all the way against the stop. Next slide the other stop on to sandwich the roll in between the two stops. Lastly tighten stop down in place by rotating lever until tight.  5. Feed the bag into the bagger per the diagram below. Do not forget to place the divider roller into bag (this keeps the two sides of the film separated so you can turn into a bag). NOTE: the printer tray will slide out of the way if you pull on the knobs on either side and pull it back.  **NOTE: This part is a bit of a pain and is easier with two people. Also have a screwdriver handy to help push the bag through. Be cautious when reaching inside the bagger, there is a heating element inside that is hot to the touch.**  6. Once the bag is through and feeding on its own go around and press the start button on the controller. It will cut the bag and when the slide comes back there will be an empty bag waiting on clips.  Section 7: Common Issues ======================== 1). **[Failure to grip - will result in the bagger alarming out and requiring a reset. ]** - This requires you to hit a circular blue reset icon on the bagger HMI located on the bottom left of the HMI screen, after hitting the reset icon, it will then read \"drop bag\", you will then press the \"drop bag\" icon, after that is pressed the icon will then read \"continue\" and upon pressing that, the bagger should then try to re-feed the bag and start running again. If the press is timed out at this point the press and robot will also need to be put back into automatic.  Section 8: Rebagging Clips ========================== 1. On occasion you'll end with extra clips. They could be from the QA Reject shots, a broken seal...whatever the reason, you can easily rebag them. To do so you will need to stop the press. Go to bagger. Put the clips in the bagger and press black button on controller to cycle it. Then press start button on robot.  Section 9: Burn Marks ===================== 1. Occasionally you will see burn marks on the clips as shown below. While this is **[NOT]** a reject condition, we do want to get rid of them. To do this we simply need to clean the mold. Use a scotchbrite pad and mold cleaner. Focus on the vents and the corners where you see the burn marks.   Section 10: LOTO Point ====================== 1. The lockout point for this press is located on the back of the injection of the injection, just down from the press controller. **LOTO is required if you are ever going to enter the press.** Section 11: Pressure Compliance Rejections ========================================== 1. Occasionally the press will automatically reject parts b/c the iQ controls sense that the injection pressures are out of tolerance. If this happens for only a couple shots its not a big deal. If it happens for 10-15 shots in a row, then there is a problem. 2. **Don't touch the process when this happens. As a general rule of thumb on this machine, you should never make a process change.** This could cause the iQ to re-reference itself and create a ton of scrap. So don't make any changes or reference the curve without talking to process engineering first. 3. If the press is rejecting shot after shot it could be one of two things; (1) the mold and nozzles are filling up with glass, (2) the glass content is out of spec. 4. So, the first thing to do is purge through the mold and barrel with straight PP. Reference the section on Frozen Cavities on how to do this. It's the same process, except you don't adjust any of the heats in this case. 5. After you've purged the mold try running production again. If problem persists it is time to get an ash test done in the lab on the material. While this is being done, drain the hopper and try a different batch of material. If problem continues it is time to stop the press and contact process engineering. Section 12: Mold Cleaning ========================= 1. The press needs to be stopped and the mold cleaned every Sunday night. 2. Using mold cleaner and scothbrite clean all vents and cavities (the areas shown in red below).  **NOTE: Do not forget to lock out press before entering area between the platens.** 3. Grease the wear plates with general purpose grease (gray tube, red grease) and check them for tightness. Inspect tool for any water or hydraulic leaks. 4. Reference Mold Maintenance section in SOC book for more info. ------------------------------- --------------------- ---------- Appendix - Document Revisions Revision No. Reason for Re-Issue Date 0 Initial Release 12/7/22 1 Changed Recipe 2/15/24 2 New auto-bagger 11/11/24 ------------------------------- --------------------- ----------