Machine 19 tool heater manifold

WATER HEATER
CLR1 Air gun Station 124 outside clean room 1
FACILITIES Floor reapir outside clean room 1 by welder 1

MC23 Central feed for machine 23

CLR2 Clean room 2 light panels

Kolzer Frame
ALUMINISING
MC19 Robot Fault
MC1 Tie-Bar Locking Clamps
GLUE MACHINE Bonding Robot

M/c 26 Hopper loader

CFS
MC3 Lubrication Oil

ALUMINISING Aquablaster

MC20 Water Leak

Turntable
MC3
Aquablaster
ALUMINISING
M/C 3 Turntable
MC3
CFS Machine 23 hopper
MC1 Machine 1 turntable
JIGS FIXTURES FML JIG

Hopper Throat
MC9

Foam Cut Outs

JIGS FIXTURES

Kolzer Frame
ALUMINISING
Heater Fan Unit
M/C 23 No contact force on nozzel

Machine 20 contamination in barrel

 Hopper loader on dryer 5053
Balzer
Balzer Frame

3M Orbital Sander

Balzer Shield

Fume Extractor

MC9 Leaking Throat

MC19 Robot Axis Fault

M/C 11 Hot runner

MC19 Machine 19 moving half tool heater

ALUMINISING Aluminising Blazer

Leaking Water Fitting

MERC ASMBLY LPKF Laser

Water Heater
WATER HEATER
Heat Guns
ALUMINISING Balzer
Hot runner

M/C 9
MC9
Hor runner
MC3 Machine 3 hot runner fault

Air line installed on bench

OTHERS
MC1 Machine 1

MC1 Machine 1

Work Station Light

CLR1

MC22 Hopper Loader

COATING PLANT Oven Stopping in Cycle

MC29 MAGUIRE Dryer
 MC22 Hopper

Balzer

MC22 Lubrication fault

CLR1 Phasa 1544

Sonic welder in semi clean room 1

CLR1
Polisher
MERC ASMBLY
GLUE MACHINE VW GLUER

Breakdown room
OTHERS
all Welders
OTHERS
OTHERS Hot Plate Welder
MC20 Injection moulding machine 20
OTHERS 450 3D Printer

DB10 Dryer
CFS
ALUMINISING Aquablast
MC6 M/C
MC9 Machine 9
CLR1 Electrical Tester - CLR 1
FACILITIES Warehouse door
OTHERS 450 3D Printer

Piovan Dryer
MC20
ALUMINISING Aquablast
TPM Phasa 1544
TPM By Facelift Bumper Lam IR Vibration Wwlding
COATING PLANT UV Rotation VSD
MOBILE DRYERS Shini Dryer
COATING PLANT Moving trays

MC29 Zone 27 on hot runnner down

MC9 Machine 9

External Closing Interlock

MC19

Removal of Partition
OFFICES
MC7 Hot Runner
CLR1 Oven
MC26 Robot

Tool
MC19
TOOLROOM Zone not heating up on tool
MC21 Robot 222983
JIGS FIXTURES FML JIG
TOOLROOM Check thermocouple
MC29 Dryer D900
CLR1 Clean room 1 welder
CLR1 Clean room 1 air- con
CLR2 Static Tester

MC1 Rotary Table Fault

MC19 Material Feed

WATER HEATER Tooltemp water heater

MC19 Driver of the Studding Jig
TPM X290 X Stus Insertion Station
TPM LPKF Twinweld 3D 6000
TPM Bentley BY636 Facelift Bumber Lamp Assembly
TPM Bentley BY636 Facelift Bumber Lamp Assembly
MC1 all alarm faults present
MC8 Nozzle temp. not reaching set temp.
TOOLROOM Thermcouple fault
Locking tie bars not clamping over upon mould
MC1
hight.
MC1 Lockin nuts 1 and 3
JIGS FIXTURES FML pressure tester
COATING PLANT Carrige on unloading
GLUE MACHINE VW gluer
CLR2 Loading trolly

Laser Cell
CLR2

Hopper Loader
MOBILE DRYERS
ALUMINISING Air-Con Leak
MC2 Sensor Plug

Accumulator Pressure
MC21

MC26 Ejector Plugs

GLUE MACHINE VW Gluer - Jig Fixture

OTHERS Air-Con Unit

Hopper Loader
MC8
Hopper Loader
MC4
 ALUMINISING Lone Working Alarm

MC20 Hopper Loader

MC18 Hot Runner Cables

Fire Door Break-Bars

OTHERS

Pneumatic manifold
MC21
TOOLROOM Pneumatic manifold

ALUMINISING 625
CFS 65
CLR1 295
CLR2 205
COATING PLANT 280
FACILITIES 70
GLUE MACHINE 120
JIGS FIXTURES 100
MC1 1450
MC18 60
MC19 230
MC2 60
MC20 200
MC21 160
MC22 190
MC23 480
MC26 40
MC29 3390
MC3 165
MC4 25
MC6 20
MC7 10
MC8 30
MC9 140
MERC ASMBLY 105
MOBILE DRYERS 60
OFFICES 10
OTHERS 230
TOOLROOM 315
WATER HEATER 275
Calcium build up around small valves on
20
manifold and was written on ticket as rusting.

Air gun affecting test station. 45

Floor to be repaired 10
Not clearing the line fully so material left in
480
line and going cold.
Light Diffusers need cleaning. 120

Bearings on the kolzer frame need replacing 40

Robot isn't working 20

No locking position for tie-bar 4 30
Bonding robot stopped mid cycle 15
Flap on hopper not working properly causing
45
M/C to run out of material
Lubrication oil level is low on M/C 3. 15
New motor pump nees fitting to the
240
aquablaster

Water leak coming from second injection unit

30
from pipe underneath carraige

Machine won't allow the turntable to rotate to

align pin slot. Can't bring moving half forward 30
to meet up with tool

the sand in the Aquablast is not flowing

Turntable is not Moving and is stuck out of
60
position
Line not clearing
Turn table fault tranducer broken. 960
Failing leak test 40

Throat was leaking, now water has been

disconnected which is causing a lump 35
everytime the machine is stopped

Need some more rounded foam cut outs for

30
the leak and electrical jigs at FML

Need a circular spacer making for the centre

150
alignment pin on the frame.

Heater unit from ceiling isn't running 15

No force contact on the nozzel 15

Getting contamination from barrel due to

100
nozzle come loose and face not shut off.
Not pulling material. 35
Balzer is not venting 15
Balzer frame cannot slide into chamber 20
Pneumatic airline required for new orbital
sander which will be used next to the buffing 180
station adjacent to plasma cell
New shield required for the balzer frame 60
Fume extractor part of laser cell unit by CLR 2
20
needs a service.
Throat leaking on machine again 40
Robot axis fault - 3 times this shift having to
turn off and on and only last between 10-30 120
minutes before occurring again.
Hot runner box isn't heating zone 7 & 8 15

Was told by Patric red motor light on at the

front and not working. He just asked me to
swap with tool heater from machine 21. Tool 15
heater still needs looking at as I was taken off
to sort out transducer on machine 1.

Balzer stopped in the middle of the cycle 30

One of the fittings on the moving half of the

60
tool is leaking from the thread. Please replace

Laser on the LPKF isn't working again 180

Another high pressure water heater is
15
required for the fixed half on the machine
Three new heat guns need PAT testing 10
Balzer stopped in the middle of the cycle 15
faulty thermocouple on zone 11 ,12 ,13 60
water leaking from the throat into barrel, after
15
Moday morning repair
need to check heater and thermocouple 15
Zones 11 and 12 not reaching temp. 60
to install air line to bench to airgun to blow
90
down parts.
Not able to use turn table aftre loading new
15
tool
Machine juddering when opening in setting
45
mode.
Work station 167 inside room needs a light
60
installing to it.
Hopper loader flap sensor may have an issue.
Hopper's been emptied three times during
morning shift and begins to pull after adjusting
10
around with the flap. Thought it was the
plastic holding it open slightly at first. Please
check it out.
Oven is stopping in cycle 180
Error "Cans not locking" 30
Material pipe hanging off and leaking air 60
Balzer stopped in the middle of the cycle
60
twice through the night
Lubrication 1 Pressure not built up 120
No power to HMI 20
No leaver to tighten up bolt at the back so
20
miss aligning.
Need an E-stop foot pedal installed instead of
30
push button.
Alignment of nozzle 45
Install wrist trap/ foot tester in break down
room
Requested by Jay Denniston to have all
threaded inserts replaced on all welders.
Heats not coming up to tempreture.
Core signals incorrect 60
Tip change errror on screen. 60
DB10 CFS temperature wasn’t exceeding
20
beyond 120C.
No rinse water 60
M/C stopping after every 5 shot 20
Dummp mplug missing fore cores 30
Leaking from the jig 30
Handle has it has broke off 60
material got stuck when going to the head 60

Dryer keeps tripping out then coming back on 90

Air pipe to the gun is damaged 30

TPM 30
TPM 30
Overheating on braking motor. 60
Moisture not being taken out of material. 20
Trays moving to fast in oven 15
Zone 27 on hot runner is shooting up over
3360
retching the setting point
MC not opening 20
Machine is showing "external closing
interlock" fault is active and cannot close the 20
moving half

Remove central partition from the group of

10
tables located in room next to Garry's office

Zone 6 on hot runner isn't showing on HMI 10

E.Stop Button comes out 15
Drive Controller Fault on Robot 0
Moving half core is saying plug missing,witch
30
is not ,can't open the tool
Zone 59 not heating up 30
Monitoring fault with robot. 80
Staple guns not shooting staples straight. 20
Asked to check thermoucouple. 15
Found water leaking from tank.
Pins not moving 45
28.5 temp not going down 60
Adjustment to test plate 35
Rotary table has no position. Needs
150
configuring
Material pipe is blocked from central feed to
15
M/C 19
No water flow and not heating up 240
Driver of the Studding Jig not working 10
TPM 45
TPM 30
TPM 15
TPM 15
Alarms need clearing 60
found faulty theromcouple 30
theromcouple fault 240

Locking nut number 4 not locating correctly. 150

Shoes would not open 40

Handle broken off 10
Sensor on unloading carraige not working. 25
E-stop hit 20
Broken pin holder 15

Extractor hose has broken off. Needs refitting 15

Hopper loader on Shinny dryer stops pulling

40
regularly and having to keep tapping the flap

Air-Con is leaking water 40

Sensor plug for robot head has broken 60
Check accumulator pressure. It's only
reaching 9-9.5bar where as it should be 20
12bar.
Ejector plug inserts required for both sides of
tool. Cores are currently wired into cho- 40
blocks?
P16 jig fixture P16SLRH isn't being read on
40
the machine and won't load the recipe
Air-con unit in scanning room (Mouldshop 1)
isn't functioning correctly. Half of the filter is
cold, but somehow blowing warm air. Isn't
leaking though
Loader isn't pulling material, but green light is
on
Hopper loader on the barrel of M/C 4 keeps
25
pulling even when it's full and clogs up pipe
Lone working alarm doesn't work. May have
20
loose connection
There isn't any studs holding down the
hopper loader to the barrel throught plate. 20
Health and safety issue
Hot runner extention feed on M/C 18 needs
sorting out as cable is trailing from power 60
supply at the front all the way to the rear.
Need two fire door break-bars for fire exit
20
doors. One by M/C 5 and M/C 23
Relocate pneumatic manifold from the current
location to the top non operator side panel 60
like MC 22
broken air fittings 30

TPM 165
 Months Jan-20 Feb-20 Mar-20 Apr-20
Downtime 21741.6 11217 8410.2 105

Months Jan-20 Feb-20 Mar-20 Apr-20

Target 2021 11447 11447 11447 10875
Actual

Yearly Plant Downtime Trend 2020

25000 12000

11500
20000
11000

10500
15000
10000
10000 9500

9000
5000
8500
Jan-20 Feb-20 M
0
Jan-20 Feb-20 Mar-20 Apr-20 May-20 Jun-20 Jul-20 Aug-20 Sep-20 Oct-20 Nov-20 Dec-20
 May-20 Jun-20 Jul-20 Aug-20 Sep-20 Oct-20 Nov-20 Dec-20
2760 8640 7840 7355 13299 12515 10335
Average last 3 months 12049.67
Reduction proposed 5
Target for Q1 2021 11447.18
Total reduction by Year 14.2625
May-20 Jun-20 Jul-20 Aug-20 Sep-20 Oct-20 Nov-20 Dec-20
10875 10875 10331 10331 10331 9815 9815 9815

Target Vs Actual Downtime 2020

12000

11500

11000

10500

10000

9500

9000

8500
Jan-20 Feb-20 Mar-20 Apr-20 May-20 Jun-20 Jul-20 Aug-20 Sep-20 Oct-20 Nov-20 Dec-20

Actual Target 2021

minutes/month
Percent/Q
minutes/month
 Downtime November 2020
Assets Downtime Contribution %
MC29 3390 36.04
MC1 1450 15.42
ALUMINISING 625 6.65
MC23 480 5.10
TOOLROOM 315 3.35
CLR1 295 3.14
COATING PLANT 280 2.98
WATER HEATER 275 2.92
MC19 230 2.45
OTHERS 230 2.45
CLR2 205 2.18
MC20 200 2.13
MC22 190 2.02
MC3 165 1.75
MC21 160 1.70
MC9 140 1.49
GLUE MACHINE 120 1.28
MERC ASMBLY 105 1.12
JIGS FIXTURES 100 1.06
FACILITIES 70 0.74
CFS 65 0.69
MC18 60 0.64
MC2 60 0.64
MOBILE DRYERS 60 0.64
MC26 40 0.43
MC8 30 0.32
MC4 25 0.27
MC6 20 0.21
MC7 10 0.11
OFFICES 10 0.11
9405
20
Cummulative
36
51
58
63
67
70
73
76
78
80
83
85
87
89
90
92
93
94
95
96
97
97
98
99
99
99
100
100
100
100
 PLant Downtime Distrubtion
165
190 20 10 10
60 6030 40 25
60
200 100 70 65
120 105
140
205 160 3390

230

230

275

280

295

315
625 1450
480

MC29 MC1 ALUMINISING MC23 TOOLROOM CLR1 COATING PLANT WATER HEATER
MC19 OTHERS CLR2 MC20 MC22 MC3 MC21 MC9
GLUE MACHINE MERC ASMBLY JIGS FIXTURES FACILITIES CFS MC18 MC2 MOBILE DRYERS
MC26 MC8 MC4 MC6 MC7 OFFICES
 Downtime Contribution
4000 120.00

3500
99 99 99 100 100 100 100
97 97 98 100.00
95 96
93 94
90 92
3000 89
87
85
83
80
78 80.00
76
2500 73
70
67
63
2000 58 60.00
51

1500

36 40.00

1000

20.00
500

0 0.00
9 C1 G 23 OM LR 1 T R 9 S 2 0 2 C3 21 C9 E LY ES ES S 8 C2 ER S C26 C8 C4 C6 C7 CES
C2 M ISIN MC AN TE C1 HER CL
R C2 C2 M MC M CHIN MB UR LITI CF C1
M RO
C PL HEA M T M M M M Y M M M M M FI
IN OL G O A A S IXT
A CI DR OF
M F
UM TO IN TER
UE
C
ER IG S
F ILE
AL AT A B
CO W GL M J
M
O

Downtime Contribution % Cummulative

 MAGUIRE Dryer
MC29

MC29 Zone 27 on hot runnner down

MC29 Dryer D900

Error "Cans not locking" 30

Zone 27 on hot runner is

shooting up over retching the 3360
setting point

Found water leaking from

tank.
 Asset Area of problem
Machine 1 turntable
MC1
MC1 Rotary Table Fault
Locking tie bars not clamping
MC1
over upon mould hight.
all alarm faults present
MC1
MC1 Machine 1

MC1 Lockin nuts 1 and 3

Tie-Bar Locking Clamps

MC1
MC1 Machine 1

Problem A
1200

1000
91
87

800 77

66

600

400

200

Downtime Contrib
Action Plan
 Fault Downtime Contribution% Cummulative
Turn table fault tranducer
960
broken. 66 66
Rotary table has no position.
150
Needs configuring 10 77
Locking nut number 4 not
150
locating correctly. 10 87
Alarms need clearing 60
4 91
Machine juddering when
45
opening in setting mode. 3 94
Shoes would not open 40 3 97
No locking position for tie-bar
30
4 2 99
Not able to use turn table
15
aftre loading new tool 1 100
1450

Problem Analysis
120

99 100
97 100
94
91
87

80

60

40

20

Downtime Contribution% Cummulative

 Jan-20 Feb-20 Mar-20 Apr-20 May-20 Jun-20 Jul-20 Aug-20 Sep-20
Downtime

120

100
100

80

60

40

20

0
Oct-20 Nov-20 Dec-20