Ishida GUACP Operator Training Manual

Ishida Global Universal Auto

Case Packer Operator
Training Manual
Version 1.0
January 2013

Corrections/comments should be directed to [email protected] or to the Packaging Starfleet Team.

Copyright 2013 Frito-Lay, Inc.

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Version 1.0 uses Machine #1 specifications.

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Table of Contents
CHAPTER 1 - GUACP SAFETY ............................................................................................................... 7

CHAPTER 2- OVERVIEW....................................................................................................................... 11
OVERVIEW .............................................................................................................................................. 11
GUACP INTERNAL COMMUNICATION .................................................................................................. 12
CHAPTER 3- CASE ERECTING ............................................................................................................ 13
MAGAZINE AREA .................................................................................................................................... 14
SHEET MAGAZINE CONVEYOR ............................................................................................................... 17
MAGAZINE CONVEYOR PHOTO EYES B215, B216, B217, B218 ............................................................ 18
CARTON IN SHEET LIFTER PHOTO EYE B219 ....................................................................................... 20
SHEET SPACER ........................................................................................................................................ 21
UPSTREAM SIDE CARTON SUCTION CUPS.............................................................................................. 22
DOWNSTREAM SIDE CARTON SUCTION CUPS........................................................................................ 23
CASE ERECTING ARM ............................................................................................................................. 24
CASE ERECTING FLAP GUIDES............................................................................................................... 25
FAN FOLD PADDLES ................................................................................................................................ 26
TOP MAJOR FLAP STOPPER ................................................................................................................... 27
BOTTOM FLAP PUSHER .......................................................................................................................... 28
CASE ERECTING CASE TRANSFER ......................................................................................................... 29
MINOR FLAP PUSHER ............................................................................................................................. 30
MAJOR FLAP OPENER ............................................................................................................................ 31
CASE CLAMP ........................................................................................................................................... 32
CASE ERECTING AREA TAPER ............................................................................................................... 33
LOW TAPE PHOTO EYE B437 ................................................................................................................. 36
CLASSROOM DISCUSSION QUESTIONS ................................................................................................... 37
PRACTICAL EXERCISE ............................................................................................................................ 38
CHAPTER 3- BAG HANDLING .............................................................................................................. 39
BAG INFEED ROUND BELTING ................................................................................................................ 40
BAG INFEED INCLINE BELT .................................................................................................................... 41
INFEED JAM DETECT PHOTO EYE B1011 .............................................................................................. 42
BAG INFEED CONVEYOR ......................................................................................................................... 43
INFEED INNER SIDE BELT ....................................................................................................................... 44
BAG INFEED OUTER SIDE BELT ............................................................................................................. 45
DECLINE CONVEYOR .............................................................................................................................. 46
BAG ROTATION ASSIST PUSHER............................................................................................................. 47
BAG ROTATION ASSIST PHOTO EYE B1012 ........................................................................................... 48
BUMP TURNER ........................................................................................................................................ 49
DECLINE CONVEYOR SIDE GUIDES ........................................................................................................ 50
DECLINE CONVEYOR PHOTO EYE.......................................................................................................... 51
SORT CONVEYOR 1 ................................................................................................................................. 52
SORT CONVEYOR 2 ................................................................................................................................. 53
SORT CONVEYOR 3 ................................................................................................................................. 54
SLIDER ..................................................................................................................................................... 55
REAR END GUIDE DOORS ....................................................................................................................... 56
UPSTREAM AND DOWNSTREAM BAG LOADING PHOTO EYES B613 AND 614 ....................................... 57
COMPRESS CONVEYOR ........................................................................................................................... 58
CLASSROOM DISCUSSION QUESTIONS ................................................................................................... 59
PRACTICAL EXERCISE ............................................................................................................................ 60

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CHAPTER 4- CASE LOADING............................................................................................................... 61

CASE PUSHER .......................................................................................................................................... 62
OPEN FLAP PHOTO EYE B450 ................................................................................................................ 64
DROP AREA DROP SHELVES ................................................................................................................... 65
CASE IN DROP AREA PHOTO EYES B457 AND B461 .............................................................................. 66
CASE LOADING GUIDES .......................................................................................................................... 67
CASE RECEIVING GATES ........................................................................................................................ 68
CASE DROP PUSHER ............................................................................................................................... 69
CASE ELEVATOR ..................................................................................................................................... 70
CASE AT LOAD AREA PHOTO EYES B657 AND B658 ............................................................................. 71
CLASSROOM DISCUSSION QUESTIONS ................................................................................................... 72
PRACTICAL EXERCISE ............................................................................................................................ 73
CHAPTER 5- CASE CLOSING ............................................................................................................... 75
CASE LABELER........................................................................................................................................ 76
CASE CLOSING CASE PUSHER ................................................................................................................ 77
CASE ACCEPT PUSHER ........................................................................................................................... 78
CASE ROTATION DETECT PHOTO EYE 653............................................................................................ 79
CASE CONVEYOR .................................................................................................................................... 80
MAJOR FLAP RAISING GUIDE ................................................................................................................ 81
MINOR FLAP GUIDE................................................................................................................................ 82
CASE CLOSING PADDLES ........................................................................................................................ 83
CASE JAM DETECT PHOTO EYES B651 AND B652 ................................................................................. 84
MAJOR FLAP RAISE ................................................................................................................................ 85
MINOR FLAP RAISE ................................................................................................................................ 86
OUTER MAJOR FLAP RAISE AND SHIFT ................................................................................................. 87
CASE CLOSING FLAP PUSHER ................................................................................................................ 88
CASE CLOSING TAPER ............................................................................................................................ 89
LIFTER ..................................................................................................................................................... 91
DOWNSTREAM/UPSTREAM LIFTER STOPPER ........................................................................................ 92
REJECTED CASE PUSHER........................................................................................................................ 93
UNFOLDED TOP PHOTO EYE B818 ......................................................................................................... 94
REAR FLAP RAISER................................................................................................................................. 95
CASE EJECTING PE B817 ....................................................................................................................... 96
LIGHT CURTAIN REJECT PE B854 AND LIGHT CURTAIN EXIT PE B855 ............................................. 97
VACUUM PUMP AND FILTER ................................................................................................................... 98
CLASSROOM DISCUSSION QUESTIONS ................................................................................................... 99
PRACTICAL EXERCISE ...........................................................................................................................100
CHAPTER 6- OPERATOR CONTROLS ..............................................................................................101
OIT .........................................................................................................................................................101
EMERGENCY STOPS ...............................................................................................................................102
MAIN AIR/POWER CUTOFFS..................................................................................................................103
REJECT/ NO REJECT SWITCH................................................................................................................104
MAIN OPERATOR SCREEN .....................................................................................................................105
CASE SIZE ADJUST SCREEN ...................................................................................................................106
CONDITION CHECK SCREEN ..................................................................................................................107
FAULT HISTORY SCREEN .......................................................................................................................108
MACHINE PERFORMANCE SCREEN PAGE 1 ..........................................................................................109
MACHINE PERFORMANCE SCREEN PAGE 2 ..........................................................................................110
CHANGEOVER SCREENS ........................................................................................................................111
FAULT SCREEN .......................................................................................................................................115
FAULT LOCATION SCREEN ....................................................................................................................116

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CHAPTER 6- STANDARD OPERATING PROCEDURES .................................................................117

OVERVIEW .............................................................................................................................................117
STARTUP .................................................................................................................................................117
CHANGEOVER ........................................................................................................................................118
SHUTDOWN .............................................................................................................................................119
CLEARING FAULTS.................................................................................................................................120
CERTIFICATION ....................................................................................................................................121

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Chapter 1 - GUACP Safety

The GUACP is designed for safe and convenient operation. However, as with any piece
of machinery, there is potential for personal injury if safe operating practices are not
followed, or if safety features built into the equipment are bypassed.
Pay close attention to all WARNING, or CAUTION notices that are posted on the
machine or included in the manual. Warnings and Cautions follow the suggested
guidelines for the industry:

Warning Caution
The hazard or unsafe practice The hazard or unsafe practice
could result in severe injury or could result in minor injury or
death. property damage.

Before attempting to operate the GUACP, be sure that you are familiar with and follow
your plant safety procedures.

NOTE: Only trained maintenance personnel should perform maintenance on the GUACP.
Refer to the Ishida Machine Operation/Maintenance Training Manual for instructions on
locking out the GUACP
WARNING!

Contact with moving parts of packaging machinery is hazardous and may result in
serious personal injury or death.
Ishida packaging machines must not be operated without all guards in place. Never
operate the GUACP without all safety equipment in place.

NOTE: Some photographs were taken with guards removed, in order to show parts more
clearly; this in no way suggests that the machine be operated without all guards in place.

WARNING!

Improper operation of the GUACP may result in damage to the equipment or serious
personal injury or death. Read and understand the contents of this manual before
attempting to operate the GUACP.

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WARNING!

Under no circumstances ever place your hands or feet under,

around or through any guarded area on the GUACP.

Open Base of GAUCP

Never reach in or under to clear excess product, bags, cartons or

labels.

Always stop the equipment and open guard doors to remove any
debris.

Any running packaging machinery has the potential of causing

serious bodily injury if the manufacturer’s safety devices are
bypassed or ignored.

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The top of the GUACP is open. Never place your hands in

through the top of the machine for any reason without the
machine stopped and an emergency stop pressed.

Open Top Of GUACP

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Never place your hands inside the upstream bag entrance to the
GUACP without the machine stopped and the emergency stop
engaged.

Upstream Bag Entrance to GUACP

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Chapter 2- Overview
Overview
The Global Universal Auto Case Packer (GUACP) has four main areas:

 Case Erecting
 Bag Handling
 Case Loading
 Case Closing

Global Universal Auto Case Packer Diagram

The Ishida GUACP can run up to ten cases per minute and up to 150 bags per minute.
Case pack configurations may limit these speeds.
The Ishida GUACP can run products with former sizes between 4.25 inches and 13
inches and bag lengths between 5 inches and 24 inches.

The GUACP has a right hand and left hand configuration. This manual shows right land
configurations, but the functionality of all components is exactly the same on both
machine configurations.

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GUACP Internal Communication

The GUACP uses three methods of internal communication to keep the machine in time
and to prevent damage to the GUACP. They are:

Photo eyes- These are generally used to allow the GUACP to sense that a bag or a case
has reached a certain location. The GUACP now knows that it can continue to the next
step in loading the case. Photo-eyes can be:
 Retro-reflective- this type photo eye sends the laser beam against a
reflector, where it bounces back to a receiver in the photo eye.
 Send/Receive- this type photo eye sends a laser beam to another receiving
photo eye in a different location.
 Diffuse- this type photo eye sends a short beam out and senses if
something is blocking the beam.

Proximity Switches- These are generally used to allow the GUACP to sense that one part
of the GUACP is in a certain location, helping ensure that components do not jam.

Torque limiters or clutches- These will sense when too much force is being applied to
move a component of the GUACP. They will trip an “Overload” or “Fault” type error
message before the GUACP damages itself.

Components of the GUACP are driven one of two ways:

Air Cylinders- Air cylinders are used to move some components in the GUACP. Air
cylinders are inexpensive drivers used when components need to move between two
discreet positions. Example: A gate in the machine may only move from full open to full
closed positions.

Drive Motors- Drive motors power components that must move to multiple positions or
run continuously. Example: The Sort Belt runs on a drive motor.

DC Stepper Drive Motors- Stepper Drives are used when motors must stop at specific
precise locations multiple times. The Slider uses a stepper motor.

Servo Motors- Servo motors function the same way stepper motors do, but with greater
accuracy, and at higher costs. The Case Arm has the only Servo Motor on the GUACP.

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Chapter 3- Case Erecting

Unlike other UACP and GUACP machines, the Ishida GUAP has an integral automatic
case erector. The Ishida GUACP does not require a mezzanine and the associated
machinery.

Inspection Section Diagram

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Magazine Area

Flat cartons are loaded into the Magazine Area.

Left Carton Feed Width Adjust

Carton Loading Arm

Right Carton Feed Width

Adjust

Magazine Area, View from Left Rear

The Left and Right Carton Width Adjusts automatically move to a new location when the
machine changes over to a different carton size. The Magazine Area must be clear of any
cartons after the machine is drained and before the PMO begins changeover.

WARNING!

Keep hands clear of the Carton Width Adjusts when they are moving at changeover.

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The spring-loaded Carton Loading Arm applies pressure to the cartons in the magazine
while they are being loaded into the GUACP.

Angle Release Knob

Retract Lock Handle

Carton Loading Arm Detail, View from Right Side of Machine

When loading new cartons, the operator should pull the arm back until it locks behind the
retract lock handle. The operator then should rotate the arm to the GUACP’s right side.
After loading, the operator rotates the arm back to the center of the GUACP and releases
the lock handle.

To relieve pressure when clearing a jammed case without unloading the machine, the
operator should pull the angle release knob up and rotate the arm back 45°. Then the
operator can flip the cartons in the magazine backwards against the arm until they are out
of the way to clear the jam. Afterwards, the operator flips the cases back forward in the
magazine and returns the arm to the upright position.

CAUTION!

Use caution around the pinch point where the locking handle locks the Arm in the back
position.

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In the GUACP, cartons must be loaded with the minor panel down and the case label
location facing upstream. This is true for any North American cartons.

Properly Loaded Cartons

Remember: Minor panel low, labels never show.

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Sheet Magazine Conveyor

The Sheet Magazine advanced the cartons through the carton magazine.

Sheet Magazine Conveyor

A stepper motor powers the conveyor when commanded by the correct sequences of
photo eyes as described on the upcoming pages..

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Magazine Conveyor Photo Eyes B215, B216, B217, B218

There are four photo eyes associated with the Sheet Magazine Conveyor.

PE 216
PE 218

PE 215

PE 217

Magazine Photo Eyes Detail View From Right Side

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B215 is a Send/Receive style with an emitter and a collector on the opposite side of the
magazine. When blocked, this photo eye signals the Sheet Lifter that there is a case ready
to be moved to the erection section.

B216 (diffused photo eye) and B217 (retro-reflective photo eye) sense whether there are
cases in certain locations. All three photo eyes work together and send different signals
when blocked in different combinations, as seen in the chart below:

B216 B217 B215 Action

Blocked Blocked Clear Sheet Conveyor on until B215 blocked.
Clear Blocked Clear The GUACP will attempt to run three more cycles,
then send a fault message if B215 does not see a
carton
Blocked Clear Clear Sheet Conveyor on. If B217 or B215 are not blocked
within a few seconds, a fault message is displayed on
the OIT.

B218 is a diffused photo eye closest the end of the machine. When it is clear of cartons, it
signals the GUACP to display a “Low Case” warning message on the OIT.

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Carton in Sheet Lifter Photo Eye B219

Photo eye B219 is a diffused photo eye located at the top of the stroke of the Sheet Lifter.

Photo Eye B219, View from Top Left Hand Side.

If the Sheet Lifter has made it to the top, and this photo eye is not blocked by a case, the
machine will fault.

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Sheet Spacer

The Sheet Spacer keeps only one carton at a time from moving into the Sheet Lifter.

Sheet Spacer, View Up from the Rear

A stepper motor will automatically move the Sheet Spacer up or down when the GUACP
changes over to a new carton size. As a result, all cartons must be cleared from the
machine after it is drained and before the operator starts the changeover.

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Upstream Side Carton Suction Cups

The suction cups on the upstream side of the carton transport and hold the flat carton.

Top Sheet Suction Cup

Sheet Lifter Suction Cups

Upstream Carton Suction Cups, View from Rear of Machine through Magazine Area

On the upstream side of the carton, the Top Sheet Suction Cup extends and pulls the first
carton in queue through the Sheet Separator. Then, the two Sheet Lifter Suction Cups
grab the carton and slide it up into place for opening.

The position of the Top Sheet Suction Cup changes when the case size changes.

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Downstream Side Carton Suction Cups

On the downstream side, two suction cups hold the carton on place before the XXX
opens and repositions it for folding.

Downstream Side Carton Suction Cups, View from Right Side Looking Back.

The Sheet Lifter moves the carton into position on these two suction cups. A stepper
motor changes the position of the two suction cups when carton size changes.

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Case Erecting Arm

The Case Erecting Arm rises and grasps the carton as the Sheet Lifter releases the carton
and moves back downward.

Two Vacuum Cups

Articulating Joint

Five Vacuum Cups

Case Erecting Arm, View from Upstream, Inside the Machine

The Case Erecting Arm is servo driven. The arm has two sections joined at an articulating
joint that bends up to 90°. Two vacuum cups above the joint grab the minor panel and the
five vacuum cups below the joint grab the major panel. As the arm returns to the down
position, the arm bends 90°, and pops the carton open. The arm supports the case in this
way until the bottom flaps have been folded. Then the top two suction cups release and
the top of the arm returns to the full-down position.

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Case Erecting Flap Guides

Four Case Erecting Flap Guides hold the flaps in place while fan folding.

Case Erecting Flap Guides, Downstream (Left) and Upstream (Right), View From Left Side of Machine

An air cylinder moves each of the Case Erecting Flap Guides in to hold a flap in place. A
second air cylinder moves the guides in while the carton is being folded.

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Fan Fold Paddles

Four Fan Fold Paddles fold the carton closed.

One of Four Fan Fold Paddles

One dual-action air cylinder controls rotation of the major Fan Fold Paddles and another
dual-action air cylinder controls rotation of the minor Fan Fold Paddles. On taped cases,
the minor flaps fold first, followed by the major flaps. On folded cases, all four paddles
close simultaneously.

Each paddle also has an air cylinder that moves it inward during the folding process.

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Top Major Flap Stopper

The Top Major Flap Stopper opens and stabilizes the top major flap before fan folding.

Top Major Flap Stopper, View from Right Hand Side

Two air cylinders move the Top Major Flap Stopper. One moves it up and down, the
other extends and retracts it.

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Bottom Flap Pusher

The Bottom Flap Pusher is a scissor-type assembly mounted on the right side door of the
fan fold area.

Bottom Flap Pusher, Extended, View with Door Open

An air cylinder extends the Bottom Flap Pusher after the fan fold is complete to tam the
box flaps together. It retracts it to allow the next carton to be erected. The Pusher is
engaged on both Vend and Retail cartons.

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Case Erecting Case Transfer

After the carton bottom is folded, the Case Erecting Case Transfer moves to the
downstream minor panel of the carton. When the GUACP is ready, it moves the carton to
the loading area.

Case Erecting Case Pusher, Ready to Move Carton, View from Top, Left Hand Side

A stepper motor moves the Case Pusher forward and backward. An air cylinder raises the
Case Transfer Plate to clear the new carton, and then drops the arm down behind it.

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Minor Flap Pusher

On the carton top, the Minor Flap Pusher extends to open the leading minor flap before
the carton moves from the Case Erecting area.

Minor Flap Pusher, Retracted, View from Left Side of Machine

An air cylinder extends and retracts the Minor Flap Pusher

Minor Flap Pusher, Extended With Case, View From Above

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Major Flap Opener

On the top side of the finished carton, the Major Flap Opener opens and extends the top
major flap.

Major Flap Opener, View from Right

Major Flap Opener, Extended, View from Above

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Case Clamp

The Case Clamp extends and holds the carton in place while the bottom is folded.

Case Clamp, Extended, View from Right Hand Side

Case Clamp, Extended, with Carton, View from Right Hand Side, Above

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Case Erecting Area Taper

The case erecting section has its own taper.

Case Erecting Area Taper, View from Right

An air cylinder moves the Taper back and forth as the carton passes behind it. A second
air cylinder moves the Taper temporarily out of the way of other folding components
between taping cycles.

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To change the tape roll, press TAPE CHANGE on the Fault Screen.
The taper will lower to the load position. Release the locking handle and swing the taper
out and down as seen below.

Taper Swung Out for Loading Tape, View from Right

When threading the taper, thread the tape at a 90° angle through the guides.

Tape Threaded Through 90° Guides

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Continue threading the taper using the yellow arrows around the rollers.

Properly Threaded Tape Through The Rollers

When raising the Taper back into position, ensure that the guide post is in the alignment
slot.

Guide Post in Alignment Slot

Then swing the Taper back into position and secure with the locking handle.

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Low Tape Photo Eye B437

The Low Tape Photo Eye checks the size of the tape roll when the taper moves under the
photo eye.

Photo Eye B437, View from Right

When the tape no longer blocks the photo eye, a “Low Tape” warning message will pop
up on the OIT. The machine will continue to run until it runs out of tape.

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Classroom Discussion Questions

1. What warning accompanies the Case Magazine?

2. How does the GUACP confirm that a carton is in place for the Case Erecting Arm to
pick and open?

3. Name the components that use vacuum in the Case Erecting Area.

4. Describe how Fan Fold Paddles work differently erecting taped and fan folded cases.

5. Name two components that hold open the top of the carton while the bottom is fan
folded.

6. What button must be pushed when changing tape on the Case Erecting Area Taper?

7. What should the Operator check before raising the reloaded Taper back into position?

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Practical Exercise

This practical exercise requires the cooperation of the Packaging Department in your
plant. Do not attempt to perform this exercise unless you are under your trainer’s
supervision.

1. Go to the packaging area with your trainer. Your trainer will designate a GUACP for
you to use to perform this practical exercise.
2. Identify the following components and describe their function for the trainer:
 Magazine Area
 Sheet Magazine Conveyor
 Magazine Conveyor Photo Eyes B215, B216, B217, B218 17
 Carton in Sheet Lifter Photo Eye B219
 Sheet Spacer
 Upstream Side Carton Suction Cups
 Downstream Side Carton Suction Cups
 Case Erecting Arm
 Case Erecting Flap Guides
 Fan Fold Paddles
 Top Major Flap Stopper
 Bottom Flap Pusher
 Case Erecting Case Transfer
 Minor Flap Pusher
 Major Flap Opener
 Case Clamp
 Case Erecting Area Taper

Trainer Check:

Done Correctly Needs Improvement

Comments_______________________________
________________________________________
________________________________________
________________________________________

______________________________
Performance Based Trainer Signature

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Chapter 3- Bag Handling

After exiting the TSC Inspector, the bags pass through an infeed section, a decline
section, a sort section where the bags are aligned, and a load area where the bags are
finally accumulated and compressed to be inserted into an open carton.

Infeed Decline Sort

Bag Handling Section Diagram, Overhead View

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Bag Infeed Round Belting

The bag will cross six bands of Infeed Round Belting before entering the Incline
Conveyor.

Bag Infeed Round Belting, View from Upstream

The gaps in the Infeed Round Belting allow any stray chips to fall through and stay out of
the GUACP.

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Bag Infeed Incline Belt

Bags travel up the Bag Infeed Incline Belt.

Bag Infeed Incline Belt, Upstream View

The belt is powered by a DC motor and the speed will change depending on the program
selected.

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Infeed Jam Detect Photo Eye B1011

If this photo eye at the top of the Incline Belt remains blocked for more than three
seconds, the GUACP will stop and display an “Infeed Jam” fault message.

Infeed Jam Detect Photo Eye, View from Left Side

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Bag Infeed Conveyor

Bags transfer from the Incline Belt to the Bag Infeed Conveyor.

Bag Infeed Conveyor, Upstream View

The Bag Infeed Conveyor runs off the same DC motor as the Incline Belt and at the same
speed.

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Infeed Inner Side Belt

The Infeed Inner Side Belt helps align and transport the bag as it moves down the Infeed
Conveyor.

Infeed Inner Side Belt, Upstream View

The speed and position of the Inner Side Belt change with different case pack programs.

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Bag Infeed Outer Side Belt

The Bag Infeed Outer Side Belt aligns and positions the bag on the Infeed Conveyor.

Bag Infeed Outer Side Belt, Upstream View

The speed and position of the Outer Side Belt change with different case pack programs.

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Decline Conveyor

The Decline Conveyor transfers bags from the Infeed Conveyor to the Sort Conveyors.

Decline Conveyor, Downstream View

The speed and the angle of the Decline Conveyor changes with different case pack
programs.

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Bag Rotation Assist Pusher

An air cylinder extends the Bag Rotation Assist Pusher when the bag needs to be turned
90°.

Bag Rotation Assist Pusher, View from Left

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Bag Rotation Assist Photo Eye B1012

The Bag Rotation Assist Photo Eye is a diffused photo eye mounted over the Bag Rotate
Assist.

PE B1012, View from Left

The photo eye fires the Bag Rotation Assist if:

 The bag speed is less than 80 BPM.
(and)
 The bag length is greater than 6.5” (16.5mm).
(and)
 If the ration of width of bag and length of bag exceeds 1.9.

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Bump Turner

An air cylinder extends the Bump Turner to turn bags that must rotate 90° to be packed.

Bump Turner, View from Left

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Decline Conveyor Side Guides

The Decline Conveyor Side Guides guide the bag down the Decline Conveyor.

Decline Conveyor Side Guides, Upstream View

Side Guide, View From Left

The width between the Side Guides changes with different case pack programs. A stepper
motor moves one or both of the side guides at changeover.

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Decline Conveyor Photo Eye

The Decline Conveyor Photo Eye is a send/receive photo eye mounted at the end of the
Decline Conveyor.

Decline Conveyor Photo Eye Detail, View from Left Side

The Decline Conveyor Photo Eye counts the bags to time the movements of the rest of
the handling and loading components.

If this photo eye remains blocked for three seconds, the GUACP will stop and display a
“Decline Conveyor Photo Eye Blocked” fault. After recovery from this type of fault, the
GUACP will always reject the current case, open, as the bag count cannot be determined.

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Sort Conveyor 1

Bags fall from the Decline Conveyor to Sort Conveyor 1.

Sort Conveyor 1, View from Left

A stepper motor drives Sort Conveyor 1. This conveyor moves a precise amount with the
addition of each bag depending on the case pack program and the number of bags in a
row.

Sort Conveyor 1 can angle at one of four specific angles depending on the case pack
pattern. Air cylinders change the conveyor position at changeover.

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Sort Conveyor 2

Sort Conveyor 2 moves bags from Sort Conveyor 1 to Sort Conveyor 3.

Sort Conveyor 3, View from Left

Sort Conveyor 2 is driven by a stepper motor.

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Sort Conveyor 3

Bags arrive at Sort Conveyor 3 and are then loaded into the waiting carton.

Sort Conveyor 3, View from Left

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Slider

The Slider moves the completed row of bags into the waiting carton.

Slider, View from the Left

A stepper motor moves the Slider back and forth to different positions for different case
pack patterns.

A second stepper motor changes the width of the slider depending on the case pack
configuration. The Slider’s width adjusts only at changeover.

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Rear End Guide Doors

Air cylinders close two Lexan doors at the upstream end of Sort Conveyor 3 to create a
solid rear surface for the row before loading.

Rear End Guide Doors, Partially Closed, With Protective Shipping Cover, View from Left Upstream

Some small bag high speed programs may not use the Rear End Guide Doors if there
isn’t time to close them between row advances.

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Upstream and Downstream Bag Loading Photo Eyes B613 and 614

The two photo eyes sense if the last bag is too far from the rest of the row.

B 613

B 614

Upstream and Downstream Bag Loading Photo Eyes, View from Left

On a small bag program where the bags face the major panel, if a bag has become
separated from the shingled row and it blocks either photo eye, Sort Conveyor #3 will run
a little longer to attempt to clear the bag in to the load area. If the recovery attempt does
not clear the photo eyes, the machine will display a “Bag Jam at Sort Conveyor 3” fault.

On all other programs, if the photo eyes sense a lagging bag, the GUACP will stop and
display a “Bag Jam at Sort Conveyor 3” fault.

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Compress Conveyor

The Compress Conveyor moves the first bag in the row to an upright position and
compresses the row for easier loading.

Compress Conveyor, View from left

Air cylinders moves the Compress Conveyor in before the row of bags is loaded. A
stepper motor turns the Compress Conveyor.

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Classroom Discussion Questions

1. How many belts handle bags before they finally arrive at the load area?

2. What two components on the Infeed Conveyors only function with side pack bags?

3. How are the Decline Conveyor Side Guides adjusted?

4. What two components align the bags before they are pushed into the load area?

5. Describe the function of the four photo eyes in the Bag Handling Section.

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Practical Exercise

This practical exercise requires the cooperation of the Packaging Department in your
plant. Do not attempt to perform this exercise unless you are under your trainer’s
supervision.

1. Go to the packaging area with your trainer. Your trainer will designate a GUACP for
you to use to perform this practical exercise.
2. Identify the following components and describe their function for the trainer:
 Bag Infeed Round Belting
 Bag Infeed Incline Belt
 Infeed Jam Detect Photo Eye B1011
 Bag Infeed Conveyor
 Infeed Inner Side Belt
 Bag Infeed Outer Side Belt
 Decline Conveyor
 Bag Rotation Assist Pusher
 Bag Rotation Assist Pusher Photo Eye B1012
 Bump Turner
 Decline Conveyor Side Guides
 Decline Conveyor Photo Eye
 Sort Conveyor 1
 Sort Conveyor 2
 Sort Conveyor 3
 Slider
 Rear End Guide Doors
 Upstream ans Downstream Bag Loading Photo Eyes B613 AND 614
 Compress Conveyor

Trainer Check:

Done Correctly Needs Improvement

Comments_______________________________
________________________________________
________________________________________
________________________________________

______________________________
Performance Based Trainer Signature

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Chapter 4- Case Loading

In Case Loading, the carton will pass through a Drop, an Upper Load, and Lower Load
Areas.

Drop Area

Upper Load
Area

Lower Load
Area

Overview of Three Case Loading Area

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Case Pusher

The Case Pusher slides the carton sideways into the Drop Area.

Case Pusher, View from Upstream, Left

An air cylinder moves the Case Pusher back and forth

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Two components attached to the Cash Pusher help keep the carton in position.

Lower Flap
Pusher

Minor Flap Holder

Lower Flap Pusher and Minor Flap Pusher View from Above, Left

The Lower Flap Pusher aligns the lower major flap into the load area.

The Minor Flap Pusher extends to align the leading minor flap as the carton passes to the
Case Pusher.

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Open Flap Photo Eye B450

The Open Flap Photo Eye is mounted on the rear of the Case Pusher.

Open Flap OE, View from Above, Left

This reflective photo eye looks into the erected case. If the laser returns from the reflector
across the machine, the flaps are not folded closed. The machine will stop and display an
“Open Flap” fault message.

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Drop Area Drop Shelves

The Case Pusher moves the carton to the Drop Area, where it rests on two Drop Shelves.

Drop Shelves, View from Right

Air cylinders retract the Drop Shelves to move the carton from the Drop Area to the
Loading Area.

The Drop Shelf in the right of this picture moves forward and backward at changeover to
accommodate different carton sizes.

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Case in Drop Area Photo Eyes B457 and B461

Two Case in Drop Area Photo Eyes mounted behind the Drop Shelves confirm that a
carton has made it to the Drop Shelves.

B457

B461

Case in Drop Area Photo Eyes, View from Above

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Case Loading Guides

The Case Loading Guides are two air cylinders being controlled from one solenoid
(Y710). These guides are located at case loading and guide the case while the case is on
the Case Elevator and is being loaded.

Case Loading Guides, View from Right

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Case Receiving Gates

The Case Receiving Gates are two air cylinders being controlled from one solenoid
(Y707). These gates are located at case loading and hold the erected case until it begins to
fill. Once the case starts to fill the gates will retract and allow the Case Loading Guides
and Case Elevator to manage the position of the case.

Case Receiving Gates, View from Right

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Case Drop Pusher

An air cylinder drives the Case Drop Pusher up and down. It helps move the carton from
the Drop Area to the Load Area.

Case Drop Pusher, View from Right

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Case Elevator

The Case Elevator is used to hold the case while loading and to move the case up or
down to accommodate different rows in the case.

Case Elevators, Lowered, View from Right

After the carton arrives in the load area, a stepper motor raises the Case Elevator and it
grips the bottom of the carton with six vacuum cups. It will move the case to a new
position as each row of product is added. When the carton is full, the Case Elevator will
lower and rotate the case for delivery to the XXX conveyor. Air cylinders control the
rotation. The metal plate around the vacuum cups is spring loaded to compensate for
irregular cases.

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Case at Load Area Photo Eyes B657 and B658

Two Case at Load Area photo eyes confirm that the carton made it from the Drop Area to
the Load Area.

B657

B658

Case at Load Area Photo Eyes, View from Right

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Classroom Discussion Questions

1. What three positions does the carton pass through while loading?

2. Describe the function of the photo eyes in the load area in the order the carton should
trip them.

3. What two components move the case from the drop area to the load area?

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Practical Exercise

This practical exercise requires the cooperation of the Packaging Department in your
plant. Do not attempt to perform this exercise unless you are under your trainer’s
supervision.

1. Go to the packaging area with your trainer. Your trainer will designate a GUACP for
you to use to perform this practical exercise.
2. Identify the following components and describe their function for the trainer:
 Case Pusher
 Open Flap Photo Eye B450
 Drop Area Drop Shelves
 Case in Drop Area Photo Eyes B457 AND B461
 Case Loading Guides
 Case Receiving Gates
 Case Drop Pusher
 Case Elevator
 Case at Load Area Photo Eyes B657 AND B658

Trainer Check:

Done Correctly Needs Improvement

Comments_______________________________
________________________________________
________________________________________
________________________________________

______________________________
Performance Based Trainer Signature

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Chapter 5- Case Closing

In the Case Closing section the case is labeled and either fan folded or taped closed.
Open or faulted cases are rejected.

Inspection Section Diagram

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Case Labeler

A labeler is mounted upstream of the lower loading area.

Example of a Case Labeler

Labeler models vary by site. Consult the specific labeler manuals

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Case Closing Case Pusher

An air cylinder moves the Case Closing Case Pusher, which transfers the loaded case to
the Case Conveyor.

Case Closing Case Pusher, View from Right

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Case Accept Pusher

An air cylinder extends the Case Accept Case Pusher to help guide the filled case to the
Case Conveyor.

Case Accept Pusher, View from Right

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Case Rotation Detect Photo Eye 653

The Case Rotation Detect Photo Eye is mounted at the bottom of the load area just before
the Case Conveyor.

Case Rotation Detect Photo Eye

This diffused photo eye confirms that a case made it to the lower load area and that it
properly transitioned to the Case Conveyor.

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Case Conveyor

The Case Conveyor moves the filled case through the case closing section on two rubber
flighted belts with lugs attached at specific intervals. The conveyor is powered by a
stepper motor.

Case Conveyor

The Case Conveyor raises and lowers to accommodate different height cases. A DC
motor changes the Case Conveyor height at changeover.

The Operator can make minor adjustments to the Case Conveyor height from the OIT if
cases continue to be poorly fan folded.

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Major Flap Raising Guide

The Major Flap Raising Guide is on the right side of the machine over the entrance to the
Case Conveyor.

Major Flap Raising Guide, Extended

The unit raises the outer major flap to vertical to prepare it for fan folding. An air
cylinder pushes a wedge-shaped sheet metal guide down the outside of the case which
raises the outer flap. It keeps the flap up until the case gets to case closing.

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Minor Flap Guide

The Minor Flap Guide is mounted at the top of the entrance to the Case Conveyor.

Minor Flap Guide, view from underneath

The Minor Flap Guide is an air cylinder fired arm that controls the minor flaps of the
filled case as it is pushed to the Case Conveyor. The arm pushes the leading minor flap
towards the discharge of the machine and pushes the trailing minor flap out of the case to
prepare the case for closing.

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Case Closing Paddles

Four Case Closing Paddles, similar in design to the Bottom Closing Paddles in the Case
Erecting Area are in the corners of the Case Closing Area.

One of Four Case Closing Paddles.

The minor and major flaps can close simultaneously for a fan fold, or the majors can
follow the minors when taping the case closed. Air cylinders move all the paddles.

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Case Jam Detect Photo Eyes B651 and B652

The Case Jam Detect Photo Eyes looks across the machine between the folding area and
Lifter. If one of these photo eyes remain blocked too long, the GUACP stops and a
“Case Jam” fault message displays on the OIT.

Case Jam Detect Photo Eye, View from Right

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Major Flap Raise

Four components raise the flaps prior to folding. The Major Flap raise lifts the far major
flap to the up position.

Major Flap Raise, View from Right

The Major Flap Raise is a rotary air cylinder with a round rod attached to the rotary shaft.

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Minor Flap Raise

A leading and trailing Minor Flap Raise pushes up the minor flaps prior to folding.

Trailing Minor Flap Raise, View from Inside

Air cylinders move the Flap Raises up and down.

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Outer Major Flap Raise and Shift

The Outer Major Flap Raise and Shift sweeps down onto the case and moves the outer
major flap up and out of the case if necessary.

Outer Major Flap Raise and Shift, View from Right

Two air cylinders operate this component.

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Case Closing Flap Pusher

After the case is closed, an air cylinder extends the Case Closing Flap Pusher to tamp
down the top of the case.

Case Closing Flap Pusher, View from Right

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Case Closing Taper

A taper will taper shut the top of the box, depending on the product being run.

Case Closing Taper, View from Right

An air cylinder drops the taper down into place for taped cases. The taper itself is
unpowered and works on friction alone.

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An override switch on the right side of the machine can drive the Taper back up to clear a
jam or change tape rolls. Press the button before opening the safety door.

Taping Unit Up Control Switch Detail, View from Right Side of Machine

To rethread the tape head, stop the machine and open the access doors. Mount a new roll
on the spindle, then pull the tape down and thread it following the yellow guide arrows
on the unit.

Tape Head Threading Arrows Detail

The smooth side of the tape should always touch smooth rollers and the sticky side of the
tape should touch the rough surfaced rollers.

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Lifter

Cases exit the Case Conveyor to the Lifter, where they exit the GUACP to be palletized
or are rejected.

Lifter, View from Right

The Lifter has six rollers which are powered by a DC motor. The motor powers the end
roller through a cog belt and then the rest of the rollers are connected with another cog
belt.

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Downstream/Upstream Lifter Stopper

The downstream and upstream sides of the Lifter each have a Lifter Stopper.

Downstream Lifter Stopper, View from Right

Each Lifter will extend to either hold a case on the Lifter or prevent a case from entering
the Lifter. An air cylinder raises and lowers the Lifter Stopper.

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Rejected Case Pusher

The Rejected Case Pusher slides the rejected case off the side of the Lifter.

Rejected Case Pusher

An air cylinder moves the pusher forward and backward.

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Unfolded Top Photo Eye B818

The Unfolded Top Photo Eye is a reflective photo eye. The photo eye signals when a case
did not get closed properly and sends a signal to reject that case.

Unfolded Top Photo Eye

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Rear Flap Raiser

When an unfolded top is detected, the Rear Flap Raiser goes up to make sure that an
unfolded rear flap clears the GUACP during reject.

Rear Flap Raiser

A rotary air cylinder moves the Rear Flap Raiser.

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Case Ejecting PE B817

The Case Ejecting Photo Eye is a reflective photo eye. The photo eye signals when a case
is in the proper position to be ejected.

Case Ejecting Photo Eye

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Light Curtain Reject PE B854 and Light Curtain Exit PE B855

The Light Curtain photo eyes are six photo eyes and reflectors wired in series. One set
covers the reject path from the Lifter and another covers the normal case exit path.

Light Curtain

If any one of the six photo eyes is blocked, the machine will shut down. This is a safety
feature to keep people from reaching in to the machine while it is running. If a case is
being rejected or exited to the palletizer, the photo eyes will be turned off only long
enough for the case to clear.

WARNING!

Never run with the any of the light curtain photo eyes disabled. Never try to
defeat the light curtain safety features. Never stick your hand into the Lifter
area without the emergency stop engaged.

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Vacuum Pump and Filter

The GUACP utilizes vacuum cups to hold cases. Poor vacuum will result in many case
faults. The filter must be cleaned weekly.

Vacuum Pump (left) and Vacuum Filter (right)

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Classroom Discussion Questions

1. What photo eye confirms that the case has transitioned from the lower loading area to
the Case Conveyor?

2. What four components raise the flaps prior to folding closed?

3. Name the two reject conditions for a case on the GUACP.

4. What safety warning accompanies the Light Curtains?

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Practical Exercise

This practical exercise requires the cooperation of the Packaging Department in your
plant. Do not attempt to perform this exercise unless you are under your trainer’s
supervision.

1. Go to the packaging area with your trainer. Your trainer will designate a GUACP for
you to use to perform this practical exercise.
2. Identify the following components and describe their function for the trainer:
 Case Closing Case Pusher
 Case Accept Pusher
 Case Rotation Detect Photo Eye B653
 Case Conveyor
 Major Flap Raising Guide
 Case At Taper Photo Eye B654
 Minor Flap Guide
 Case Closing Paddles
 Case Closing Photo Eye B651
 Case Jam Detect Photo Eye B652
 Major Flap Raise
 Minor Flap Raise
 Outer Major Flap Raise and Shift
 Case Closing Flap Pusher
 Case Closing Taper
 Lifter
 Downstream and Upstream Lifter Stopper
 Rejected Case Pusher
 Unfolded Top Photo Eye B818
 Rear Flap Raiser
 Case Ejecting Photo Eye PE B817
 Light Curtain Reject Photo Eyes
 Vacuum Pump and Filter

Trainer Check:

Done Correctly Needs Improvement

Comments_______________________________
________________________________________
________________________________________
________________________________________

______________________________
Performance Based Trainer Signature


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Chapter 6- Operator Controls

OIT
The Operator will control almost all the GUACP’s functions from the Operator Interface
Touchscreen (OIT) mounted on the side of the main electrical panel.

OIT

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Emergency Stops
The Ishida GUACP has three emergency stops, one near the OIT, one near the closing
taper, and one at the exit end/carton loading area.

Emergency Stop

Press the emergency stop in to engage it. Twist and pull the emergency stop to restore
power.

Only use the Emergency Stops to shut down the machine in an emergency situation or
after stopping the machine from the OIT.

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Main Air/Power Cutoffs

The Main Power and Air cut Offs are on the upstream side of the machine.

Main Power Cutoff

Main Air Cutoff

Air pressure should be set at 70 psi.

ADD Warning LOTO

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Reject/ No Reject Switch

A switch on the side of the machine enables or disables the unfolded case reject option.

Reject/No Reject Switch

If the switch is set to NO REJECT, and an unfolded case is detected, the GUACP will
fault instead of rejecting the case.

Some tight layouts will not have room to side reject an unfolded case. In addition, the
Operator may want to temporarily disable the reject option while working around that
area of the machine.

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Main Operator Screen

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Case Size Adjust Screen

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Condition Check Screen

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Fault History Screen

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Machine Performance Screen Page 1

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Machine Performance Screen Page 2

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Changeover Screens

During Changeover

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Fault Screen

Fault Screen

When a fault occurs, the Fault Screen will pop up.

The red box at the top will display the specific fault and the area where the fault occurred.

The buttons along the center will release all the components within that section to make
retrieving the jammed case or carton easier.

The labeled dots in the lower left hand corner will light up when that specific door or
emergency stop is engaged.

Pushing the green FAULT RESET button will make the GUACP attempt to reset the
fault.

The FAULT LOCATION button will bring up the Fault Location Screen.

The CONIDTION CHECK button will return to the Condition Check Screen.

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Fault Location Screen

Fault Location Screen

The Fault Location Screen will display a close up of the fault location on a line drawing
of the GUACP to aid in troubleshooting.

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Chapter 6- Standard Operating Procedures

Overview
Operators should always use the Standard Operating Procedures when starting up,
shutting down, or changing over the UACP. They are the safest, most efficient method of
operating the UACP without damaging the machine.

Note that on the Ishida UACP, there are no manual adjustments for the PMO to make
during startup, changeover or shutdown.

Startup
1. Turn Main Power on.
2. Turn Main Air Pressure on.
3. If running a different product than listed, press DRAIN OR CHANGEOVER. If
running the same product, load cartons and case labels and go to step 17.
4. The changeover screen appears. Press PRESS TO START SELECTION.
5. From the list provided select the product class of the new product.
6. From the list provided select the weight of the new product.
7. From the list provided select the air fill type of the new product.
8. From the list provided select the case of the new product.
9. From the list provided select the pack pattern of the new product.
10. From the list provided select the speed of the new product.
11. The summary of the selections will appear. If correct, press APPLY.
12. Press START. A popup screen says “Adjusting”. The GUACP will adjust the
Magazine Guide Rails at this point.
13. When the adjustments are complete, a screen will say ”Load new cases”.
14. Load new cartons.
15. Load and program case labels.
16. Press OK.
17. Press START. The GUACP will make all the remaining internal adjustments at
this point. The GUACP will erect cases and fill the machine through the load area.
18. Start bagmaker/weigher/seal checker.

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Changeover

1. After draining the weigher, press STOP on the OIT.

2. Check that you have at least two cases in the magazine.
3. Press DRAIN OR CHANGEOVER.
4. A popup screen will ask you to confirm that you want to drain the machine. Press
YES.
5. A popup screen will confirm that the drain function is executing. The machine
may not appear to be moving, but it is still draining. The process may take as long
as XX. The machine will reject up to four unclosed cases. Do not press CANCEL
unless you want the process to stop.
6. Remove any excess cases from the magazine.
7. The changeover screen appears. Press PRESS TO START SELECTION.
8. From the list provided select the product class of the new product.
9. From the list provided select the weight of the new product.
10. From the list provided select the air fill type of the new product.
11. From the list provided select the case of the new product.
12. From the list provided select the pack pattern of the new product.
13. From the list provided select the speed of the new product.
14. The summary of the selections will appear. If correct, press APPLY.
15. Press START. A popup screen says “Adjusting”. The GUACP will adjust the
Magazine Guide Rails at this point.
16. When the adjustments are complete, a screen will say ”Load new cases”.
17. Load new cartons.
18. Load and program case labels.
19. Press OK.
20. Press START. The GUACP will make all the remaining internal adjustments at
this point.

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Shutdown
1. After draining the weigher, press STOP on the OIT.
2. Check that you have at least two cases in the magazine.
3. Press DRAIN OR CHANGEOVER.
4. A popup screen will ask you to confirm that you want to drain the machine. Press
YES.
5. A popup screen will confirm that the drain function is executing. The machine
may not appear to be moving, but it is still draining. The process may take as long
as XX. The machine will reject up to four unclosed cases. Do not press CANCEL
unless you want the process to stop.
6. Remove any excess cases from the magazine.
7. Turn off Main Air Valve.
8. Turn off Main Power
9. Blow out machine.

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Clearing Faults
1. On Fault Screen, determine the area where the fault occurred by reading the top line
of the displayed fault.
2. Press the button labeled with that section’s name. The GUACP will release the
components in that section to make retrieving the jammed carton or case easier. If it
is a bag jam fault, the GUACP will run all the conveyors until all the bags in the
machine are in the load area.
3. Remove the jammed case, carton, or the bags from the load area.
4. Close all doors.
5. Press RESET. The GUACP will display a Resetting Screen until the reset is
complete.
6. When the Main Screen displays, press START.

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Certification
Demonstration : GUACP Operator’s Name ________________
Operations Expert Trainer’s Name________________

OPERATOR PERFORMANCE REQUIREMENTS

Successful completion of this Performance Checklist means that the participant is

able to:
(Indicate all requirements are met by initialing and dating on the appropriate lines.)
(Scenarios and demonstrations should be completed in whole.)

Trainer Operator Date

1. Identify and describe the function of the major
Components of the GUACP:
a) Magazine Area ______ ______ ______
b) Sheet Magazine Conveyor ______ ______ ______
c) Magazine Conveyor Photo Eyes ______ ______ ______
d) Carton in Sheet Lifter Photo Eye ______ ______ ______
e) Sheet Spacer ______ ______ ______
f) Upstream Side Carton Suction Cups ______ ______ ______
g) Downstream Side Carton Suction Cups ______ ______ ______
h) Case Erecting Arm ______ ______ ______
i) Case Erecting Flap Guides ______ ______ ______
j) Fan Fold Paddles ______ ______ ______
k) Top Major Flap Stopper ______ ______ ______
l) Bottom Flap Pusher ______ ______ ______
m) Case Erecting Case Transfer ______ ______ ______
n) Minor Flap Pusher ______ ______ ______
o) Major Flap Opener ______ ______ ______
p) Case Clamp ______ ______ ______
q) Case Erecting Area Taper ______ ______ ______
r) Photo Eye B437 ______ ______ ______
s) Bag Infeed Round Belting ______ ______ ______
t) Bag Infeed Incline Belt ______ ______ ______
u) Infeed Jam Detect Photo Eye ______ ______ ______
v) Bag Infeed Conveyor ______ ______ ______
w) Infeed Inner Side Belt ______ ______ ______
x) Bag Infeed Outer Side Belt ______ ______ ______
y) Decline Conveyor ______ ______ ______
z) Bag Rotation Assist Pusher ______ ______ ______
aa) Bag Rotation Assist Photo Eye ______ ______ ______
bb) Bump Turner ______ ______ ______
cc) Decline Conveyor Side Guides ______ ______ ______

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Ishida GUACP Operator Training Manual

Demonstration : GUACP Operator’s Name ________________

Operations Expert Trainer’s Name________________

OPERATOR PERFORMANCE REQUIREMENTS

Successful completion of this Performance Checklist means that the participant is

able to:
(Indicate all requirements are met by initialing and dating on the appropriate lines.)
(Scenarios and demonstrations should be completed in whole.)

Trainer Operator Date

1. Identify and describe the function of the major
Components of the GUACP (cont.)
dd) Decline Conveyor Photo Eye ______ ______ ______
ee) Sort Conveyor 1 ______ ______ ______
ff) Sort Conveyor 2 ______ ______ ______
gg) Sort Conveyor 3 ______ ______ ______
hh) Slider ______ ______ ______
ii) Rear End Guide Doors ______ ______ ______
jj) Upstream and Downstream Bag Loading Photo ______ ______ ______
kk) Compress Conveyor ______ ______ ______
ll) Case Pusher ______ ______ ______
mm) Open Flap Photo Eye ______ ______ ______
nn) Drop Area Drop Shelves ______ ______ ______
oo) Case in Drop Area Photo Eyes ______ ______ ______
pp) Case Loading Guides ______ ______ ______
qq) Case Receiving Gates ______ ______ ______
rr) Case Drop Pusher ______ ______ ______
ss) Case Elevator ______ ______ ______
tt) Case at Load Area Photo Eyes ______ ______ ______
uu) Case Labeler ______ ______ ______
vv) Case Closing Case Pusher ______ ______ ______
ww) Case Accept Pusher ______ ______ ______
xx) Case Rotation Detect Photo Eye ______ ______ ______
yy) Case Conveyor ______ ______ ______
zz) Major Flap Raising Guide ______ ______ ______
aaa) Case at Taper Photo Eye ______ ______ ______
bbb) Minor Flap Guide ______ ______ ______
ccc) Case Closing Paddles ______ ______ ______
ddd) Case Closing Photo Eye ______ ______ ______
eee) Case Jam Detect Photo Eye ______ ______ ______
fff) Major Flap Raise ______ ______ ______
ggg) Minor Flap Raise ______ ______ ______
hhh) Outer Major Flap Raise and Shift ______ ______ ______

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Ishida GUACP Operator Training Manual

Demonstration : GUACP Operator’s Name ________________

Operations Expert Trainer’s Name________________

OPERATOR PERFORMANCE REQUIREMENTS

Successful completion of this Performance Checklist means that the participant is

able to:
(Indicate all requirements are met by initialing and dating on the appropriate lines.)
(Scenarios and demonstrations should be completed in whole.)

Trainer Operator Date

1. Identify and describe the function of the major
Components of the GUACP (cont.)

iii) Case Closing Flap Pusher ______ ______ ______

jjj) Case Closing Taper ______ ______ ______
kkk) Lifter ______ ______ ______
lll) Downstream/Upstream Lifter Stopper ______ ______ ______
mmm) Rejected Case Pusher ______ ______ ______
nnn) Unfolded Top Photo Eye ______ ______ ______
ooo) Rear Flap Raiser ______ ______ ______
ppp) Case Ejecting Photo Eye ______ ______ ______
qqq) Light Curtains ______ ______ ______
rrr) Vacuum Filter and Pump ______ ______ ______

2. Describe the functions of torque limiters, photo eyes,

and proximity switches on the GUACP. ______ ______ ______

3. On the OIT of the GUACP, navigate to and explain

the following screens and all their components:
a) Main Operator Screen ______ ______ ______
b) Case Size Adjust Screen ______ ______ ______
c) Condition Check Screen ______ ______ ______
d) Fault History Screen ______ ______ ______
e) Machine Performance Screens ______ ______ ______
f) Changeover Screens ______ ______ ______
g) Fault Screen ______ ______ ______
h) Fault Location Screen ______ ______ ______

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Ishida GUACP Operator Training Manual

Demonstration : GUACP Operator’s Name ________________

Operations Expert Trainer’s Name________________

OPERATOR PERFORMANCE REQUIREMENTS

Successful completion of this Performance Checklist means that the participant is

able to:
(Indicate all requirements are met by initialing and dating on the appropriate lines.)

Trainer Operator Date

4. In less than 60 seconds each, demonstrate how to properly clear a:

a) Sheet Loading Fault ______ ______ ______

b) Bottom Closing Fault t______ ______ ______
c) Case Drop Fault ______ ______ ______
d) Case Loading Fault ______ ______ ______
e) Case Closing Fault ______ ______ ______
f) Jam Clear Fault ______ ______ ______
.
5. Demonstrate how to safely start-up the GUACP in
under ten minutes. ______ ______ ______

6. Demonstrate how to safely changeover the GUACP in

under ten minutes. ______ ______ ______

7. Demonstrate how to safely shutdown the GUACP in

under five minutes. ______ ______ ______

8. Safety Certification Guide Lines:

a) Demonstrate the proper way to lift and load cases: ______ ______ ______
b) Demonstrate proper ladder safety ______ ______ ______

9. Demonstrate adjusting the GUACP for out of specification cartons ______ ______ ______

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Ishida GUACP Operator Training Manual

Demonstration : GUACP Operator’s Name ________________

Operations Expert Trainer’s Name________________

OPERATOR PERFORMANCE REQUIREMENTS

Successful completion of this Performance Checklist means that the participant is

able to:
(Indicate all requirements are met by initialing and dating on the appropriate lines.)

Trainer Operator Date

10. Explain why air fill must be at aim for the GUACP. ______ ______ ______

11. Explain what internal mechanical adjustments an Operator

would make to the GUACP. ______ ______ ______

12. Identify the most likely causes of the following issues

on the GUACP:
a) Sheet Loading Fault ______ ______ ______
b) Bottom Closing Fault t______ ______ ______
c) Case Drop Fault ______ ______ ______
d) Case Loading Fault ______ ______ ______
e) Case Closing Fault ______ ______ ______
f) Jam Clear Fault ______ ______ ______

13. For a duration of two hours, maintain:

a) Average two minutes. mean time to repair faults ______ ______ ______
b) Maintain 85% GUACP Efficiency. ______ ______ ______

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