Sr.

NO Automation Cell -1
1 Ensure all safety doors closed and emergency switch open
2 Robot shoud be there in Respective Home Position
3 Glue level should be above 50% of buffer tank
4 Ensure correct Gripper fingers and Fixtures mounted in Cell respective to the Item change
5 Water level and piant level should be checked and it should above the safety level
6 Robot Gripper Number and Actual model Number should be same
7 Turn table should be either in POS 1 or POS2
8 Change program module in Pendant with respect to Item change for R1 and R3
9 Defining Fixture position as to be checked
10 Core presence photo cell in assembly table as to cleaned and remove core if any
11 Check there should not be half package indication on Assembly table in ABB Automation panel
12 Paint tank2 Level should be depend on production target and paint should be change with the interval of 5 Days
13 Put Wash tank1,dip tank1,paint tank1 in Auto mode
14 Keep robot gripper cleaning time as Water time : 3s , Air time : 1s for both the cell
15 Clean glue nozzle with 0.028 inch pin
16 Wash viscousity should be checked and viscousity range depends on item reqirnment normally around(14-16)s
Sr.NO AUTOMATION CELL-2
1 Ensure all safety doors closed and emergency switch open
2 Robot shoud be in Respective Home Position
3 Glue level should be above 50% in glue buffer tank
4 Ensure correct Gripper fingers and Fixtures mounted in Cell respective to the Item change
5 Water level and paint level should be checked it should above the safety level
6 Check the Robot Gripper number in Operator panel, it should be same as actual model
7 Turn table position should be either in POS 1 or POS2
8 Change module in main program with respect to Item in both R4 and R5
9 Paint tank2 Level as to be checked and paint should be changed with the interval of 5 Days
10 Put Wash tank2,dip tank2,paint tank 2 in Auto mode
11 Keep robot gripper cleaning time like Water time : 3s , Air time : 1s
12 Clean glue nozzle with 0.024 inch pin
13 Wash viscousity should be checked and viscousity range depends on item reqirnment normally around(14-16)s
14 Keep Turn table,transfer table,robot,oven in auto mode
15 Ensure full opening of inlet Pnematic valve for Robot,Washing tank,Dippingtank and gluing station
Sr.NO
CORE BOX MOUNTING PROCEDURE
1 Ensure full tigthtening of Core box presence /absence sensor sensing pin
2 Check the orientation of core box before mounting
3 Check core box in station sensor and station position sensor are actuated
4 Ensure full cleaning of core box before mounting
Sr.NO
LPG Tunnel Oven STARTUP Procedure
1 Incoming Pneuamtic pressure should be in the range of (5-6)bar
2 Lube level in FRL unit as to be checked and it should more than 50 %
3 Information has to be given to Utility before power on LPG supply
4 Pallet positions has to checked
5 Check the Availibility of Trolley and tackel near by unloading station
6 Minimum inlet LPG pressure should be 2 bar
7 LPG line pressure should be drained out before opening the LPG valve
8 Pallet fixtures has to mounted respective to the item change
9 Plu fans,Blowers ,Cooling fan should be switsched ON before the burner ON
10 Power ON M1,R1&R3,M2,R4&R5,UHAI(ABB Automation Panel)
11 Choose the Line with respect to the requirnment
12 Temperature setup depends core weight
Sr.NO
PROCEDURE TO STOP
1 Put conveyor in Auto Stop mode
2 Close LPG main valve to Drain out and ensure no pressure in Pressure indicication gauge
3 Swithch OFF plug fans,Blowers,Cooling fan
4 Switch OFF burners
5 Power OFF the main supply
Sr.NO
SAND PLANT STARTUP PROCEDURE
1 Sand level check up all hoppers (Normal Silica sand,chromite,imported/gudur)
2 Check Binder level in binder tank
3 Ensure proper cleaning of binder and hardener inlet nozzle in mixture
4 Calibration of Binder and Hardener should be done before production
5 Binder and Resin temperature should be within the range of (24-26)degrees
6 Ensure proper cleaning on sand trolley Hopper and gate
7 Additive level in additive dosage unit should be above the level sensor
8 Safety doors as to be closed and acknowleged
9 If SP-1 operated M3&M4,then SP-2 sand trolley to be kept in parking position
10 If SP-2 operated for M1,then SP-1 sand trolley to be kept in parking position
11 Check the recepie before production
12 Pneumatic air pressure should be within the range of (5-6)bar
13 Hydraulic oil level has to be checked
14 Resin Absorbtion cylinder home position as to be checked
15 Ensure no additional weight should be kept above the sand weighing scale
16 Load cell error should not be less than -2
17 Ensure Sand trolley below the mixture
Sr.NO
PROCEDURE TO STOP
1 Clean Binder feeding nozzle,Mixture and Sand trolley
2 Switch Off the main supply