0553594 Huhtamaki

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What Arrived: There are some parts missing and we would like it to be restored to operational condition. (Machine Serial Number:0504-06103) Customer give rates of 180MPM - 200MPM, 250-300 Products in a batch. 100 Batches per hour. Shipping PC, with touch screen, and cables, for re-image of hard drive, and verification of boot up.
Description of Problem: EQUIPMENT IS FROM WO# 2004132 APL 2000-550 Serial Number 0502-02352 -(1) 85mm Belt -(1) Product Guide MFT 550 IP FXLD Serial Number 0504-06103 - NO Feed Belts or pulleys or nothing for them -(2) Stripper Wheels -(4) Discharge Belts 20mm wide, elastic (no pulleys for them -(1) Custom Mag Sid Guide - Motor is off machine and reached 180 F (1) Stack Light (1) E/R (1) Microscan Barcode System Pneumatic Elevator Stacker w/ nomadic Custom Electrical Box Touch Screen w/box All on a big stand.
Work Done: Peter N. should intrest in helping evaluate for upgrades and so forth. 1/24/17 DK Completed rough evaluation of Feeder and APL. Greg C. was helping with the Stacker / Elavator, and we found an issue with the Control PC. Mike C believes it is probably a failed hard drive. Sent customer email to see if they could send us the working Control PC to clone the hard drive. 2/2/17 DK Shane budgeted 8 hours to repair + $30 Cost Hard Drive. 2/10/17 DK Asked several times for Peter and ME help with elevator stacker, and never got it. After talking to the customer they asked for a budgetary quote to start with. 2/21/17 DK Prepared repair quote and emailed to the customer. 2/23/17 DK Mike D started mechanical work on machine. Had meeting with ME, and they are working on engineering of the Pusher Cylinder. 3/14/17 DK Accounting to send 50% invoice. 3/16/17 DK Received 50% payment. 3/17/17 DK Customer asked us to suspend work on machine. Suspended work. 3/21/17 DK Customer sent email stating their customer will not have a definitive answer until later in the year. Schuled an internal meeting to discuss for 4/5/17. 3/30/17 DK Email customer options MFT team came up with. Email is attached. 4/5/17 DK Customer sent email saying we are back on. It is attached. Mike D. resumed work. 4/6/17 DK Mike completed mechanical re-furb. Finished Barcode isolation board. 4/17/17. DK Was not pleased with load on feeder, re-did discharge rollers. 4/18/17 DK Shane had issues with image file. Sending customer PC w/ new hard drive for them to reimage, per Shane. Got info from customer on pusher cylinder, and forwarded to Ed, for engineered solution for custom elevator pusher machine. 4/24/17 DK Software Card found broken on floor. Sent company email asking for clarification. To date..have not received any. Pusher Cylinder on order, 6 Week Lead Time. 4/26/17 Ed differed Pusher to integration. Asked Tom for help with this. Limit Sensor, and Solenoids have arrived. 5/3/17 Replaced burnt thermistor w/ 18 AWG wire, on Motherboard, it can know run a motor. Passed all testing except APL enable output, elected to skip this repair, as machine does not need this function. Put MB ASSY in 24 hour burn in, and observed for proper operation. 5/4/17 DK Motherboard passed 24 hour operation. Realized APL output does need to be fixed, because this Feeder runs with an APL. Found U4 failed, causing output issue. Jane to replace U4. Got Discharge angle and rollers set. 5/5/17 DK Jane replaced U4 and Motherboard is fully functional. Installed Motherboard in Feeder, and performed functional test of APL, Feeder, and Barcode system, they all passed. Put in 24 hour burn in, and observed for proper operation. 5/8/17 DK Feeder passed 24 hour burn in. 5/9/17 DK Attempting 200MPM testing, and having issues with Drive Pulley / Vac Chamber getting too hot. Making some improvements, but more tweaks are needed. Chamber furthest from Keypad is still getting hot. To run burn in at same interval of customers through put. 22,500ms on 13,500ms off. 5/12/17 Tested at a little higher through put of 22.5 s on 10 s off at 200MPM. After some adjustments, found temperature equilibrium after 20 minutes of run time. Feeder ran in 1 hour burn in with out registering an internal temperature higher then 120 on chamber, everything else was cooler. 5/15/17 Pusher Cylinder Arrived. Sent request to customer for status update6/8/17 DK Getting no feed back from customer on samples, and them re-imaging control PC. Left Bryan VM. Sent request to customer for status update, again via Email. 6/23/17 Customer believes PC is in need of replacing, to work with Greg C. and Shane on next steps. 7/6/17 DK Customer attempt reimage of hard drive, and return control PC, and we will see what we can do about the display issues. 7/7/17 Customer states they are in production run, and cannot stop to image hard drive. Customer asked about replacing control unit, give estimated price of $15K. 8/7/17 DK Customer stated the new hard drive needed to be replaced, and the Motherboard in the PC. Customer said they will be returning the PC, and product samples. 8/28/17 DK Have yet to see PC or product samples. Sent customer an email. 9/11/17 DK PC and samples arrived!!!!!!!!!!!!! 9/18/17 DK PC booted to screen showing "Keyboard not connected". to talk to Greg C about. 9/22/17 DK PC booted with keyboard. using with barrowed keyboard and mouse from Shane. 9/25/17 DK Found monitor mount broken, made new 80 20 mount. Made new plate for barcode sensor mount. 9/26/17 DK Samples are of all different flavors. Not enough of one sample for 15min video. Sent customer email asking for more samples of all one flavor, or permission to skip video. 7013700 sensor not sensitive enough for APL. Will try 7013200. Updated repair quote for this. 9/27/17 DK Taking some time away from this repair to work on another RMA. Change Sensor, look at stalling Discharge Roller, and timeout for Barcode Reader needs to be lowered for proper error detection. Customer sent email asking for us to do a what we can with samples available in regard to the video. Will get some video for them. 9/28/17 DK Found Redlight staying off. Found problem on Motherboard. RedLight signal being pulled down. Jane to lift pin U4.3 to see if the Opto is pulling it down. 9/29/17 DK Redlight issue is a shared signal that sends the Redlight output to J1. This explains why the Elevator / Stacker was not stopping when the Feeder faulted. After much effort and discussion with Greg C, found that the U4 previously used in repair of this board was not a direct replacement. This caused an over current on the Xylinx FPGA, and this is what failed. The wrong part was used because of a note in Syspro. Worked with Mark B. To get note corrected, and correct Optos in order to be stocked. Sent PO request to Deb to order the FPGA, and a Tool to remove it. Emailed customer with update. When parts arrive replace U4 6211200, U11 6093500, re-solder U48.13. 10/3/17 DK U11 & U4 are in stock. Part to change U11 is due 10/20/17 DK 10/10/17 Now part to change U11 is due in 10/27/17. Updated customer via email. 10/24/17 DK Part to change U11 came in. 10/26/17 DK Give Viki instructions and parts to replace U4 6211200, U11 6093500, re-solder U48.13. 10/27/17 DK PCB was severely damaged when Xilinx FPGA replacement was attempted. Deemed board repairable. 11/3/17 DK Validated / updated used Motherboard PN 82202 SN 9203 with Power Supply SN CA53274036, and installed in machine. Updated assigned serial numbers. 12/1/17 Added flow control to Pusher Cylinder. 12/4/17 DK Got machine running a 200 MPM, product count of 100. Best I can do with samples received. No more then 350 of any flavor. Micah made video of machine running. 12/6/17 DK Could not get machine to respond to Limit Sensor in any way. Asked Customer about it. I also could not get in to the Menu of the PC, asked customer about this.12/7/17 DK With the Greg's help got the Micro Scan all dialed in and verified proper operation at 200MPM. 12/8/17 DK Mike C was able to tell me PC password was 1969. Nicole said the Limit Sensor function was commented out of latest code. This is enough to conclude neither machines ever made use of the Limit Sensor while in production. Revised Repair Quote and sent customer close out email. Once we receive a revised copy of the PO WE CAN SHIP!!!!!! 12/11/17 DK Cleaned up junk, and got equipment ready to send to Larry. Shipping under SO# 12/13/17 DK
Repair Quotation Notes: Completed By:

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Edit	XID	Part Number	Serial Number	Part Name	Complete	Total Hours	Hours Remaining	Qty	Cost	Price	Discount	Cal Price	On Hand
Edit	28515	1182700		APL CONVEYOR BELT 2000 1W	Set Complete		0 hrs	2		$242.00	0.00	$484.00	6
Edit	28516	7013200		LOW PROD SENS DIST LO-DO M12M	Set Complete	1 Standard Production Build	1 hrs	1		$608.00	0.00	$608.00	0
Edit	28517	6826200		BULB 24V 5W 45MM LIGHT	Set Complete		0 hrs	1		$9.00	0.00	$9.00	26
Edit	28518			CUSTOMER FEEDER TO BARCODE SCANNER BOARD	Set Complete		0 hrs	1		$375.00	0.00	$375.00
Edit	28519	3577200		UNIVERSAL DOUBLE JOINT 304	Set Complete		0 hrs	1		$149.00	0.00	$149.00	8
Edit	28520	3577400		UNIVERSAL DBL JOINT 404 SS SS	Set Complete		0 hrs	1		$80.00	0.00	$80.00	6
Edit	28521			CUSTOM P-BRACKETS	Set Complete		0 hrs	2		$420.00	0.00	$840.00
Edit	28522	1159700		TIMING BELT 0515117	Set Complete		0 hrs	1		$71.00	0.00	$71.00	4
Edit	28523	1054200		TIMING PULLEY HTD 051520 19B AF	Set Complete		0 hrs	1		$127.00	0.00	$127.00	21
Edit	28524	4110500		STRIPPING CRANK ARM LDC	Set Complete		0 hrs	1		$184.00	0.00	$184.00	0
Edit	28525	1197300		FEED BELT ECG FDA 304606SDV	Set Complete		0 hrs	3		$376.00	0.00	$1,128.00	8
Edit	28526	4291800		VACUUM CHAMBER IM-30	Set Complete		0 hrs	3		$978.00	0.00	$2,934.00	8
Edit	28527	4118700		IDLER PULLEY 304620C	Set Complete		0 hrs	3		$121.00	0.00	$363.00	12
Edit	28528	4118200		DRIVE PULLEY 304620C	Set Complete		0 hrs	3		$49.00	0.00	$147.00	46
Edit	28529	1097300		STRIPPER WHEEL 304620 85D	Set Complete		0 hrs	3		$104.00	0.00	$312.00	443
Edit	28530	1177500		XLD DISCHARGE BELT EPDM 204604	Set Complete		0 hrs	8		$138.00	0.00	$1,104.00	13
Edit	28531	4128200		DISCHARGE PULLEY 204620K	Set Complete		0 hrs	8		$41.00	0.00	$328.00	31
Edit	28532	4103200		REBUILT FEEDER BEARING HOUSINGS	Set Complete		0 hrs	1		$696.00	0.00	$696.00	0
Edit	28533			BLOWER ASSYEMBLY	Set Complete		0 hrs	1		$205.00	0.00	$205.00
Edit	28535			ELEVATOR / STACKER REPAIR	Set Complete		0 hrs	1		$1,980.00	0.00	$1,980.00
Edit	28536			LABOR	Set Complete		0 hrs	42		$165.00	0.00	$6,930.00

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			*PRODUCT STACK SHELVES ARE NOT INCLUDED WITH BASE-PICK WHAT IS NEEDED*


			**ALL ITEMS BELOW ARE INCLUDED IN COSTING & PRICING PN 9740001**