0750480 Procter & Gamble FemCare

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Project Scope: Customer has requested on-site support for a feeder belt breakage issue on feeder #1 of their female pad feeding line. Original Project WO # 2019084 Install SO #0750415
Equipment Summary: (Machine Serial Number:Multiple)
Work Done: Matthew Olson solo trip to P&G Day 1 (1/13/2020) Travel 5.5 hrs Onsite 5 hrs Day 2 (1/14/2020) Onsite 10.75 hrs Indirect 1 hr Day 3 (1/15/2020) Onsite 9 hrs. Day 4 (1/16/2020) Onsite 6 hrs. Travel 6 hrs. Initially investigated possible common root causes of the belt breakage on Feeder 1. The guide rods were in the correct place, vacuum chambers were installed correctly, and all proper shims were in place. The only oddity found was the LHS drive pulley set screws were loose, enabling it to free spin. After installing the new belts I noticed the feed belts was running really hard against the LHS, just like the P&G team has been observing. I then took the Idler shaft and pulleys and swapped them left for right. After doing that the belts appeared to be riding slightly more on the RHS of the pulleys. After the swap I proceeded to run product through the feeder, with a few mins, and only going 300 ppm I broke the RHS drive belt. This lead me to believe the Idler shaft or pulleys had something to do with the belt breakage, so we got parts delivered the following day. The next morning I took the idler shaft and pulleys from feeder 2 and installed them into feeder 1. The belts were still tracking poorly and after feeling some play in the RHS of the drive shaft I decided to swap out the bearing housing. After making the swap I again jogged the feeder and still noticed the belts running hard to the right. That is when I loosened the Idler shaft on either side to see if the belts would track better. After loosening the LHS the belts were tracking perfectly, so I placed an extra shim in there then tightened everything back up. After installing the shim we have run for 1.5 days at both 300 and 600 ppm without a belt breakage or even a bad jam up. Once the feeder was functioning I then began to tune up the system to reduce the number of errors to validate the system. One thing we noticed causing errors was that the APLs were spaced too far away from the feeders. Jason put them exactly where Bernie had told him to but didn't know that might change if the magazine guides were moved. So I explained how to set them up and what to look for. By raising up the S curve, reducing the stripper wheel height, and increasing the height of the entrance to the discharge we were able to validate Feeder 1 at 300 ppm. Once complete we increased the speed to 600 and got feeder 2 put back together. I was able to successfully run feeder 2 for 8 mins before a jam occurred so I was feeling confident that the validation of both feeders at 600 would be quick. After a quick training session for the contract workers loading the APLs we began to tune up and validate both feeders at the same time. The entire day (wed) was spent tuning and mildly tweaking the system to get the feeders running smooth under P&G's real running conditions. After failing to pass the validation test for the 3rd time I disabled the minor jam fault setting that was causing the majority of the feeder faults. By the end of the day we are half way through the 4th validation attempt and will pick it up again in the morning. Thursday morning we picked up from where we left off on attempt #4. We successfully rand 5 of 6 2 min runs to pass the validation. We then changed the speed on the PLC to 300 to validate the system at the slower running speed. By 9:05 we ran 11 successful runs in a row to pass the validation without a single error. Important note at least 3 of the successful runs would have faulted out due to a "product jam" where we visibily noticed 2 pads stacked ontop of each other. This is not a concern for their team since the have the ability down stream to reject/remove these pads from their line. So we intend to keep the minor jam fault turned off. Final steps today were to bring over some of Curts team to get their eyes on it while running, start up and stopping to improve the PLC control.
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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	42844			LABOR - HOUR ON SITE	Set Complete		0 hrs	30		$0.00	0.00	$0.00
Edit	42845			LABOR - 1/4 HOUR ON SITE	Set Complete		0 hrs	3		$0.00	0.00	$0.00
Edit	42846			LABOR - TRAVEL	Set Complete		0 hrs	11		$115.00	0.00	$1,265.00
Edit	42847			LABOR - 1/4 OF TRAVEL	Set Complete		0 hrs	2		$28.75	0.00	$57.50
Edit	42848			TRAVEL EXPENSES - CAR	Set Complete		0 hrs	1	$383.53	$452.57	0.00	$452.57
Edit	42849			TRAVEL EXPENSES - AIRFARE, CHANGE FEES, LUGGAGE	Set Complete		0 hrs	1	$1,400.49	$1,652.58	0.00	$1,652.58
Edit	42850			TRAVEL EXPENSES - HOTEL	Set Complete		0 hrs	1	$483.72	$570.79	0.00	$570.79
Edit	42851			TRAVEL EXPENSES - PARKING, MEALS, GAS	Set Complete		0 hrs	1	$336.45	$397.01	0.00	$397.01
Edit	42852			SERVICE TRIP PRE-TRAVEL PREP FEE	Set Complete		0 hrs	1		$250.00


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	Active R & D


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


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