0750530 Hallmark Cards, Inc

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Project Scope: Operator training for the equipment sold to Hallmark on WO#2019132. Along with updating all old feeders to the latest software Ver: 5.135
Equipment Summary: (Machine Serial Number:Multiple)
Work Done: Hours Breakdown 8/17/20 Travel: 5 hrs Onsite 5 hrs. 8/18/20 Onsite: 8 hrs. 8/19/20 Onsite: 9 hrs 8/20/20 Onsite: 8 hrs. 8/21/20 Onsite: 5 hrs. Travel: 5 hrs. Changes made on this trip - Updated all feeders to the latest software with jam protect VER 5.135 No issues updating feeder software. -Made all feeder menus the same, only options available in settings are Prod Length, Dist Blanking window, and Min Prod Length. -Made local backups on all feeders and on my travel computer so we would have a copy for the new machines. Will add this backup to the Hallmark folder on the MFT server. Setting Changes Made Setting Old Value New Value Reason Acceleration 180,000 35,000 Smooth out starts, reduce wear on everything Deceleration 180,000 50,000 Smooth out stops, reduce wear and hard stops Gap Length 5 1 Remove false product jam errors on the feeders. Max Speed 200 250 Increase throughput/make up for lower accel and decel List of observations and tasks performed -APL Belt walking, stickiness, and the high level of dye it has picked up from the eps. ( Already Reached out to Ed and Clay about these issues and they are in the process of make the changes at MFT with a less tacky coated belt) -While near the machines I witnessed a product jam up on the card feeder and it tripped the new jam detect software, and did not blow the fuse. -During my time at Hallmark there were zero blown fuses! Woot Woot! -Early on in the trip the errors 2104 and 104 kept popping up on several machines. After a power cycle they went away. -Observed the side tamper screw backing out. Doug grabbed a longer one that worked better. -Some of the lighter envelopes do not need the vacuum to be on, it really is color and size dependent. -The Vacuum chambers on one of the EPS feeders were angled down, allowing most of the vacuum to escape. After we corrected that the feeder was performing as expected. -For the star hoppers to not jam up, at the higher speeds, the air must be set just right, this became even more evident when we began running at 250 mpm with 049 EPS. -We tested using an advanced product sensor on one of the EPS feeders. It functioned as expected. This was an attempt to stop the false Product Jam Faults. It worked but so did the IR pair after I decreased the Min gap value in the settings. -Spoke with Heather to establish the PMs for our feeders. -Spoke with Doug and Heather on the suggested belt change intervals. Questions from Hallmark -What is the clearance or tolerance of the vacuum chambers to the belts? Doug shimmed up some of the vacuum chambers to get them sucking through the belts ( I will be reaching out to Ed) -How to ensure they get sets of 3 belts in bags with the proper shims. Simply to ensure they have enough shims and make it easier on Maintenance. ( I will be reaching out to David to get an answer) -Why don't we have a crown on the Feeder side of the APL roller? To keep the belt from walking all over the place. (Already reached out to Ed, will follow up once I'm back at MFT) -Why do we have such a complicated diagram for the Serial cable needed to backup and restore the feeders? Glen brought that to my attention. ( I'll be following up on that with our EE/Software department) Hallmark Suggested Changes -Doug, will be trying a new device to keep the 17% gearing pulleys from moving. ( I am spacing what he called it ) -Doug, is going to upgrade the guide rods (skis) at the end of the discharge. Doug has already ordered them and will be testing them out -Maintenance, asked if they can trim the plate on the electrical side of the feeder, it's a pain to take off and put back on with the air nozzles in the cases. I said go for it, taking just a little off the side, still unable to get your fingers behind it. -Maintenance, Made the suggestion that it might be helpful to add spacers between the feed belt drive pulleys. ( I'll speak with Ed/Clay about their thoughts) Changes to future equipment -Trim the plate in front of the 17% gearing to make it easier to access. ( I will chase this down on the MFT build up doc) -Use the latest backup to set up all future Feeders. Ensure the settings options are setup correctly, along with accels and decels -APL belts, not sure where this is but the changes have been started. -increase the length of the side tamper on the card APL. Continued Training Worked alongside the Hallmark crew again to really dial in the feeders. Kyle seems to really have it down now, great young man to work with. Once we got the vacuum chamber aligned and made the setting changes above the feeders were working great. We further discussed the small changes needed to ensure the Feeders would hit the expected throughput on the system. We pushed the speed and number of drops per hour, until we hit our expected value, or were running faster than the folder or downstream robot could keep up with. On Wed they hit a new record for the MFT equipment, 275,000 cards during an 8 hr shift. The operators appear to be more comfortable seeing the system running at the higher speeds, and knowing it's capable. Bounced between the 2 MFT lines ensuring both crews were getting their questions answered. Due to a bottleneck downstream of line 1 the operators were running slower. Once that issue is resolved they will need to make a few more minor changes to hit the expected throughput. Worked with a total of 9 different operators, some stayed late from 3rd shift and on Wed I stayed late to ensure 2nd shift had all of their questions answered as well. -Big takeaways from the operator training: If the stripper wheels feel extremely touchy, you have overlapped EPS, then a 1/4 turn later they are getting damaged, try turning off the vacuum. This fixed 2 different types. EPS are of course the most difficult to run. Ensure you have a good S curve setup then change 1 variable at a time to avoid making new issues. Some of the EPS needed to have a "lower" S curve. More products below the heel,but still fluffy, increasing the surface contact between the EPS and feed belts Ensuring the EPS and cards are transferring into the Feeder with minimal staggering. This is done by slowly cranking in the APL towards the feeder. Maintenance Training On Thursday and Friday I walked 9 different maintenance workers through the belt changes. We removed the feed belts and reinstalled them. Once that was complete I showed them what was needed to change out the discharge belts. Answered any questions they had and explained the new software features. -Big takeaways from the maintenance training: Always use the new shims that come with the new belts, toss the old ones. Check ALL set screws as you remove the shafts. Make sure the set screws are all lined up on the flat of the shaft. Ensure all 3 belts have matching numbers on the inside. Once the belts are in check the vacuum chambers, make sure the top is parallel to the belts. Always check to make sure the stripper wheels are level with the new belts. Cut 2 strips from an envelope and perform the pull test. Correct as needed. Do the same to the entrance of the discharge after a belt change.
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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	45039			LABOR - HOUR ON SITE	Set Complete		0 hrs	35		$215.00	0.00	$7,525.00
Edit	45040			LABOR - 1/4 HOUR ON SITE	Set Complete		0 hrs	0		$53.75
Edit	45041			LABOR - TRAVEL	Set Complete		0 hrs	10		$115.00	0.00	$1,150.00
Edit	45042			LABOR - ADDITIONAL CHARGES	Set Complete		0 hrs	0		$0.00
Edit	45043			TRAVEL EXPENSES - CAR	Set Complete		0 hrs	1	$475.34	$560.90	0.00	$560.90
Edit	45044			TRAVEL EXPENSES - AIRFARE, CHANGE FEES, LUGGAGE	Set Complete		0 hrs	1	$326.20	$384.92	0.00	$384.92
Edit	45045			TRAVEL EXPENSES - HOTEL	Set Complete		0 hrs	1	$622.88	$735.00	0.00	$735.00
Edit	45046			TRAVEL EXPENSES - PARKING, MEALS, GAS	Set Complete		0 hrs	1	$373.07	$440.22	0.00	$440.22
Edit	45047			SERVICE TRIP PRE-TRAVEL PREP FEE	Set Complete		0 hrs	1		$250.00

+ denotes that software settings are available for this piece of equipment.

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