The objective of this Standard Operating Procedure for Preventive Maintenance of Carton Pack Machine is to outline the steps and guidelines for conducting preventive maintenance on the Carton Pack Machine to ensure its optimal performance, extend its lifespan, and minimize downtime.
Standard Operating Procedure for Preventive Maintenance of Carton Pack Machine :
OBJECTIVE:
To lay down the Procedure for the Preventive Maintenance of Carton Pack Machine installed in packing area.
SCOPE:
This SOP is applicable for the Preventive Maintenance of Carton Pack Machine installed in packing area .
RESPONSIBILITY:
Technician/ Operator shall be responsible for proper execution of preventive maintenance as per SOP.
Engineering – Head shall be responsible for reviewing the SOP and for ensuring proper execution of preventive maintenance.
ACCOUNTABILITY:
Engineering – Head shall be accountable for proper implementation of the SOP.
DEFINITIONS:
Nil
PROCEDURE:
Preventive maintenance shall be executed as per the SOP No.: SOP/EN/XXXYYY – Execution of Preventive Maintenance.
Ensure that the spare parts are available at the time of preventive maintenance.
Preventive Maintenance – Mechanical
Preventive Maintenance of Carton Pack Machine: Checking of belts
Check the timing belts the carton pack machine. If found damaged/worn out, replace the same.
Checking shall be done quarterly.
Checking and lubrication of bearings, chains, gears and sprockets.
Check sprockets, gears, chain and cams for any damage. If found damaged, replace the same.
Lubricate bearings, cams, gears, chain and sprocket with the help of grease gun.
Checking shall be done quarterly.
Checking of sensors and machine for proper performance as follows
Clean all the switches and electrical connections, sensors for the dust and dirt and check for the proper functioning.
Check the VFD operation for machine speed.
Check the performance of Blister magazine and sensor. The blister magazine has high-level and low-level sensors. The magazine will dispense blister into the cartoner product conveyor only when the stack is within this two limit.
Check the blister dispensing, is by a pair of counting wheels on which the stack rests. Each rotation of the wheels dispenses exactly one blister. Wheels are given the required number of rotations by a servo motor.
Check the working of carton magazine. Carton magazine is designed to hold a stack of flat cartons.
Check the performance of carton delivery and placement sensors.
Check the performance of carton transport mechanism.
Check the embossing machine performance.
Check the overload product pushing sensor, overload during the product pushing is detected by the sensor and stops the machine.
Check the performance of flap closing arrangement.
Check tuck in mechanism; front and rear flaps are closed by corresponding tuck in mechanisms which are mechanically driven and synchronized with other movements.
Check the carton outfeed; a pair of timing belts, whose separation is adjusted for carton length, carries closed carton out of the carton chain. If the carton is earlier sensed as incomplete, then the carton is rejected.
Apply the suitable lubricant on gear-boxes and all rotary parts.
Checking of sensors shall be done after every three months.
Preventive Maintenance – Electrical
Checking of terminals and wiring
Ensure that the main electrical supply to the machine is switched OFF.
Visually check all the power and control wiring and terminals in the electrical panel and for control elements mounted on the machine for any loose connection and damage.
Check and ensure by using the screwdriver that all the wires are properly tightened at the distribution terminals inside the electrical panel and on the terminals of all the control elements.
Checking shall be done six monthly.
Preventive Maintenance of Carton Pack Machine:-Checking of motor
Check the insulation resistance of motor winding with the help of megger.
Check the phase continuity and winding continuity of motor with the help of tong tester.
Physically check the motor terminal box and terminal connections.
Check the voltage and ampere ratings of motor with the help of tong tester.
Check the direction of rotation; it should be as per recommended direction.
Checking shall be done after every six month.
Check the VFD operation for machine speed.
Preventive Maintenance of Carton Pack Machine:Checking of contactors
Switch OFF the Electrical supply to the Machine.
Remove all the power and control wires from the contactor terminals
Remove the dust from control panel with help of air blower.
Remove the contactor from the panel and visually check all the contacts for signs of pitting and deposit of carbon on the contacts.
Clean the contacts, terminals and all the moving parts of the contactor by spraying contactor cleaner, replace the contacts if found damaged / welded.
Put back the contactor in the panel and re-terminate all the power and control wires properly to their original locations.
Check the earthing of the panel body.
A good earthing shall show less than 2 Volts between the Neutral Wire of the Incoming Power supply and Panel Body.
Checking of contactors shall be done six monthly.
Checking of Camera and its mountings shall be done on quarterly basis.
Checking of printers shall be done on quarterly basis.
InPreventive Maintenance of carton pack machine, Post Preventive Maintenance – Check List
Whenever any modifications and major works are carried out to the equipment, the same shall be mentioned in the equipment history card as per the respective SOP.
Connect the equipment main power supply and start the equipment.
Ensure that the equipment is running smoothly, without any abnormality.
If any abnormality is observed in the above, same will be attended in co-ordination with User department Head.
Record all the preventive maintenance activity for Carton Pack Machine as per Format No.: SOP/EN/XXXYYY.
ABBREVIATIONS
CRF No. : Change Request Form number
QA : Quality Assurance
VFD : Variable Frequency Drive
REFERENCES
Nil.
DISTRIBUTION LIST
SOP for Preventive Maintenance of Carton Pack Machine shall be distributed to the following departments Quality Assurance, Engineering as per user request.
ANNEXURES
Preventive Maintenance Check List & Record for : SOP/EN/XXXYYY Carton Pack Machine
Checklist and Record for Preventive Maintenance of Carton Pack Machine
Equipment Name
Location
Equipment ID
Frequency
Things to be done:
Check List
Remarks
Quarterly Check List
Checking of belts for timing; damaged; wear and tearing.
Checking and lubrication of bearings; chains; gears and sprockets.
