REPLACEMENT OF BLADE

AT LOAF LINE BAND SLICER MACHINE

20 APRIL 2020
 SUMMARY

• Last April 18, Engineering perform replacement of blade in the band slicer
machine. Replacement has been transpired due to broken blade incident
that had happened last April 13 (Blade #5) and April 16 (Blade #9). To avoid
stoppage in the production replacement of blade was necessary.

• Previous replacement of blade was conducted last November 25, 2019.

However, looking on the maintenance record running hour before the failure
was only 461 hours which is below the standard replacement period at every
500 hours.

• In order to improve machine reliability and understand the failure cause, Engineering perform deeper analysis in on order
identify the gaps and look standard ways to prolong the use of blade in the machine.

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 SUMMARY

Blade Replacement History:

RUN HOUR
Item No DATE MTBF ACTIVITY REMARKS
METER
Encounter broken blade during production. Check tension on each
1 25 Nov. 2019 465.0 465.0
Replaced 13pcs slicer blade. blade
Check tension on each
Encounter Broken blade last April 13 &16.
blade. Ensure to loosen
2 13 Apr. 2020 926.0 461.0 Schedule replacement of 13 pcs slicer
blade tension every
blade last April 18.
weekend
Incident Matrix:
MTTR – Mean Time to Replace ; 500 hrs for Blade MTBF – Mean Time Between Failure

• MTBF measures the predicted time that passes between one previous failure of a mechanical/electrical system to
the next failure during normal operation. In simpler terms, MTBF helps to predict how long an asset can run before the
next unplanned break down happens.

• To increase MTBF proper procedural use of equipment and maintenance must be followed and observed.

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 SUMMARY

Checking the possible causes of premature breaking of blade

may be attributed to the following;
o Insufficient cleaning of the finger holder and lattice.
Accumulation of crumbs residual can create tension in
the blade
o Proper tension in the blade was not attained or
followed during production run and after operation.
o Narrow gaps between the blade and adjacent
components. Mis-aligned or damaged finger holders
PROPER BLADE DISTANCE (3~4mm)

• From above listed sources of failure. The first two reasons will likewise damage the blade. As way forward action this
activity should be thoroughly followed between production and engineering personnel.

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 RECOMMENDATION

1. Instill qualification and technical capability of operator to handle the machine. Prior assigning to the machine, the
operator has to have proper training plan and record with regards to the use of equipment. Proper adjustments and
set up are vital to prolong mechanical life of the machine.

2. Enhance cleaning of finger holder every end of production. Production personnel has to clean the gaps between
the holder since it is part to be cleaned. Accumulation of bread dust can add tension to the blade. or it can
damage the finger holder

3. Adjustment of blade tension (loosen) every end of production. The shaft supporting the drum is burdened with load,
which may shorten life time of the machine. this activity will be done by engineering

4. Maintain proper lubrication of mechanical components with accordance to maintenance procedure

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 RECOMMENDATION

FINGER
HOLDER

Cleaning of finger holder is required every Release tension of blade every end of Relieving the tension of blade would
end of production. Ensure proper use of production. initially to be done by prevent it from elongation (strain) and
PPE from the operator side. engineering damage to the drum.

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 BLADE REPLACEMENT PROCEDURE

1. Make sure the machine is turned off. 2. Ensure proper looseness prior blade 3. Loosen the screw shafts both in the upper
prior the activity. Release the tension removal and disassembly. and lower drum. Remove any blockages.
between blade and drum Take-out blades piece by piece.

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 BLADE REPLACEMENT PROCEDURE

4. Ensure the old blades removed are 5. Clean the upper and lower drum. Check 6. After cleaning ensure to wipe it with
placed in the safe location to avoid any for wear and tear alcohol for sanitation.
injury.

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 BLADE REPLACEMENT PROCEDURE

7. Clean new set of blades prior installation. 8. Install blades sequentially. Twist blade 9. Align the blades in the drum. Make
Make sure to use non fiber cloth when installing between the upper and sure all blades are facing same direction
lower drum.

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 BLADE REPLACEMENT PROCEDURE

10. Installation of blade piece by piece 11. Ensure all blades were placed in 12. Make Sure to do final check in the slicer
between finger holders. Without checking assembly prior returning the guide plates.
it will damage the blade as well the Make sure all components are complete
holder prior restarting.

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 BLADE REPLACEMENT PROCEDURE

13. Use blade tension meter to check the 14. Ensure the tick-mark are in the center 15. Final cleaning using compressed air.
fitness of blade. Make sure to operate the of the tension meter.. Make sure necessary lubrication on moving
equipment while checking parts. Check and inspect mechanical
components

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 REPLACEMENT ACTIVITY (FUJISHIMA SLICER)

Disassembly of blade (11 pcs) Remove blade piece by piece Remove blade piece by piece

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 REPLACEMENT ACTIVITY (FUJISHIMA SLICER)

Ensure to place the blade properly Ensure to place the blade properly Cleaning and sanitation of machine prior
endorsement to production.

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 OBSERVATIONS (START-UP OPERATION,20 APRIL)

Some residual component from the blade Some loaf pieces has some black spots in the This contamination if not checked can be a
were transferred to the loaf inside surface and not seen in the crust side. serious findings when it goes to the market.

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 OBSERVATIONS (START-UP OPERATION,20 APRIL)

1. On next blade replacement. Engineering will prepare the blade for further cleaning by dipping it with
alcohol to remove the oil protective layer in the blade.

2. Request additional set of loaves (from 5pcs to 10pcs )during pre-start-up to ensure cleanliness of blade
and avoid foreign matter contamination to produced FG’s

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