CRF

Sr No. Station Issues Description Remark

1 CRF All machine LM guide need to oiling and greasing Done
2 Punching-01 All belt up-down LM guide need to replace and fix Waiting for spare
3 Punching-02 All belt up-down LM guide need to replace and fix Not Done
4 LZ station Control box switch loose Done
5 LZ station Hydraulic Oil Leakage from L flip Cylinder Not Done
6 Auto taping-A needed Belt roller cover guard Not Done
7 Auto taping-A Sensor need to check Not Done
8 Punching-02 need to belt replace Done
9 Punching-01 Belt drive motor coupling damage and all bolt broken Done
10 U-Bending Limit cylinder not working properly Done
11 Punching-01 Hydraulic pipes mounting broken Not Done
12 U-Bending side positioning cylinder and stopper need to change Not Done
13 rolling Grease leakage from rolling station Auto-lube feeder pump Not Done
14 Punching-01 Needed roller support for belt Done
15 Punching-02 Needed roller support for belt one done & one not done
16 Loading loading station motor cover and panel cover are open Not Done
17 Loading loading station track rail need to anchor Not Done
18 punching-03 scrap conveyor not working Not Done
19 CRF all pneumatic connection need to check and encounter leakage Not Done
20 CRF all pneumatic solenoid valve need to cleaning and proper fix Not Done
21 LZ station LZ bending Hydraulic valve and relay need to check Done
22 Auto taping-A Auto taping All LM need to lubricate and pump replace Not Done
23 CRF All chiller need to cleaning and water change (if its required) Done
24 CRF All electrical panel cleaning and proper wire routing and covering Done
25 Over turn Overturn station pneumatic cylinder air leakage Not Done
26 Loading All sheet sensor bypass .its need to change and on Not Done
27 Loading All vacuum cup set and generator need to replace and cleaning Not Done
28 rolling Gear Oil Leakage from rolling station Not Done
29 robot Robot need to greasing Not Done
30 separator all roller and driver belt alignment Not Done
31 Joint all roller and driver belt alignment Done
32 punching-01 All belt up-down pneumatic cylinder need to check and change Done
33 punching-02 All belt up-down pneumatic cylinder need to check and change Done
34 CRF All station pnumetic DCV silencer damaged and not available Need to fix Not Done
35 CRF Die mould need to Sharpen and regrinding Done
 BACKWALL

Sr No. Station Issues Description Location or Image

A) Side Bending Station-01 Hydraulic oil leakage
from hydraulic cylinder
B) Side Bending Station-01 Air leakage from front
1 Side Bending-01
stopper Pneumatic cylinder
C) SM-15,16 Servo Motor coupling need to fix
with grub screw
A) Side Bending Station-02 Hydraulic oil leakage
from hydraulic cylinder
2 Side Bending-02
B) SM-17,18 Servo Motor coupling need to fix
with grub screw
4 Embossing Embossing Station Belt Damage Need to change

All Hydraulic power pack Flexible Gear Motor

5
coupling Damage need to change

6 Edge or End Bending SM-30 Servo Motor coupling damage need to

replace
7 Backwall All machine LM guide need to oiling and greasing
all pneumatic connection need to check and
8 Backwall
encounter leakage
all pneumatic solenoid valve need to cleaning
9 Backwall
and proper fix
All chiller need to cleaning and water change (if
10 Backwall
its required)
All electrical panel cleaning and proper wire
11 Backwall
routing and covering
12 Backwall All station coupling check and tight
13 Backwall Output area Inspection Light
Remark

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 DML

Sr No. Station Issues Description Location or Image

1 ST-03 Hydraulic oil leakage from Left side mold no C-101 Not Done
2 ST-04 Hydraulic oil leakage from Accumulator bottom side Not Done
3 ST-05 Hydraulic oil leakage from display cutting mold upper side Not Done
4 ST-05 & 06 Hydraulic oil leakage in top side middle crown area Not Done
5 SM-08 Air leakage from Pincer-08 Done
6 ST-06 Hydraulic oil leakage from Hydraulic seamless pipe welding joint area
7 ST-07 Hydraulic oil leakage from upper side Not Done
St-08 Both side press die support get loose time to time and gap become
ST-08 smaller between upper and lower plate , and due to this die unbalance and Not Done
8 break the cylinder rod and create unnecessary breakdown
9 ST-08 only 12 cylinder working out of 16 Not Done
10 ST-08 oil leakage Not Done
11 ST-09 scrap falling not properly on conveyor Not Done
12 SM-44 heavy vibration Not Done
13 SM-44 drag chain condition not OK cable is out of the drag chain Done
14 SM-46 & 47 Vibration and loose Not Done
15 ST-Auto changeover auto die changeover station backward and forward sensor damage Done
16 SM-49 Auto die changeover servo cable not available Done
17 ST-Auto changeover not working in auto mode Done
18 ST-Auto changeover First slot auto die changeover pneumatic cylinder not working Done
19 DML All machine LM guide need to oiling and greasing Done
20 DML all pneumatic connection need to check and encounter leakage
21 DML all pneumatic solenoid valve need to cleaning and proper fix Done
22 DML All chiller need to cleaning and water change (if its required) Done
23 DML All electrical panel cleaning and proper wire routing and covering Not Done
24 DML Output area Inspection Light Not Done
25 DML Die mould need to Sharpen and regrinding Done
 TRANSFERLINE

Sr No. Station Issues Description Location or Image

1 Press-1 Oil Lekage from Upper slide corner side Done
2 Press-2 hydraulic oil leakage from Upper and lower Clamp and Slide Corner side Not Done
3 Press-3 hydraulic oil leakage from Upper and lower Clamp and Slide Corner side Not Done
4 Shuttle Vibration and abnormal sound coming while shuttle movement Not Done
5 Press line All machine LM guide need to oiling and greasing Not Done
6 Press line all pneumatic connection need to check and encounter leakage Done
7 Press line all pneumatic solenoid valve need to cleaning and proper fix Not Done
8 Press line All electrical panel cleaning and proper wire routing and covering Done
9 Press line Scrap Conveyor need to check belt tension and lubrication Done
10 Press line All hydraulic pump need to clean and oil change Done
11 Press line Output area Inspection Light Done
 DOOR FOAMING

Sr No. Station Issues Description Remark

1 Drum 1 Mixing head 2 under maintenance from 12 sept 2021 - Pending Not done.
2 Drum 1 DOP circulation not working and DOP leakages. Not done.
3 Drum 1 Electric panel AC not working switches trip issue when excess heating from Jan 2022. - Pending Done.
4 Drum 1 Polyol temperature out of spec when iso 18.9 deg. polyol observed 27 deg. cause puff leakages. Not done.
5 Drum 1 Dry part electric panel AC not working from Dec. 2021. - Pending Not done.
6 Drum 1 Assy Conveyor & post foaming conveyor sensor need to fix properly. - Pending. Done.
7 Drum 1 HMI display hang issue. Pending Not done.
8 Drum 1 Dry Part control panel main switch need to fix on outside panel. Not done.
9 Drum 2 Polyol temperature control issue. temperature rise above 24 deg. C ( 2 April 2022) When FF production running, Done.
10 Drum 2 We are facing flange puff leakage issue. need to chiller water line & solenoid valve cleaning. - Pending. Done.
11 Drum 2 DOP circulation not working. Incomplete Work
12 Drum 2 Dry Part control panel main switch need to fix on outside panel. Not done.
13 Drum 2 Dry part main control panel lock not properly due to cable connection. Not done.
14 Drum 2 Iso leakage on wet part mixing head line. - Pending. Not done.
15 Drum 2 MTC red alarm continues on.- Pending. Not done.
16 Drum 2 Assy Conveyor & post foaming conveyor sensor need to fix properly. Done.
17 Drum 2 Required C clamp support for conveyor cable tray. Incomplete Work
18 Drum 3 Polyol Mixing head line leakage - Pending. Done
19 Drum 3 Hydraulic oil leakage from Mixing head. Not done.
20 Drum 3 DOP circulation not working. Not done.
21 Drum 3 HMI display hang issue. -Pending Not done.
22 Drum 3 Required Iso polyol line paint & insulation. - Pending Not done.
23 Drum 3 Safety door sensor Required - Pending. Not done.
24 Drum 3 Hydraulic unit fault alarm frequently from last 2 month - Pending.( Pls check hydraulic internal line maybe leakage ) Not done.
25 Drum 3 Pre heating booth required for panel heating. Not done.
26 Drum 3 Dry prat panel not lock due to cable connection inbetween door lock. Not done.
27 Drum 3 Required cable tray for conveyor cable. Incomplete Work
28 Drum 1 ISO motorized filter seal lekage. Not done.
29 Drum 1 Polyol wet part safety sensor by pass Not done.
30 Drum 2 Conveyor light hanging condition need to fix Done.
31 Door Foaming all pneumatic connection need to check and encounter leakage Not done.
32 Door Foaming all pneumatic solenoid valve need to cleaning and proper fix Not done.
33 Door Foaming All electrical panel cleaning and proper wire routing and covering Not done.
34 Door Foaming all Drum fixture MTC hot water line need to flushing and claening Done.
35 Drum 1 Drum-1 Mixing Head calibration Done.
36 Drum 1 Polyol tank Pressure regulator not working from 2 jan. 2023 Not done.
37 All 3 drum mould cleaning & tape pasting on top plate Done.
38 All trollley rework, cleaning & rubber pasting. Done.
39 All drum gear & head track greasing Done.
40 Iso Polyol filter Cleaning Done.
41 Drum 1 & Drum 3 Adapter rubber need to replace Not done.
42 Wet part mezzanine & staircase cleaning & Iso Poly tray cleaning Done.
43 MTC cleaning Done.
44 All mould & drum Allen bolt tightned Done.
45 DOP fillup in mixing head line DOP bowl. Done.
 PU Cabinet PM Activity
Sr.No Area Issues Description Photos Responsible Department

1 Wetpart Chiller No 01 Sometime Condenser Pressure High Alram. Maintenance

2 Wetpart ISO And Poly Filter Cleaning. (PM) Production

CD Side DOP Pack Sytem Stop Not Working. And DOP Filter
3 Wetpart Maintenance
Cleaning(PM)

4 All Side All side Head Calibration. (PM) Maintenance

5 Wetpart Cannon System HMI Working Very Slow. Maintenance

6 Wetpart CD Side DOP Pipe Cleaning. (PM) Maintenance

7 Pre Assembly Buffer Pre Assembly Buffer Sometime Only One Side Cabinet Dilivery. Maintenance

8 Draipart All Side Moving Shuttle Alluminium Bar Brokern. Maintenance

A6 And B6 Mould Only One Side Runnig Due to Change over

9 AB Side Maintenance
time Bottom Tub Strike Top Side Piller.

10 AB Side B Side Shuttle Drage Chain And Wiring Broken. Maintenance

11 CD Side C4 Mould Servo Alarm Issue. Maintenance

12 CD Side C Side MTC Water Hose Pipe Bending Issue. Maintenance

13 CD Side C side Voltage Chaek Meter not Working. Maintenance

14 CD Side D Side Emergency Gate Push Button Not Working Maintenance

15 CD Side D3 Mould One Side Servo Not Adjuste Properly. Maintenance

16 Draipart All Convoyer Belt Tight And Shuttle Lubriction.(PM) Maintenance

17 CD Side D2 Mould Water Pipe Broken. Maintenance

18 Wetpart Safety Air Duck Valve Broken. Maintenance

19 AB Side A side Head Hydraulic Pipe Lekage. Maintenance

20 CD Side C4 And D2 one Side Air Blower Not Working. Maintenance

21 AB Side A side One Safety Barrier Not Working. Maintenance

AB And Cd Side Turing Table Boult Loose And Broken Problem.

22 Post Foaming Maintenance
(PM)

Bothe Tilter Hydraulic Cooling System Not Working. Radiator

23 Post Foaming Maintenance
Fan Off

24 Post Foaming Cd Side Diverter Touch With Roller. Maintenance

25 Post Foaming Compresoer Are Sometime Network Connector Broken. Maintenance

26 Post Foaming Buffer Ab Sider Diverter Chain Missing. Maintenance

All Diverter Up Dowe And Chain Issue Chake All Diverter and
27 Post Foaming Buffer Maintenance
pm Tham.

28 Wetpart A Side MTC Water Leakage Maintenance

29 Pre Heating Room heating blower not working Maintenance

30 Draipart All Tube Light Not Working Maintenance

31 A Side Fixturs A5 & C5 Fix Draiv Error And Penal Emergency alarm Not Reser Maintenance

32 Post Foaming AB Side Turning Table Aligment not ok Maintenance

33 Cabinet Foaming Machine Paint PE

34 Cabinet Foaming AB Side Exit Door Was Bypass Maintenance

35 Draipart ALL FIX And Shuttal Lead screw Grising Maintenance

36 Draipart B side And C Side ISO Hosepipe Change Maintenance

37 Wetpart Cannon System HMI Working Very Slow. Maintenance

Mold Temp. Display & Actual Temp. Variation Display Not

38 Draipart Maintenance
Working Properly

39 Draipart 3M Tap is To Be Applied in All Fixturs. PE

40 Draipart Flushing To All Side Walls Maintenance

41 Mold All Mold Require Cleaning & Maintenance Production

42 D side Mixing head Iso line leakage -Pending from last 8 month.
AB Side Drag chain iso line leakages many more place
43 - Corrected.
CD side head lubrication not working from last 4 month
44 - Corrected .
Iso Motorized filter seal break iso leakages from last 9 month
45 - Corrected
46 HMI display hang issue. Pending
47 All ABCD side moving shuttle aluminum bar broken. - Pending.
48 C side voltage display not working. Pending
Mould temperature display & actual temperature variation
49 display not working. - Pending
50 D side emergency gate push button not working. Pending.
51 D2 Mould water pipe broken. pending.
52 Safety air duct valve broken. Pending.
53 A side hydraulic pipe leakage. Pending.
54 C4 & D2 hot air blower not working. Pending.
Both tilter hydraulic cooling system notworking & radiator fan
55 off. Pending.
56 AB side divertor run with 2 chains out of 3 nos - pending.
Remark

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 TANKYARD

Sr No. Station Issues Description Location or Image

1 AC Display not working from last 9 month - Pending Not Done
2 C5 blended polyol Buffer tank required pressure gauge 16 bar available 6 bar - Pending . Not Done
3 C5 tank Sensor bypass from last 11 month- Pending . Not Done
4 Iso Pump stop from 26 July 2022 due to coupling issue- Pending . Done
5 Easy froth stream distributor not working properly from last 3 month.- Pending . Not Done
6 Storage tank actuator valve continuous air supply when delivery pump is off.- Pending Not Done
7 Iso delivery pump & polyol unloading pump flange leakages.- Pending . Iso done, poly not done
8 Iso C tank unloading issue due to actuator not open.- Pending . Not Done
9 Chiller 1 ok Chiller 2 antifreeze alarm on 18 Deg.C.- Pending . Not Done
10 Iso poly pump pressure gauge display not showing all 6 gauges.- Pending . Not Done
Iso poly new tank mechanical display & temperature display 3 nos not working out of 5
11 nos.- Pending Not Done
12 All electrical panel cleaning and proper wire routing and covering Not Done
 PREASSEMBLY

Sr No. Station Issues Description Location or Image

Pre assy line buffer only one side cabinet delivery when AB & CD both side single
1 model running. - Pending. Done
2 all pneumatic connection need to check and encounter leakage Incomplete work
3 all pneumatic solenoid valve need to cleaning and proper fix Done
4 All electrical panel cleaning and proper wire routing and covering Not Done.
 INJECTION MOULDING

Sr No. Station Issues Description Location or Image

1 IMM All machine needs to be oiling and greasing Done
2 IMM Auto greasing pump not working on all machine Not Done
3 Machine-03 hydraulic Oil leakage from tie bar inlet line Not Done
4 Machine-02 Moving plate need to be calibration Not Done
5 Machine-05 Moving plate need to be calibration Not Done
6 IMM All robots need to be preventive maintenance Done
7 IMM All robot guards cover open its need to be fix Not Done
8 Machine-04 Part Exit conveyor VFD not working its running on high speed Not Done
9 IMM Loose wire and connection need to fix and insulate Not Done
10 IMM All machine LM guide need to oiling and greasing Not Done
11 IMM all pneumatic connection need to check and encounter leakage Not Done
12 IMM all pneumatic solenoid valve need to cleaning and proper fix Done
13 IMM All chiller and line need to cleaning and water change (if its required) Not Done
14 IMM All electrical panel cleaning and proper wire routing and covering Done
15 IMM All machine tie bar and split nut mechanism need to be clean Not Done
16 Machine-04 High pressure release valve taking 17 sec instead of 6 sec Done
17 IMM Hydraulic Power pack oil filter need to clean and oil need to replace(if its required) Done
18 Machine-03 Hydraulic oil leakage from power pack manifold Not Done
19 Machine-01 Material loading limit Switch Done
20 Machine-01 Thermocouple (nozzle) Done
21 Machine-02 robot card issue Not Done
22 Machine-03 Always oil leakage problem Not Done
23 Machine-05 robot card issue Not Done
 FINAL LINE

Sr No. Station Issues Description Location or Image

1 SPT Conveyor 2 nos roller not working from last 2 month Not Done
3 FA-1 Required light at loading line stage.or Repair Done
4 Line frequently stops due to Inficon leak check machine maintenance - Required PM
6 FA-1 tub-light fitting at rbp fixing stage. Done
7 FA-1 change holding alarm glass fitting stage to discharge lock-ring stage. Not Done
8 FA-1 two nrv resistor required for brazing torch. Done
9 FA-1 change domestic power supply board position.(down the position) Not Done
10 FA-1 reflector plate required in fa-1 Done
11 FA-1 mcb main board damage at crisper station.(fixing not properly) Not Done
12 FA-2 two capter pump not available in vacuum station. Not Done
13 FA-2 13 capter not working at spt. Not Done
14 FA-2 change pressure valve and flushing required in both gas charging machine Done
15 FA-2 extension board required for rework station(spt rework area) Not Done
16 FA-3 extension board required at rework area. Not Done
17 FA-3 proper routing and fixing of component check machine. Done
18 FA-3 new holder required for est machine. Not Done
19 FA-4 strapping machine - 3 not working.(motor handover to maintenance). Not Done
20 RBP rbp panel bending machine -2 not working. Not Done
21 FA-1 f1-drier to caliper lock-ring gun Not Done
22 FA-1 f1-Helium discharge machine Not Done
23 FA-2 f2 SPT rework vacuum pump not working Not Done
24 FA-2 f1-Helium machine no-1 not working Not Done
25 FA all pneumatic connection need to check and encounter leakage Not Done
26 FA all pneumatic solenoid valve need to cleaning and proper fix Not Done
27 FA All electrical panel cleaning and proper wire routing and covering Not Done
 DTF

Sr No. Station Issues Description Location or Image

1 DTF-1 1. Heaters are not working. Heaters and their fuse not available in maintance. ( 137 nos ) Not Done
2 DTF-1 2. Lower plate and middle frame pneumatic cylinder wiper removed. Not Done
3 DTF-1 3. Vacuum pump is not working over a year. Not Done
4 DTF-1 4. Transport blade required. Not Done
5 DTF-1 5. MTC required in spare. Not Done
6 DTF-1 6. Vacuum pump required in spare. Not Done
7 DTF-2 1. Heaters are are not working. ( 35 heaters ) Not Done
8 DTF-2 2. Lower frame pneumatic cylinder wiper remove in auto condition. Not Done
9 DTF-2 3. Trimming press automagically down in rest position. Not Done
10 DTF-2 4. Auto mould loading not. Not Done
11 DTF-2 5. Vaccum pump not working no 2 Not Done
12 DTF-2 6. MTC required in spare. Not Done
13 DTF-2 7. Vaccum pump required in spare. Not Done
14 DTF-2 8. Lifter motor is not installed. Not Done
15 DTF-2 9. Middle frame locking is not working by HMI need to operate from DCV vaulve. Not Done
16 DTF-2 10. Upper plate locking is not working by HMI need to operate from DCV vaulve. Not Done
17 DTF-2 11. Mould presence sensor is not working properly. Not Done
18 DTF-2 12. Trimming press tool carriage pneumatic cylinder and chain issue. Not Done
19 DTF All machine LM guide need to oiling and greasing Not Done
20 DTF all pneumatic connection need to check and encounter leakage Not Done
21 DTF all pneumatic solenoid valve need to cleaning and proper fix Not Done
22 DTF All chiller and line need to cleaning and water change (if its required) Not Done
23 DTF All electrical panel cleaning and proper wire routing and covering Not Done
 CTF

Sr No. Station Issues Description Location or Image

1 COMI-1 1. Blowing issue Not Done
2 COMI-1 2. Main heating panel door lock not working. Not Done
3 COMI-1 3. Main heating panel on switch not in work. Not Done
4 COMI-1 4. Most of the air regulators are not working. Not Done
5 COMI-1 5. Turbogel no 5, 6 and 7 are not working. Not Done
6 COMI-1 6. Turbogel temperature communication issue. Not Done
7 COMI-1 7. Following heaters are not working. Not Done
8 COMI-1 Upper heating- 29 Not Done
9 COMI-1 Lower heating- 24,43,45,47,49,96 Not Done
10 COMI-2 1. Safety sensor damaged. Not Done
11 COMI-2 2. Trimming press no 2 not working nearly 20 months. Not Done
12 COMI-2 3. Transport blade need to change. Not Done
13 COMI-2 4. Following heater are not working Not Done
14 COMI-2 Upper heating - 33 to 40,152 Not Done
15 COMI-2 Lower heating - 15,28,29,86,117 Not Done
16 COMI-2 Upper pre heating- 17 to 24 Not Done
17 COMI-3 1. Mail line voltage issue. Not Done
18 COMI-3 2. Carriage table problem. Not Done
19 COMI-3 3. Sheet lifter servo motor not in work. Not Done
20 COMI-3 4. Carriage table communication problem work slow Not Done
21 COMI-3 5. Cutting station run in 1st cycle in the absence of liner ( test cutting ) Not Done
22 COMI-3 6. Press punch door lock not in working Not Done
23 COMI-3 7. All door safey bypass machine can run if door is not locked. Not Done
24 COMI-3 8. Start side button need to bypass Not Done
25 COMI-3 9. After heating come singles need to be green full time Not Done
26 COMI-3 10. In 1st cycle no testing required for cutting. Not Done
27 COMI-3 11. Transfer do not left his place before if transport not in his initial position. Not Done
28 COMI-3 12. Bubble sensor reading not working. Not Done
29 COMI-3 13. Upper bell saftey lock need to interlock it should not go up if saftey bell not in unlock position. Not Done
30 COMI-3 14. Trimming press gate lock damaged. Not Done
31 COMI-3 15. Carriage table will not stop push button in middle. Not Done
32 COMI-3 16. Lower plate pneumatic cylinder wiper removed. Done
33 COMI-3 17. Main heating panel door lock damaged. Not Done
34 COMI-3 18. Turbogel no 1 is not working. Not Done
35 COMI-3 19. Turbogel temperature communication issue. Not Done
36 COMI-3 20. Following heaters are not working. Not Done
37 COMI-3 Upper heating - 7,8,40,41,90,142,151, Not Done
38 COMI-3 Lower preheating - 58 Not Done
39 COMI All machine LM guide need to oiling and greasing Done
40 COMI all pneumatic connection need to check and encounter leakage Not Done
41 COMI all pneumatic solenoid valve need to cleaning and proper fix Done
42 COMI All chiller and line need to cleaning and water change (if its required) Done
43 COMI All electrical panel cleaning and proper wire routing and covering Not Done
 EXTRUDER

Sr No. Station Issues Description Location or Image

1 Pressure before filter is high in 130 Screw. Not Done
2 Oil leakage from oil level indicator in 130 Screw. Not Done
3 130 Screw flange heater not working. Not Done
4 65 Melt Pump drive not working in auto mode because unavailable of card. Not Done
5 Top roller temperature controller not working. Not Done
6 In main chiller, gas leakage from compressor No. 1. Not Done
7 65 screw flange heater not working. Not Done
8 Exhaust not working. Not Done
9 Dehumidifier frequently stop. Not Done
10 65 screw pressure sensor not working Not Done
11 All machine LM guide need to oiling and greasing Not Done
12 all pneumatic connection need to check and encounter leakage Not Done
13 all pneumatic solenoid valve need to cleaning and proper fix Not Done
14 All electrical panel cleaning and proper wire routing and covering Not Done
 GRINDING

Sr No. Station Issues Description Location or Image

1 Machine-03 Need to be descaling Not Done
2 ALL All rotatry and revolving parts need to be lubrication Not Done
3 ALL All machine blade need to be sharpning and change Not Done
4 ALL All electrical panel cleaning and proper wire routing and covering Not Done