Plastic411 now offers 2-3 day maintenance courses! Each course is developed to be plant-specific, covering Hydraulic, Electrical, Pneumatic and Mechanical Preventative Maintenance/ Troubleshooting & removal/ installations. This is not classroom training. Plastic411 training programs are taught directly on the production floor. The following training modules are available:
Disclaimer: Electrical installations and repair will be covered, but it is important to note that electrical work should be performed by employees holding electrical certifications. Do not perform electrical work if you are not qualified!
Machine components & terminology
Basic machine functions/ order of sequence
Components & purpose of a good PM program.
Daily, weekly, monthly, quarterly, semi + annual
Work orders & log sheets & reporting procedure.
PM Maintenance vs Breakdown Maintenance
Tracking of breakdowns & PMs for trending
Create a file for each machine
Is there a CMMS system for data logging?
Proper PPE & practices
Proper tools for the job!
Thread types: NPT, BSPT, BSPP, JIC, JIS, ETC..
Safety guard & cover inspections
Screw & barrel components/ functions
Barrel alignment checking/ adjustment methods
Nozzle bodies, tips, orifices & radius check
Nozzle fwd pressure checking/ proving
How to locate & stop plastic leaks
(Why the long nozzle?)
Nozzle heater wiring up high/ 12:00 for no drool
Screw cushion/ check valve assy test
Continuous taper nozzles. Why?
Purging for maintenance
The high value of “Machine Clean to Inspect” and how to do it properly.
Spare parts use from stock, reporting & re-ordering
Lubrication system review, checking, proving
Correct grease & oil types for machine
Toggle, ram clamp inspection & cleaning
Discussion on operation.
Platen cleaning & stoning
Machine level/ platen support/ platen parallel/ tie bar stretch.
(Importance and understanding)
Oil cooler operation/ function/ checking/ cleaning/ cooling valve & temp checking.
Feed throat cooling operation & maintenance.
Brief discussion on cooling tower chemical control & purpose as well as water hardness & calcium build up.
Machine hydraulic manifold inspection for leaks, valve condition and electric plug condition
(Look out for water leaks near plugs for short circuits)
Hydraulic oil types and testing/ maintenance
Oil analysis (how to draw samples)
Interpreting lab results
Suction filter cleaning & o-ring checks
High pressure filter changing
Pump sounds (cavitation & aeration)
Oil tank cleaning
Magnets in the tank to collect shavings
Pump coupling inspection
Hydraulic basics: F=PxA, Pressure intensification
Oil accumulator safety, operation & nitrogen pre-charge checking.
Hydraulic hose inspections.
Machine type + methods & passwords
Pressure, flow, stroke, temperature
Test machine functions for accuracy:
Injection & hold pressure and speed linearity
Back pressure accuracy
Barrel heating understanding & operation
Thermocouple types/ identification/ maintenance/ repairs.
Check and record each heat zone voltage and amp draw.
Electrical panel cleaning & wire connection PM checking.
Visual Inspection for burnt wires or frayed wires
(With power locked out)
Electric Panel fan & filter change
Panel door lock operation
Check machine grounding
Check and record the main power source between phases
Check and record the power supply voltages
Software back up
Mold program backup
CPU battery changing
Vacuum pump systems
Repairing pumps, valves, Servo valves, cylinders