Started with Fresh Graduate

This is a company started of with all fresh graduated admin and management staffs. Of course they are some line workers, especially those engineering technician who were needed to assist in installation works.

To take care of the inexperience in automated production line, some experienced consultant were engaged to help in planning, organizing and implementing the project. This is costly, but at least it works if the owner does have enough capital.

After the plant has been run to approximately 85% of it rated capacity, some problems started to appear as the plant is getting "old". And that was the time I was engaged to settle some of the technical issue.

Personally I do not care too much on the positioning held provided the company give me what I want.

The first idea I started to highlight on human resource of the company is that the company should not limit the recruitment to fresh graduate with good result in academy. However, as the situation was as such, I had to work by and patiently train the staffs that were available.

This was progressing alright for about two years and one of my prediction comes true. Some key personnel started to leave us as this is the first company that they started their courier. Even though the company is treating them quite well, they cannot stop searching for jobs elsewhere due to curiosity about the business world. This is normal to freshies in employee market.

With their leaving, it is not the end of the world but I had re-shuffle the team to cater for the change. I am also taking this opportunity to reset the system used to-date and try to move toward an organization behavior that I believe to be more efficient.

2014-03-26 W&P divider back to normal

This post is to confirm that the weight adjusting issue on W&P divider had been overcome.

I am glad to inform that Jan from W&P Haton agreed to bring back the damaged motor and  helps us to claim under warantee. Of course the final approval is yet to be confirm by the motor manufacturer after they check for the root cause of motor failure. At the moment, a new motor had been replaced to us by W&P professionally.

2014-03-25 Problem Faced on the W&P Divider weight adjusting Motor

Production Team reported that the divider weight adjusting was not functioning last week. On checking, we noticed that the weight adjusting motor had been out of order.

We tried to get the same servo motor from the new divider and replace it to the existing divider for trial. It worked but alarm [DIV/105] Halstrup Walcher servo drive error (M226) was activated frequently. We noticed that the newly fixed weight adjusting servo motor become very hot and thus decide to temporary remove it again for further investigation.

By refering the the User Manual (you can refer to the soft copy linked the the MyTIBakery Database) page 73/118 to 80/118, we realized that the calibration of the servo motor need to be done and thus we decide to carry out a second trial.

On checking to the existing system, we that the Maximum Pos is set to 10300 (refer picture below), this is for V500 series of divider. Our divider is series V900, thus the Maximum Pos should be set to 10810.

 

Thus we re-calibrate the Maximum Position to 10810 and then follow the procedure in page 77/118 and 78/118 to reset the calibration of the weight adjusting motor. The new setting as shown in the picture below:

The divider is now running back to normal. I asked the technicians to keep on monitoring the divider operation to ensure that no alarm will be activated and if any alarm, we may have to remove the new motor again.

IMPORTANT:

The weight adjusting servo motor is a very small motor and cannot take up heavy load. Hence the setting to the accurate maximum position of the feedback signal is of utmost important.

As the initial setting of maximum position prior to my checking was 10300 (which is for V500 divider), it means that the maximum position given by the servo motor when the mechanical stop come to the maximum end is 10300. But the software of the V900 is set to "think" that the maximum position should be 10810 and 10300 is not maximum yet. Thus the motor will keep on trying to turn to increase the weight and I believe that this is the major reason the motor was damaged.

As the divider was set up correctly initially, I strongly believe that the operator had possibly set the figure by mistake. This figure can only be set with level 2 and above. I had reset the password of the level.

Please remember not to leak out the password to normal operator and mistake in a figure in the system can cause heavy damage and even possible causing dangerous operating condition.

Hoe the above briefing give a clear idea on the problem faced. If there is no more alarm [DIV/105] Halstrup Walcher servo drive error (M226), then I believe that the problem faced on this weight adjustment on W&P divider is considered CLOSED.