Month of April 2009
<ul><li>KBA Update </li></ul>Compiled by Willy Koo
KBA Downtime Summary <ul><li>Average downtime for the four KBA presses increased from 301 to 308 minutes. </li></ul>Total ...
K20 K30 Best Press for Month of April K40 K50 Under Performing Press for Month of April
K20 : One of the Best performance press, downtime percentage at  2.5%. KBA Individual Press Downtime March April
K30 : One of the Best performance press, downtime percentage at  2.5%. KBA Individual Press Downtime March April
<ul><li>K40 : Worst performance press, downtime percentage at  5.5%. </li></ul><ul><li>60 mins of Stop to change plate </l...
KBA Individual Press Downtime <ul><li>K50 : Average performance press, downtime percentage at  5.1%. </li></ul><ul><li>77 ...
KBA Units Run hours Summary
Project Update <ul><li>Replaced Ink Film roller bearing(from  NSK to SKF  ) status :  </li></ul><ul><ul><li>68 Ink Film ro...
Plan for next Month <ul><li>Schedule to continue servicing all the high  lock up . </li></ul><ul><li>Schedule to  continue...
End
COLORLINER Update Compiled by GohTK/ChanLC
Average downtime for all 4 presses decreased from 271 to 264 min COLORLINER Downtime Summary
C1 C2 Best Press for Month of April C3 C4 Under Performing Press for Month of April
C1 Down Time  C1 downtime decreased from 243 to 179 min
C2 Down Time  C2 downtime decreased from 391 to 226 min
C3 Down Time  C3 downtime decreased from 244 to 234 min
C4 Down Time  <ul><li>C4 main downtime contributor: </li></ul><ul><li>Others, DT131 mins </li></ul><ul><li>ZB040409 -U44. ...
Colorliner Units Run hours Summary
<ul><li>RTP brake puck (tipco brake pad) replacement :  RTP43, 44   (done 83%) </li></ul><ul><li>VSI motor replacement (wi...
Planned works <ul><li>Bustle wheel replacement from rubber type to  aluminum type </li></ul><ul><li>VSI motor and  key-way...
Mailroom Update Compiled by WangMK
PC1 Press downtime due to ABL issue: APR ’09 -  count  -  12 MAR ‘09 -  count  -  6
PC2 Press downtime due to ABL issue: PC2 Press downtime due to ABL issue APR ‘09  -  count  - 0 MAR ’09  -  count  - 1
Colorliner <ul><li>Installed new Printronix printer on DBH301-1. </li></ul><ul><li>Completed predictive maintenance (therm...
Major Work Done for May 09: <ul><li>To check TTR conveyor chain wear rate. </li></ul><ul><li>To continue to relocate the T...
End of Report
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Ka Brodmeeting 110509

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  • Ka Brodmeeting 110509

    1. 1. Month of April 2009
    2. 2. <ul><li>KBA Update </li></ul>Compiled by Willy Koo
    3. 3. KBA Downtime Summary <ul><li>Average downtime for the four KBA presses increased from 301 to 308 minutes. </li></ul>Total downtime (normalised to 50 hours run time) K20 - 75 mins, K30 - 75 mins K40 - 165 mins, K50 - 152 mins March April
    4. 4. K20 K30 Best Press for Month of April K40 K50 Under Performing Press for Month of April
    5. 5. K20 : One of the Best performance press, downtime percentage at 2.5%. KBA Individual Press Downtime March April
    6. 6. K30 : One of the Best performance press, downtime percentage at 2.5%. KBA Individual Press Downtime March April
    7. 7. <ul><li>K40 : Worst performance press, downtime percentage at 5.5%. </li></ul><ul><li>60 mins of Stop to change plate </li></ul><ul><li>56 mins of Scumming </li></ul><ul><li>55 mins of 2nd Edition Change </li></ul><ul><li>52 mins of Lead Edge open </li></ul><ul><li>51 mins of Folder A severer triggered </li></ul><ul><li>45 mins of Hickies </li></ul><ul><li>44 mins of RRWB. 1x RS42 . 1xRS47 </li></ul>KBA Individual Press Downtime March April
    8. 8. KBA Individual Press Downtime <ul><li>K50 : Average performance press, downtime percentage at 5.1%. </li></ul><ul><li>77 mins of Drive Fault. Replaced D54.2 Motor Encoder </li></ul><ul><li>71 mins of Delay Press Startup. D54.6 Ink/Dampening clutch fault. Replaced faulty solenoid valve </li></ul><ul><li>71 mins of Lead Edge Open </li></ul><ul><li>55 mins of 2nd Edition Change </li></ul><ul><li>36 mins of RRWB. 1x D51 and 1 x D56 </li></ul>March April
    9. 9. KBA Units Run hours Summary
    10. 10. Project Update <ul><li>Replaced Ink Film roller bearing(from NSK to SKF ) status : </li></ul><ul><ul><li>68 Ink Film roller completed. </li></ul></ul><ul><li>RS UPS 3G3 Battery Replacement.. 100% completion </li></ul><ul><li>K20 SMC quick coupling installation with support bracket on outer couples completed. </li></ul><ul><li>Installed Slitter trays under Draw rollers to reduce Hickies. 100% completed </li></ul><ul><li>Unit Power Packs (HVE overhaul program) </li></ul><ul><ul><li>D44 and D45 (Jan 09) </li></ul></ul><ul><ul><li>D46 and D47 (Feb 09), D43 and D42.1/2/3/4 (Mar 09) </li></ul></ul><ul><li>Folder Audit from 22Apr’09 to 07May’09 with KBA folder specialist Klaus. Completed K30 and K40 Folders. </li></ul><ul><li>Flush & swap Delta SD fountain solution. K30 & 40 using Uniset fount and K20/50 using Hydronews fount </li></ul><ul><li>Installed new FFKM valves for D34 to D37 spray bar units for evaluation purpose </li></ul><ul><li>Lockup bar servicing status. </li></ul>
    11. 11. Plan for next Month <ul><li>Schedule to continue servicing all the high lock up . </li></ul><ul><li>Schedule to continue the replacement of the Ink Film bearing from NSK to SKF. </li></ul><ul><li>Schedule to replace spray bar quick coupling O ring with routine SB maintenance. </li></ul><ul><li>Schedule to the Unit Tower Power Pack Overhaul Cycle at K40 . </li></ul><ul><li>Continue the Folder Audit from 22Apr’09 to 07May’09 with K20 &50 folders . </li></ul><ul><li>Schedule to install new FFKM valves on K36.7/8 and K37 for Spray bar evaluation. </li></ul><ul><li>Schedule to install the portable ink pump to be stationed outside the main ink tank room. </li></ul>
    12. 12. End
    13. 13. COLORLINER Update Compiled by GohTK/ChanLC
    14. 14. Average downtime for all 4 presses decreased from 271 to 264 min COLORLINER Downtime Summary
    15. 15. C1 C2 Best Press for Month of April C3 C4 Under Performing Press for Month of April
    16. 16. C1 Down Time C1 downtime decreased from 243 to 179 min
    17. 17. C2 Down Time C2 downtime decreased from 391 to 226 min
    18. 18. C3 Down Time C3 downtime decreased from 244 to 234 min
    19. 19. C4 Down Time <ul><li>C4 main downtime contributor: </li></ul><ul><li>Others, DT131 mins </li></ul><ul><li>ZB040409 -U44. Smoke coming out from U44B13sd . Stop press & found cyl brake unable to release.Replaced the cyl brake node & the DSCR relay. Also retightened all wire terminals. </li></ul><ul><li>Jaw folder belt guide fault, DT62mins </li></ul><ul><li>NP 230409, Pile-up at delivery fly - Replaced worn belt & belt guide assembly due to bushing worn </li></ul><ul><li>ZBCLASS 260409, Jaw folder belt guide fault -Replaced 2pcs of damaged tucker blades </li></ul><ul><li> ZB010509, 2 counts . Pileup at delivery fly. -Replaced all friction strips & guide belts due to damaged. </li></ul><ul><li>RC WB, DT59 mins </li></ul><ul><li>ZB230409 & ZBCLASS260409 - U44 WB after splice. Checked AB drive healthy & measured power supply within spec. </li></ul><ul><li> NP270409,NP280409,NP300409 - U45 WB due to bumpy rolls. </li></ul>C4 downtime increased from 205 to 419 mins. 131 62 59
    20. 20. Colorliner Units Run hours Summary
    21. 21. <ul><li>RTP brake puck (tipco brake pad) replacement : RTP43, 44 (done 83%) </li></ul><ul><li>VSI motor replacement (with stopper keyway): U35B10, 22C10 . (VSI motor done 66.8%, VSI motor keyway done 62% ) </li></ul><ul><li>Osc. roller seal/bearing replacement : U15A10, U30C13 . </li></ul><ul><li>Iron-Iron setting : U15, U20, U24, U25A/B, U30 & U34 . </li></ul><ul><li>Replacement of U23 horizontal drive shaft sleeve & bearings </li></ul><ul><li>Removal of U29 bull motor </li></ul>Colorliner - Major work done
    22. 22. Planned works <ul><li>Bustle wheel replacement from rubber type to aluminum type </li></ul><ul><li>VSI motor and key-way stopper replacement. </li></ul><ul><li>Oscillating roller seal replacement. </li></ul><ul><li>Unit iron- iron settings. </li></ul>
    23. 23. Mailroom Update Compiled by WangMK
    24. 24. PC1 Press downtime due to ABL issue: APR ’09 - count - 12 MAR ‘09 - count - 6
    25. 25. PC2 Press downtime due to ABL issue: PC2 Press downtime due to ABL issue APR ‘09 - count - 0 MAR ’09 - count - 1
    26. 26. Colorliner <ul><li>Installed new Printronix printer on DBH301-1. </li></ul><ul><li>Completed predictive maintenance (thermoscan) for KBA electrical cabinets. No abnormality. </li></ul><ul><li>Replaced all K201 ABL strikers to Festo type( 70% lower cost). </li></ul><ul><li>Replaced 100pcs of grippers with new spring support bracket on UTR501(performance-ok). </li></ul><ul><li>Completed PZF arrestor cleaning to eliminate the problem of the tables unable to merge. </li></ul>Major Work Done for April 09: <ul><li>Completed replacing TTR4A line conveyor grippers(2360pcs). </li></ul><ul><li>Replaced all ageing air hoses and fittings for C4 ABLs’ striker unit. </li></ul><ul><li>Relocation of TST 21(turntable) pneumatic system for easy access to the valve and regulator. </li></ul><ul><li>Replacement of SBD main contactor at ETB 1 to 8 cabinets(Sprecher contactor obsolete). </li></ul><ul><li>IDS MC7 replaced with new industrial PC loaded with Ferag/EAE software. </li></ul>Mailroom
    27. 27. Major Work Done for May 09: <ul><li>To check TTR conveyor chain wear rate. </li></ul><ul><li>To continue to relocate the TST pneumatic system. </li></ul><ul><li>To replace C4 STB worn chain track. </li></ul><ul><li>To install new Yokogawa PLC for SBD 43 and 44 conveyors. </li></ul>COLORLINER KBA <ul><li>To replace driver on TF35. </li></ul><ul><li>Replacement of new spring support bracket and rubber rings for UTR501 grippers. </li></ul><ul><li>To replace new control board and test the WHS baler SEW drive. </li></ul><ul><li>To install exhaust fans on TRST panels (currently only intake fans) </li></ul>
    28. 28. End of Report

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