The Performance Optimization Program
...It's not just replacing parts.
The goal of MPI Performance Optimization Program (POP) is to increase your casting throughput by optimizing machine performance during production runs and reducing machine downtimes. We accomplish this goal by:
- Monitoring the set up and operation procedures used in your Wax Room
- Identify and suggest how to improve procedures that optimize throughput.
- Test and service systems
- Review machine functions andprocedures with your operators.
Here is how the Process Optimization Program works.
A series of service visits are set up that allow you to schedule which wax injector and personnel will be available for a process optimization visit. The number of wax injectors in service determines the number of visits per year.
During each scheduled visit our service technician inspects all MPI machines and performs a full process optimization service on the scheduled machine.
The service includes a comprehensive function test of each system, inspect component wear and replace consumables including filters, seals and O-rings.
|
The major systems included are:
- Machine Pneumatic System
- Machine Hydraulic System
- Machine Wax Seals
- Overall Machine Performance
- Machine Operations Test
A detailed POP checklist is used to identify each function and component and is available on request. At the completion of the service, the customer receives a written report on all work performed. In addition, MPI provides the customer with recommendations for process improvements and future maintenance procedures for their machine(s).
Subscribers to the program confirm the following benefits:
- Reduced machine down time
- Consistent quality wax pattern production
- Reduced number of scrap patterns
- Decreased cycle time
The MPI Process Optimization Program is making perfect sense for our customers and we believe that it will make perfect sense for you.
For more information about the MPI Process Optimization Program call 845-471-7630 or your local MPI Agent.
|
|
| Machine Operation Testing
General sequence check of machine and options:
- Flex-Noz® Operation.
- Purge wax cylinder.
- Refill wax cylinder.
- Clamp
- Unclamp
- Wax Flow control
- Safety device operation.
- Die clamping operation.
- Hydraulic Pattern Ejector operation.
- Check auto sequence using all variations of machine options.
- Check emergency stop during all phases of machine auto cycle
Process Optimization Parts:
Machine Wax Seal
Checks and Service
- Rebuild Flex-Noz injection nozzle and replace all seals.
- Rebuild injection compartment wax valves and replace all seals.
- Rebuild wax injection piston and cylinder and replace wax seals.
- Inspect heated wax hose.
Inspect all wax fittings.
- Rebuild wax valve and replace all seals.
Machine Pneumatic System
Checks and Service
The following is checked for leakage, wear and function:
- Flex-Noz air cylinder.
- Pneumatic directional valves.
- Pneumatic filter/regulator.
- Pneumatic tubing, to be replaced as required.
- Pneumatic fittings, to be replaced as required.
—Machine Model Specific Components
- Mold release pressure tanks.
- Mold release nozzle assembly.
- Rebuild pneumatic actuators.
|
Machine Hydraulic System
Checks and Service
The following is checked for leaking, wear and function:
- Clamp cylinder.
- Injection cylinder.
- Hydraulic manifold.
- Hydraulic pump.
- Hydraulic hoses and fittings.
- Hydraulic pressure gauges.
—Optional Components -
- Shuttle table hydraulic cylinder.
- Safety guard hydraulic cylinder.
- Knock out cylinder.
- Auto die clamp cylinders.
- Additional hydraulic manifolds
- Check hydraulic system pressure and adjust if required.
- Change oil filter.
- Inspect hydraulic oil and change if required (Customer to supply hydraulic oil and
waste oil tank).
Miscellaneous Checks and Service
Lubricate:
- Platen guide rod bushings.
- Nozzle positioner guide rods .
- Inspect water strainer. Replace as required.
- Check all heating and cooling zones for correct operation.
- Check all temperature controllers for drift from set point
- Check all pilot lights and push buttons.
- Replace bulbs as required.
—Machine Model Specific Components
- Inspect mold release spray nozzle assembly.
- Clean or rebuild as required.
- Inspect mold release strainer. Clean or replace as required.
- Replace air vent filter.
—Machine Optional Components
- Check and adjust as needed, wax level control proximity switch.
- Check and lubricate die hoist assembly.
- Check all special safety guarding.
|
|
