JOB 2: FRS TP conveyor testing Flashcards
What is the primary function of the Finish Roll Store (FRS)?
Storage area for finished rolls prepared to be shipped out to customers
Why was the FRS system taken out of service in 2014?
Operation errors/lack of communication between shipping and wrapping line
What is the main goal of reinstating the FRS system?
to reduce the loading times of the shipping department
What specific tests need to be performed on the FRS tunnel balcony TP conveyors?
Functionality testing: making sure the conveyor moves in both directions without faults.
I/O: converyors stop when the role is in the correct position. this will also confirm the health of the sensor
Visual inspections: any visible signs of damage etc.
How is the functionality of the TP conveyors verified during testing?
Visual: checked for any obvious signs of damage.
watched to see if the conveyor functioned as required
I/O: we are able to visually see the input come into the I/O rack and it perform the required function
What is the purpose of the IO testing for the TP conveyors?
prove the functionality of the sensors and conveyor
How are the reflective sensors tested to ensure proper operation?
Visual: checked for no obvious signs of damage
Why is a physical inspection of sensors and reflectors necessary?
if they didn’t notice the roll it would drive itself off the end of the conveyor and off the balcony. Health and safety concern
if they were damaged it would interlock the system preventing it from working as the sensor inputs form and blocks and triggers within the automation process.
What happens if issues are identified during the testing process?
appropriate measures are taken to rectify the issue, often following the 6 point fault finding procedure
How does reinstating the FRS system contribute to reducing shipping times?
currently rolls destined for the same lorry are located in different storage bays. relocation will allow them to be moved between bays so they are stored locally to one another reducing the time spend driving between bays
rolls will be relocated overnight to outfeed conveyors for first shipments of the next day
How does the Door and Laser system contribute to workplace safety?
provides a physical barrier between personnel and the moving machinery by preventing access through the door until it is safe to do so.
The light gates when triggered cause an emergency stop causing the crane to interlock and stop. this prevents any continued roll or conveyor movements. You can pass through the light gate when the crane is parked up.
Which specific SSOW and OPL guidelines were followed during the described job?
carried out isolations in accordance to the working in the electrical maintenance department and wrapping line door entry.
No testing was done live in accordance to the working in the electrical department
What specific health and safety training was completed before carrying out conveyor testing and inverter changes?
Manual handling, Health and safety induction training, isolation procedures
documentation was attached to the work order which was read before commencing with the work, this included isolations and safe entry
What PPE was required for the described job, and why was each item necessary?
Hearing protection - to reduce exposure to loud noise, hearing protection is required in this area
Safety glasses - site policy, this area has swarf and metal filings everywhere so this will protect the eyes
Work clothes - steel toe caps, protective work trousers and appropriate t -shirt.
Gloves - protect from sharps
Which key legislation and regulations were followed during the work process?
Health and Safety at Work 1974- paperwork, risk assessments, PTA, Work plan, followed written safety guidance.
PPe- worn
PUWER - All test equipment was inspected to GS38
Manual handling - lifted and moved the inverter in accordance to the manual handling training I received.
