Progressive provided Accumulator Head removal, rebuild and replacement of damaged Hydraulic Valves and Electrical Components on the Accumulator Head assemblies to the customer.  The following details both Accumulator Head rebuilds and associated required rework.

Accumulator Head Disassembly / Removal from Machine / Shipping to Progressive

Disconnect wiring for Accumulator Head heaters.

• Disconnect wiring for Accumulator Head thermocouples.
• Disconnect cables to Accumulator Head linear transducers, LVDTs and Accumulator Head junction boxes.
• Run temporary wiring for heating tooling area of Accumulator Heads for removal of Accumulator Head tooling (Accumulator Head tooling to remain with Customer).
• Remove Accumulator Head tooling.
• Remove Accumulator Head Program Rod Coupling.
• Disassemble and remove the Hot Melt Pipe (Adapter) feeding both Accumulator Heads. 
• Inspect Extruder Barrel Zone 5 aluminum heater coolant flow and resistance of the heater elements for damage.  Report findings to customer.
• Prepare Accumulator Heads for removal.

 Accumulator Head Rebuilds

• Disassemble mechanical Accumulator Head components.
• Clean mechanical Accumulator Head components.
• Inspect mechanical Accumulator Head components.
• Report any indication of damaged internal Accumulator Head mechanical components to Customer.
• Remove Tooling and Pushout Hydraulic Cylinders
• Disassemble Tooling and Pushout Hydraulic Cylinders.
• Inspect Tooling and Pushout Hydraulic Cylinders.
• Replace the seals for Tooling and Pushout Hydraulic Cylinders.
• Report any indication of damaged internal Tooling or Pushout Hydraulic Cylinder mechanical components to Customer. 
• Remove Top Blow Pneumatic Cylinders
• Disassemble Top Blow Pneumatic Cylinders.
• Inspect Top Blow Pneumatic Cylinders.
• Replace the seals for Top Blow Pneumatic Cylinders.
• Report any indication of damaged Top Blow Pneumatic Cylinder mechanical components to Customer. 
• Remove and replace Accumulator Head Hydraulic hoses with new hoses and fittings.
• Remove and replace the three (3) Hydraulic valves, connectors and wiring on both Accumulator Head Hydraulic manifolds.
• Remove and replace the Hycon Hydraulic pressure transducer and connector with cable on each Accumulator Head Hydraulic manifold.
• Replace Accumulator Head Mica Band heaters, high temperature wiring and plugs.
• Replace Accumulator Head thermocouples, thermocouple extension wiring and plugs.
• Replace Hot Melt Pipe (Adapter) heaters, high temperature wiring and plug.
• Replace Hot Melt Pipe (Adapter) thermocouple, thermocouple extension wiring and plug.
• Replace Accumulator Head position transducers, connectors and wiring.
• Replace Accumulator Head Tooling LVDT transducers, connectors and wiring.
• Replace Right Accumulator Head junction box, terminals, receptacle and wiring.
• Inspect Left Head Electrical junction box, terminals, receptacle and wiring.  Replace if necessary.
• Inspect conduit, plugs and wiring to Accumulator Head Electrical junction boxes.  Replace if necessary.
• Replace Accumulator Head Overfill and Accumulator Head Empty rocker arm limit switches and wiring.
• Inspect Accumulator Head Hydraulic manifolds for damage.  Report findings to customer.
• Hydraulic hard piping will be cleaned and painted with high temperature flat black paint. 
• Hand rail guards around the Accumulator Heads, which have been damaged by the fire, will be cleaned and painted safety yellow.

 Return of Accumulator Heads / Installation / Run-off

• Prepare Accumulator Heads for return to Customer.
• Ship Accumulator Heads to Customer’s facility.
• Unload Accumulator Heads at Customer’s facility.
• Install Accumulator Heads on above described Customer’s machine.
• Install Hot Melt Pipe (Adapter) to machine Extruder and Accumulator Heads.
• Connect necessary Hydraulic hoses to Accumulator Head manifolds.
• Connect Accumulator Head Electrical junction boxes to machine plugs.
• Connect Accumulator Head and Hot Melt Pipe (Adapter) heater wiring to machine.
• Replace Extruder Rupture Disk monitor rocker arm limit switch, wiring and mounting for the rocker arm limit switch.
• Inspect and replace (as necessary) the water cooling fittings and hoses on the last Extruder Barrel zone (Zone 5).
• Inspect and replace (as necessary) Extruder Melt Pressure transducer, connector and wiring.
• Run-off of machine (confirmation of proper operation).

Customer reply to below survey: I would have to give you ALL 5’s for an overall score of 5 and a yes to both of the last 2 questions.

Additional Customer Comments:

Emailed Survey:

In an attempt to continually self improve, Progressive Controls & Automation LLC has composed the following survey.  Please take a couple of minutes and reply to the below 10 questions in red (or some other text color that will stand out) and return the results.

The following survey is in regards to the recent service performed at your facility.

Please fill out this questionnaire honestly.  The goal of this questionnaire is to improve the service provided to customers to insure complete satisfaction.

Thank you, in advance, for your time.

1.  Please rate, on a scale of 1 to 5, the response to your initial request for service.

(1 = needs improvement; 5 = above typical expectations).

2.  Please rate, on a scale of 1 to 5, the timeliness of arriving at your facility.

(1 = needs improvement; 5 = above typical expectations).

3.  Please rate, on a scale of 1 to 5, the strategy presented to overcome your issues.

(1 = needs improvement; 5 = above typical expectations).

4.  Please rate, on a scale of 1 to 5, the quality of the actual work that was performed.

(1 = needs improvement; 5 = above typical expectations).

5.  Please rate, on a scale of 1 to 5, the work ethic of the service personnel.

(1 = needs improvement; 5 = above typical expectations).

6.  Please rate, on a scale of 1 to 5, the communication between yourself and the service personnel.

(1 = needs improvement; 5 = above typical expectations).

7.  Please rate, on a scale of 1 to 5, the end result of the work that was performed by the service personnel.

(1 = needs improvement; 5 = above typical expectations).

8.  Please rate, on a scale of 1 to 5, the professionalism of the service personnel.

(1 = needs improvement; 5 = above typical expectations).

9.  Would you hire Progressive Controls & Automation LLC again in the future?

10.  Would you recommend Progressive Controls & Automation LLC to others?

This new platform development initiative consisted of the following:

Training Bekum personnel on use of software.

Software training included demonstrating the RLD & screen editor functions, explaining the differences in addressing between the MACO 6500 and the MACO Compact, converting screens & RLD from MACO 6500 (MACO Alpha series) to the MACO Compact, reviewing the functional differences and enhancements of the MACO Compact.

Loading software  and configuring Bekum engineering computer.

To operate MACO Compact software, Bekum Brazil’s engineering computer required updates.  Progressive sought out these updates and confirmed all necessary software components.  Testing of software communications with Bekum’s development system was done to insure proper operations.

Reporting to & interfacing with Eurotherm/Barber-Colman development Engineers.

The MACO Compact development system in Bekum Brazil’s engineering department required firmware updates.  Progressive also created standard Eurotherm/Barber-Colman MACO Compact system screen sets for multiple rack/processor system configurations. 

“…<Progressive Controls & Automation LLC> help in making this venture successful is greatly appreciated.” – David K. Spahr,  Director of Engineering and Quality, Eurotherm/Barber-Colman

Application developments.

Assisted Bekum Brazil Engineers with user screen software development.  Created side menu images.  Configured .csv file button location functions.  Networked laptop computer to communicate to the MACO Compact for real time on-line RLD viewing.  Authored several detailed data sheets reflecting step by step direction of various procedures.

Final Results

Bekum Brazil indicated that the MACO Compact was a great improvement over the MACO 6500.  Bekum personnel seemed pleased with the Compact’s fast scan rate (sub-millisecond) which resulted in actual clamp accuracy that was consistently accurate to the exact millimeter.  Bekum Brazil personnel expressed that they were greatly pleased with Progressive Controls & Automation LLC help and influence.

“… Again, thank you for <Progressive Controls & Automation LLC> hard work and efforts!” -  ”…everyone that I have talked to feels that <Progressive Controls & Automation LLC> is doing great work.” - Paul Baker,  Applications Engineer, Eurotherm/Barber-Colman

Eurotherm & Barber-Colman are trademarks of Invensys PLC.

MACO is a trademark of Eurotherm.

Improve your quality by recording real time process data.

The Progressive Controls & Automation LLC  Data Logger allows customers to link multiple production lines or machine cells to a host computer for process data archiving.  Data can be recorded and stored in date & time stamped record files (csv, tab delimited, etc.)periodically (by batch or product run) or data can be streamed based on a time interval (from 1 minute up to 1 month).  Each process variable is made available for archiving.  SPC/SQC data is determined and processed for industry standard calculations such as X-Bar, X-Bar-Bar, Range & Cpk (additional custom calculations can also be easily generated).  This data is automatically stored for access by several commercially available database software (SQL, Oracle, Microsoft Access, etc.).  

Reasons for collecting such process data include:

• Inventory Control
• Automatic ISO compliance record keeping
• Information of actual readings are recorded automatically (not relying on individuals to record sensitive data)
• Batch / Product run data backup for quality assurance
• Track and identify production line / machine cell downtime
• Allows management a quick overview of what is taking place on the production floor
• Can be expanded to serve as or be easily integrated into existing MES (Manufacturing Execution System)

Progressive Controls & Automation LLC can use a number of tools to capture and analyze the statistical data from your process equipment. We have experience storing data in Microsoft Access and Excel as well as SQL Server.  Analytical reports and graphs can be produced with Microsoft Access or Excel, SQL Server Reporting Services, Crystal Reports or a tool of your choice. 

A safe work environment is a prosperous one.

Employees are the most valuable asset that a company can have.  Being ANSI & OSHA compliant is not only the smart approach to alleviate any OSHA or legal issues, it is simply the right thing to do.  Call Progressive Controls & Automation LLC today to discuss how to make sure your compnay is within compliance.

Progressive personnel has audited and helped mitigate safety compliance concerns for companies large (GM Powertrain) & small. 

The following describes the features of Progressive’s ANSI mitigation package for Accumulator Head Blow Molding machinery.

Preconfigured with quick disconnects. This ANSI compliant retrofit kit fits easily on any machine.  Designed specifically for the Sterling model line, this kit can be adapted to most other blow mold machinery manufacturers. Call or email today for a quote on this turn-key solution.

ANSI/SPI B151.15-2003 compliance kit specifications:

• All enclosed in NEMA 12 enclosure.
• 1 E-Stop monitor, 2 E-Stop relays, up to 4 E-Stop Dual Contact
• Mushroom head Push/Pull and Maintained.
• Up to 4 Dual contact magnetic switches with mounting brackets for safety gate, 2 Safety Gate monitor, 4 Safety gate relays.
• Hydraulic full flow blocking of clamp oil supply with monitoring.
• Air blocking valve with valve monitoring when gate is open, Gate open and close valve (Customer must install 1.5″ Ross air valve with manual override and lock out and new gate open close valve).
• Gate edge bumpers with bumper monitor.
• Up to 2 solid state blow air monitors (rated at 50,000,000 cycles) for blocking mold opening to ensure exhaust prior to mold opening in auto cycle.
• DC power supply and installation.

1. Please rate, on a scale of 1 to 5, the response to your initial request for service.

Upon <contact>, you contacted me via phone to assess the situation immediately. 5

2. Please rate, on a scale of 1 to 5, the timeliness of arriving at your facility.

On time arrival on Monday and both mornings. 5

3.Please rate, on a scale of 1 to 5, the strategy presented to overcome your issues.

Strategy was great. Looked over issues and prints, quickly came up with the input/output addresses for wiring. Had the programming done very quickly. All in all the strategy implemented worked out perfectly. 5

4. Please rate, on a scale of 1 to 5, the quality of the actual work that was performed.

Quality was not an issue. Performed work to expectations and programming passed all tests. 5

5. Please rate, on a scale of 1 to 5, the work ethic of the service personnel.

Work ethic was great. Very calm, cool demeanor even when problems arose. Worked faster than us. Sorry for the delays on our end! 5

6. Please rate, on a scale of 1 to 5, the communication between yourself and the service personnel.

The communication from your end was great. From the first phone call to the follow up email this morning. I thought that the communication was good. 5

7.Please rate, on a scale of 1 to 5, the end result of the work that was performed by the service personnel.

Very satisfied with the end result of work. Meets expectations.

8. Please rate, on a scale of 1 to 5, the professionalism of the service personnel.

Very professional. 5

9.Would you hire Progressive Controls & Automation LLC again in the future?

I would hire Progressive again. I do plan to utilize your services in the future. 5

10. Would you recommend Progressive Controls & Automation LLC to others?

Absolutley 5

Additional Comments:

Me and John both enjoyed working with you. Obviously you know the Maco controls very well. <company withheld> will plan to use your companies services in the future whether it is for programming changes, trouble shooting or board repair. Again it was great to meet you and I thought you did a great job for us. I really have no complaints.

Thanks again!!!!