Servicing, Training and Feedback - JHB Trip Task Manager

Servicing, Training and Feedback

JHB Trip · Task Manager

Supreme Poultry · 3-12 August.

L1

Running

New bellows fitted, roll shaft levelled. Software + telemetry still to come.

L2

Update in progress

Runnable. Recipe selection works; the rest of the update is being coded off site. Roll axle is missing.

L3 · GEA

Running

Spilling + panel resets both fixed. At 40 Hz. Needs the software only.

The four duties - how close each is to fulfilled

Claude's estimate, weighted by remaining effort. Moves live as tasks are pushed, parked or dropped.

Task list - Top Priority (P1) first*

*not associated with F1

Summary

Filters

Key

Push = choose: P1, or top priority of its duty Park = sets it aside for another day Drop = removes it for good
= Mechanical issues = Software updates = Telemetry = Training/Feedback

Parked - for another day

Software update plan - per line

✓Latest software pulled from each line's HMI and PLC, and backed up.

▸Now: coding the new changes into each line's software, off site.

○Tuesday morning: upload each to its line, then test and troubleshoot.

L2First

The development line - everything is built and proven here

  1. Recipe slots to production values - first, since L2 may be run
  2. Build offline: the drying intelligence, "Water drain from filter", the Production-screen status, and the maintenance switch
  3. Simulate every function before it goes near the machine
  4. Download, then dry runs (pump off) - verify every step, input and output
  5. Live proving run; first cycles at dry time 1000 s so a blocked chamber can't spill
•After this, L2's software is the master copy for L3 and L1. Diagnose the Empty Fryer / Fryer Drain fault alongside.
L3Second

The priority line - software only, one short stop

  1. Read L3's live drying values first - it already runs half the drying control, so its numbers seed the build
  2. Seed the recipe with the tuned pump speed (from duty #1), right first time
  3. ~45-min stop: download screen + PLC, restart
  4. Watch one full cycle, and confirm its monitoring signals
•Filter runs parallel to production, so the stop interrupts nothing. No mechanical work on L3.
L1Third

Gets the proven master copy, last

  1. Download the proven copy - already run on L2 and L3, so nothing lands on L1 untested
  2. Seed L1's recipe with its own values - it runs at 50 Hz, so its pump speed stays its own
  3. Dry-cycle check on the older hardware, then release to production
  4. Confirm its monitoring signals arrive over the new wiring
  5. Done with L1's mechanical items - the belt re-thread, and the chamber transmitter if it's arrived
•Oldest design - anything the old hardware disagrees with surfaces here, after the software is proven on the other two.

For the new SOP / Maintenance report to Supreme

The missing L2 filter roll axle

No axle, no roll can be mounted - so L2 can't run a roll however ready the software is. Where did it go, and is there a spare on site or does one come from Cape Town?

Air supply to the filters - 6 bar at the machine

Filters need 6 bar at the machine, and the air dips on start-up. Watch the incoming gauge during a cycle: if it sags there, the plant supply is short. Low air = bellows problems = filter faults.

The updated SOP - to follow after the visit

Everything learned this trip goes to our administrator in Cape Town as the feedback package; the updated SOP is sent through to the plant from there.

L1's missing roll-shaft spacer - drawing to follow from Cape Town

L1 runs a spacer short today; without both, the shaft pulls the roll skew. Sydney does not know where the missing one is, so a drawing follows from Cape Town for the workshop to make spares.

Alternative Dad saw at Finlar: pull the pipe off over the shaft and fit a stopper instead - works well. Ask if the plant has that stopper type.

The pipe at Fryer 1's outlet

Bashed in and choking flow to the filter. We suggest a long reducer with an elbow; quotation to follow.

L3 pipe fittings pop when oil spills

The under-machine pipes sit under pressure and pop when spilled oil lands on them - a symptom of the spilling, not weak fittings. L3 has no catch sump (newer machines do), so oil falls straight onto the pipes; 8 Aug the bellow-vent and chamber-supply both went, one at an old braze. Fix #1 is the drying software (stops the spilling). As protection, route the vulnerable pipes inside ~20 mm stainless steel pipe; longer term, a catch sump removes the root cause.

L3 walk-down defects

Top alarm to replace; door lock / sensor gap to close; and the belt-exit sensor is dead while the system does not flag it - a real gap, a sensor failing silent. (Being investigated on site for a diagnosis.)

Done this trip

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