Instructor‐Led Preventative Maintenance & Operation Training

We provide instructor‐led training on‐site at your location or at our Batavia, OH headquarters. This type of hands‐on instruction makes a great course, pulling in the knowledge gained and combining it with real world training on your own machinery.

2023 Maintenance & Operation Training Schedule

Cost

The cost for each 3‐day session at our Batavia, OH plant is $1,500 per student (*add $185 for Level 1 and Level 2 Industrial Hydraulic Courses). Custom on‐site classes are also available.

Course Descriptions
All courses include classroom instruction and hands‐on exercises/shop floor instruction.

Standard Maintenance & Operation

Standard maintenance and operation seminars are designed to teach machine maintenance and operation along with techniques for efficient troubleshooting and repairing machine problems. Sessions include a complete review of control screens, diagnostics and machine print review and analysis.

Course Outline

• General machine overview
• Machine sequence and operation
• Operator and machine safeties
• Troubleshooting practices
• General and preventative maintenance
• Electrical prints analysis
• Control operation, screens and diagnostics
• Hydraulic circuit analysis (as applicable)

Advanced Maintenance & Operation

Advanced maintenance and operation seminars are designed to increase repair & troubleshooting knowledge gained from previously attending a standard maintenance and operation course. Sessions include machine setup include machine setup procedures and a comprehensive review of control screens, diagnostics and machine prints.

Course Outline

• Auto Tune Barrel Heats
• Injection Velocities
• Pump/Motor Priming
• Injection Pressure Set‐Up
• Pump Error Signals
• Accumulator Set‐Up
• Position Device Set‐Up
• Servo Pump Flow Calibration
• Clamp/Pancake Field Calibrations
• Servo Pump Pressure Calibration

Level 1 Industrial Hydraulics

This first (of two levels) course correlates fluid power principles with machine operation and daily maintenance duties. Safety and basic fluid power principles first set a foundation. The construction, operation, and specific use of individual hydraulic components (pumps, directional control valves, relief valves, reducing valves) then become the focus of the class. Fluid power symbols will be compared to the physical components. Location of components in the hydraulic system and proper adjustment procedures will be identified. The course will also discuss elimination of leaks by proper fitting selection and installation. In addition, the significance of fluid cleanliness to system longevity and techniques to minimize ingestion of contaminants will be presented.

Level 2 Industrial Hydraulics

This component and control level course will dive further into the operation and troubleshooting of hydraulic components typically found on injection molding machines, along with the operation of the lubrication unit of the machine. Trainees will be given hydraulic schematics for an injection molding machine and will be asked to trace out circuits on their schematics and explain the operation of all components. Pressure compensator pumps and cartridge valves are additional components covered in this level 2 course.

The student will also learn the complete function of the injection molding machine lube units found on the Powerline, Roboshot, and other product lines at Milacron. They will be taught the proper way to troubleshoot, repair and look for problems on their equipment. As with the hydraulic topics, by taking the hands‐on approach and working on Milacron’s shop floor, the student will have a better understanding how a proper lube unit works.

Predictive and Preventive Maintenance

This three‐day course is intended for maintenance supervisors, production supervisors, and others involved with scheduling maintenance and operation time of Milacron Injection Molding Machines. The objective of the course is to provide information to reduce unscheduled downtime due to machine failure. The course will review preventative maintenance schedules and offer methods to implement predictive maintenance procedures.

Course Outline
Predictive vs. Preventive Maintenance

• Predictive Maintenance Technologies Overview
  • Vibration analysis, oil analysis, thermography, ultrasound, wear‐particle analysis
• Preventative Maintenance Review
  • Hydraulic fluid, cooling water, cabinet air filters
  • Toggle links and clamp locks, screw drives, slides and skates
  • Machine leveling, die platen parallelism
• Identifying Root Causes of Wear and Failures
  • Hydraulic fluid leakage
  • Excessive hydraulic system heat
  • Hydraulic cylinder rod scoring
  • Excessive control cabinet heat
  • Excessive strain rod bushing wear
  • Excessive extruder bushing wear
  • Excessive drive belt wear
  • Gearbox seal leakage
  • Barrel heater failures

Clamp, Injection, and Ejection Units, Including Sensors and Switches

• Scheduled maintenance review
• Developing trends for predictive maintenance analysis
  • Measuring trends of physical parameters against engineering limits
• Normal wear points
• Identifying excessive wear conditions

Using the Control System to Develop Trends

• Correlating production levels to machine condition
• Developing predictive maintenance from past history
  • Using breakdown/failure records
  • Evaluating spare parts inventory
  • Tracking with maintenance reports

Improving Production Uptime with Scheduled Shutdowns

• Scheduled shutdown vs. “run to breakdown”
• Equipment repair, rebuild, or upgrade

For more information on any of the training described above or to schedule training, please contact Jeff DePuy, Technical Training Specialist.

T +1.800.288.8306 | [email protected]