That's my latest self description as the life of a relief foreman. This update concluded that I continue to improve myself technically but that did not excuse the fact that I am the FOOL. In the latest rotation, I committed costly mistakes during duties, and I excelled in wrecking the machine. Last night, I had my first HAMMERED night and we lost 6 hours of production and have made cull tonnage of 65 since start up. The upside from that, no one gets hurt when we tried to put the sheet on the reel and I finally stopped my good streak of great runs, and start learning from my shortcomings. After all, I am not special. I wanted to stress that the crews were supportive and were at their best to make things work, however, when you are the GREEN foreman with a green crew. It's impossible not to feel that you were set up to dance with the tigers in the cage. AL said "They can't expect you to know how to fix things when you never seen it before." Thanks Al, Mark, Vanessa and Cindy, but I am still bummed.
The inserts summarized some of my mistakes in recent tours.
This was from last night comment 8/17:
#2 PM went down last night when a power bump took out a fuse for the primary BB drive fan. This is a small fan that cools the drive itself in the MCC not the drive motor. The fan went down, the drive heated up and shut down when it got to the high temperature interlock. There are no alarms or indications for this system or any of the other drives. With the PBB went the rest of the wet end.
The biggest problem from last night was the lack of flushouts. When the machine went down, there were no flushouts performed on the stock lines or the headboxes. We got VERY lucky that the headboxes did not plug up but it caught up with us on the bottom ply. The entire line from the MC pump to the consistency transmitter/meter in the basement above the filler screen was plugged like a brick. The line had to be opened in several different spots, the refiner had to be opened, and it all had to be flushed out multiple times. It took approximately 6 hours worth of work to get the line unplugged. During the work, the machine was transitioned to 33# and a duplex sheet.
It cannot be stressed enough just how important and fundamental line flushing is during any shutdown but particularly crashes. Even if you have to overflow tanks or stuffboxes or blow headboxes out on the floor, you need to do it. Make sure that you do it safely and take precautions to ensure that (like spotters or caution tape, etc) but it has to be done.
And the night before last, 8/16:
The machine was shut down this morning to replace the ENP blanket. The blanket was found to be delaminated about 6-12" in from the back edge. The area of delamination was very large and we were extremely lucky that it did not come apart on the fly. A spot on the reel was discovered last night and was traced back to the spot on the blanket but the seriousness of the situation was not recognized. It is very important to understand that if there is a problem discovered with the blanket (abnormal spots anywhere, oil/water spraying in a fixed spot, etc), its critical that you shut down in an orderly fashion and inspect the area. Particularly if there is a spot on the reel - that usually means that something "different" is going on in the nip and if its tied at all to the blanket, its not a good situation. Those situations are your opportunity to avert a press wreck and eliminate a lot of downtime. Even if it turns out to be a non issue after shutting down at least you've looked and ruled out the possibility.
The previous tour note, 7/28-7/31:
GRAVEYARD SHIFT
The draw in the machine was reduced some more this morning. The wire to press draw was reduced by about 10 fpm and this has the machine back to around 72 fpm of total draw. Try to keep it there. The draw was increased again on graveyard tonight and was too high. Anything over about 78 fpm is probably too much.
Dayshift was doing a very good job of keeping the waste left on the reel spool to a minimum. Make sure that we are always working together between the reel and winder to minimize how much we throw away. This really adds up to a lot of paper at the end of the month.
The screen rejects were found going to the couch pit today. Make sure these are going to the screening system whenever possible.
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