Mujin Support Operators Certification

Program Materials

Welcome to the Mujin System Training Course!

This session is designed to give operators and maintenance personnel a solid understanding of the Mujin system, its components, and how to operate, maintain, and troubleshoot key equipment safely and efficiently.

Introductions

 Meet the Trainers and Trainees:

 Take a moment to introduce yourself, meet the instructors, and connect with fellow participants. This session is designed to be interactive, so feel free to ask questions and share your experiences.

 Course Outline:

 The training will cover essential modules, including an introduction to the system, key components, safety protocols, maintenance schedules, troubleshooting techniques, and role-specific responsibilities.

System Overview

Purpose

To introduce the Mujin automation system's primary components, explaining their roles, interconnectivity, and operational principles. This knowledge will provide operators with a comprehensive understanding of the system, enabling safe and efficient operation.

System Layout

(Insert detailed diagram here)
 "Figure 1: System Layout for Mujin Automation System"

The Mujin system integrates advanced robotics and software to streamline material handling tasks. Its modular design enables seamless collaboration between components, ensuring high throughput, accuracy, and flexibility.

Key Components

Robot Arm (CP500L)

Description: A 4-axis articulated robot designed for precision palletizing tasks. The CP500L handles payloads up to 500 kg, with repeatability of ±0.5 mm, ensuring accurate and efficient material handling.

Operator Responsibilities:

• Inspect the robot arm for physical damage or misalignment before operation.
• Monitor movement and task progress via the HMI during active operations.

Specifications:

• Maximum Payload: 500 kg.
• Reach: 3255 mm.
• Built-In Utilities: Pneumatic valve harnesses for EOAT control.

Functionality:

1. Executes tasks like pick-and-place and stacking, adapting dynamically to irregular loads using integrated vision sensors.

Mujin Controller

Description: The central control system that orchestrates the operation of all connected components, including robotic arms, AMRs, and peripheral devices.

Key Features:

• Provides real-time diagnostics and task scheduling through the HMI.
• Manages safety interlocks and emergency protocols.

Operator Tasks:

• Use the HMI to monitor system performance and respond to alarms promptly.
• Ensure stable power to the controller to avoid disruptions.

Autonomous Mobile Robot (AMR) M150

Description: A mobile robot for autonomous pallet transportation, equipped with LiDAR and QR code navigation systems.

Key Features:

• Collision Prevention: Built-in safety sensors detect and avoid obstacles.
• Flexibility: Can be manually overridden using the HMI for troubleshooting or route corrections.

Operator Tasks:

• Inspect AMR sensors for cleanliness and proper function daily.
• Recharge batteries and check connections at docking stations weekly.

Inbound-Outbound Buffer (IBOB)[AK1] 

Description: A pallet staging area that ensures smooth transitions of pallets between processes.

Key Features:

• Aligns and feeds pallets into the stacker or AMR zones.
• Uses photo eyes to detect pallet placement and position.

Operator Tasks:

• Clean photo eyes and verify sensor alignment weekly.
• Realign misaligned pallets to prevent jams.

End-of-Arm Tool (EOAT)

Description: The attachment on the CP500L robot that performs gripping and manipulation tasks. The EOAT uses suction mechanisms for secure object handling.

Key Features:

• Includes integrated air blowers to prevent blockages.
• Modular design allows for task-specific configurations.

Operator Tasks:

• Check suction ports for obstructions daily.
• Replace worn or damaged components as part of routine maintenance

Vision System

Description: A combination of LiDAR and cameras used for object detection and alignment.

Key Features:

• Ensures precise positioning during palletizing and wrapping.
• Dynamically adjusts robotic paths based on live feedback.

Operator Tasks:

• Clean lenses weekly to maintain accuracy.
• Report calibration or alignment issues promptly.

Stretch Wrapper (WRTA200)[AK2] 

Description: Automates the process of securing palletized loads with pre-stretched film for transport stability.

Key Features:

• Adjustable tension settings via the HMI for different load types.
• Integrated error detection for film jams or misfeeds.

Operator Tasks:

• Load and thread film rolls correctly.
• Monitor wrapping progress for tears or uneven tension.

Pallet Labeler (FoxIV)

Description: Automatically prints and applies labels to palletized loads for tracking and identification.

Key Features:

• High-speed print capabilities with integrated diagnostics for error detection.

Operator Tasks:

• Align label rolls and clean printheads daily.
• Test and verify label adhesion before production runs.

Human-Machine Interface (HMI)

Description: The central dashboard for operators to control and monitor the Mujin system.

Key Features:

• Displays real-time status, alarms, and diagnostics.
• Enables manual overrides and task adjustments.

Operator Tasks:

• Familiarize yourself with navigation menus for quick troubleshooting.
• Use the “System Check” feature to ensure all components are operational before starting tasks.

Safety Brief[AK3] 

Purpose

Safety is paramount when operating and maintaining the Mujin system. This module provides operators with the tools and knowledge to minimize risks and maintain a secure work environment, focusing on essential safety protocols and procedures.

Safety Guidelines

Lockout/Tagout (LOTO)

Definition: A safety procedure used to ensure that dangerous machines are properly shut off and not restarted until maintenance or servicing is complete.

Steps:

1. Identify all energy sources connected to the equipment (e.g., electrical, pneumatic, hydraulic).
2. Shut down the system using the main power switch.
3. Attach LOTO devices to isolate energy sources:
   • Electrical: Apply lockout devices to circuit breakers or switches.
   • Pneumatic: Close valves and release residual pressure.
4. Tag the devices with information about the procedure and the responsible operator.
5. Verify that the system is de-energized by attempting a controlled startup and observing no activity.

Operator Focus:

• Always carry the LOTO keys during the procedure.
• Communicate with team members before and after LOTO application.

Stored Energy Hazards

What to Watch For:

• Electrical charges in capacitors.
• Compressed air in pneumatic lines.
• Mechanical tension in springs or moving parts.

Mitigation Steps:

• Discharge electrical components using insulated tools.
• Manually vent compressed air systems to release pressure.
• Relieve tension in mechanical systems before servicing.

PPE Requirements:

• Always wear insulated gloves, goggles, and hearing protection when working near stored energy systems.

Robot Cells & AMR Pathways

Robot Cells:

• Never enter an active robot cell unless the system is in a safe state:
  • Engage all E-stops before entering.
  • Verify system inactivity via the HMI.
• Use gates with interlocks that stop robot operation when opened.

AMR Pathways:

• Keep pathways clear of obstructions and pallets.
• Use designated pedestrian areas to avoid collision risks.
• Notify team members before moving or stopping AMRs manually.

Personal Protective Equipment (PPE)

Standard PPE:

• Safety goggles: Protect against debris or film snapping.
• Gloves: Provide grip and protect hands during handling.
• Steel-toe shoes: Prevent injury from falling pallets or components.
• Hearing protection: Required in noisy areas, such as near stretch wrappers.

Task-Specific PPE:

• Insulated gloves for electrical panel tasks.
• Face shields for handling compressed air systems.

Emergency Procedures

Emergency Stops (E-Stops):

• Locations:
  • CP500L Robot Arm: Base-mounted and control panel E-stops.
  • Stretch Wrapper (WRTA200): Two accessible buttons near film carriage and control panel.
  • FoxIV Labeler: Integrated with the control touch screen.
• Function:
  • Immediately halts system operations when pressed.
• Operator Focus:
  • Familiarize yourself with E-stop locations during the pre-operation check.

Evacuation Protocols:

• Know the nearest exits and designated assembly points.
• Assist others if safe to do so; prioritize personal safety.

Training and Role Awareness

Only trained and authorized personnel may operate or maintain the Mujin system.

Training includes:

• Hands-on practice with LOTO procedures, diagnostics, and basic maintenance tasks.
• Refresher courses to stay updated on new safety features or equipment upgrades.

Operating Procedures

Purpose

This module provides step-by-step guidance for operators to safely and efficiently run the Mujin system. Adhering to these procedures ensures consistent performance, minimizes downtime, and enhances system safety.

Pre-Operation Checks

Before starting operations, verify the readiness of all system components:

Robot Arm (CP500L):

• Ensure the arm is in the home position and free of obstructions.
• Inspect the EOAT for secure attachment, cleanliness, and any visible wear or damage.

Stretch Wrapper (WRTA200):

• Confirm that the film roll is loaded properly and the film path is clear.
• Check tension settings on the HMI to match the load type.

Pallet Dispenser (IBOB):

• Verify that pallets are aligned correctly in the stack and free of jams.
• Clean photo eyes and sensors for accurate pallet detection.

Labeler (FoxIV):

• Ensure label rolls are loaded and aligned, with no tears or jams.
• Check the printhead for cleanliness and functionality.

AMR Pathways:

• Clear any obstructions from AMR navigation paths.
• Inspect AMR sensors and charging status using the HMI.

Safety Systems:

1. Verify all E-stops are functional and accessible.
2. Confirm interlocks on gates are operational.

Startup Procedure

To initialize the Mujin system:

Power On:

• Switch on the main power supply at the electrical panel.
• Confirm that indicator lights on the Mujin Controller and HMI are active.

System Initialization:

• Log into the HMI and select “System Start.”
• Perform a system diagnostic check via the HMI to verify component readiness.

Robot Arm Calibration:

• Use the HMI or pendant to home the robot arm.
• Jog the arm manually to test all axes for smooth operation and alignment.

AMR Readiness:

• Check the AMR status on the HMI and assign tasks or routes as necessary.

Standard Operation

During active operation:

Task Monitoring:

• Use the HMI to track task progress and system status.
• Respond promptly to any alarms or error notifications displayed on the HMI.

Material Handling:

• Load pallets into the IBOB zone as needed, ensuring proper alignment.
• Remove finished pallets from the wrapping or labeling zones to avoid congestion.

Stretch Wrapper (WRTA200):

• Monitor the wrapping cycle for smooth film application.
• Inspect wrapped pallets for proper tension and film coverage.

Pallet Labeler (FoxIV):

• Ensure labels are applied correctly and legibly.
• Adjust alignment or print settings via the HMI if errors occur.

Operator Safety:

• Stay clear of the robot arm’s range and active AMR pathways.
• Notify team members before manual interventions.

Shutdown Procedure

To safely power down the Mujin system:

Cease Operations:

• Use the HMI to stop all active tasks and return the robot arm to its home position.
• Allow wrapping and labeling cycles to complete.

Power Down:

• Turn off the main power supply at the electrical panel.
• Confirm that all indicator lights are off before leaving the area.

Post-Shutdown Inspection:

• Inspect components such as EOAT, sensors, and AMR batteries for wear or damage.
• Clean vision system lenses, EOAT suction ports, and labeler printheads.
• Report any observed issues to the maintenance team.

Operating the Mujin Warehouse Execution System (WES)

Overview

The Mujin Warehouse Execution System (WES) acts as a bridge between the Warehouse Management System (WMS) and physical operations on the warehouse floor, ensuring that every task is executed with precision. This section provides a step-by-step guide on how to operate the WES effectively, covering everything from logging in to managing alarms, monitoring devices, and overseeing the complete order lifecycle.

Step-by-Step Instructions for Using the WES

Mujin Web User Interface

• Interface Layout: Familiarize yourself with the Global Header, which displays system statuses, and the Global Navigation Bar, which allows navigation between different WES applications, such as alarms, device statuses, inventory, and metrics.
• User Management: Admins are responsible for managing groups, adding or removing users, and configuring application permissions. Only admin users can access the user control settings.

Logging In and Out

• Logging In: Enter credentials on the login screen to access the WES interface. Verify system readiness by checking the main dashboard.
• Logging Out: Safely log out by clicking your username and selecting the "Logout" option. Ensure that the logout is complete.

Alarms and Notifications

• Understanding the Alarm System: The alarm system is critical for safety and efficiency. Click the alarm icon to access details, including active and historical alarms. Use filters to identify specific issues.

Order Lifecycle Management

• Order Lifecycle Monitor Overview: Use the Daily Operation Overview to monitor activities, including order statuses and live performance metrics. Track delayed or critical orders to prioritize actions.
• Navigating the Order Information Page: View detailed information on orders, pallets built, and shipping statuses. Drill down to identify which pallets are delayed and take corrective action.

System Device Status

• Device Overview: Monitor the operational health of devices, including Safety Scanners, Robot Cells, Material Handling Equipment (MHE) Cells, and Inbound Outbound (IBOB) Stations.
• Robot Cells and MHE Cells: Monitor components such as robot arms and safety scanners through the digital twin feature, allowing visual interaction with devices.

Inventory Management

• SKU Overview: Track detailed information for each SKU, such as quantity, expiration dates, and replenishment status.
• Location Overview: Visualize inventory locations using the Mujin Digital Twin to monitor pallet status and identify items quickly.
• G. Metrics and Performance Monitoring
• Metrics Dashboard: Review KPIs in real-time to identify bottlenecks and optimize workflows. Metrics are displayed by area of the warehouse, including Robot Cells, GTP Cells, and AMR operations.

Operating at the Goods to Person (GTP)

Overview

The GTP system is an essential component of warehouse automation, enabling operators to perform tasks efficiently. This section provides detailed instructions on using the GTP to complete routine tasks, ensuring maximum productivity while maintaining safety.

Step-by-Step Instructions for Common GTP Tasks

Logging In and Out of GTP

• Logging In: Access the GTP UI via the HMI, enter your credentials, and ensure successful login by verifying your name displayed on the main menu.
• Logging Out: To safely log out, navigate to the settings tab and click "Logout." Ensure all ongoing tasks are paused or completed before logging out.

Connecting the Wrist Scanner

• Selecting the GTP Application: Select "App Goods to Person" from the menu. Connect the wrist scanner by scanning the QR code at the top of the HMI screen.

Daily Operations

• Pallet Defoiling: Follow system instructions to go to the designated location, scan the frame barcode, and remove the pallet wrapping safely. Confirm task completion on the HMI.
• Manual Case Picking: Use the HMI to view 2D/3D images showing how to pick and arrange cases. Confirm the completion of each case placement using the wrist scanner.

Manual Wrapping and Labelling of Pallets

• Manual Pallet Wrapping: Wrap pallets using stretch film, ensuring consistent tension throughout. Confirm the task on the HMI.
• Manual Pallet Labelling: Print and apply labels to pallets, ensuring they are correctly affixed for visibility. Confirm task completion using the scanner or HMI.

Initiating New Tasks via GTP

• Summon Pallet: Select the appropriate method (SKU, Pallet ID, or Frame ID) to summon a pallet to the GTP area for inspection.
• Request Slip Sheet Bin: Choose a slip sheet bin from the list and request it to be emptied.

GTP Settings

• Modifying Settings: Adjust settings for the weight threshold and HMI utilization to match task requirements.

Safety Considerations

• Always wear appropriate PPE, including gloves, safety shoes, and high-visibility vests.
• Familiarize yourself with the location of E-stop buttons and safety procedures.
• Maintain a clean workspace to avoid obstructions and accidents.

Safety Brief

Purpose

Safety is paramount when operating and maintaining the Mujin system. This module provides operators with the tools and knowledge to minimize risks and maintain a secure work environment, focusing on essential safety protocols and procedures.

Safety Guidelines

• Lockout/Tagout (LOTO): Ensure that machines are shut off and energy sources are isolated before maintenance.
• Robot Cells & AMR Pathways: Never enter an active robot cell without engaging all E-stops and verifying system inactivity. Keep AMR pathways clear to prevent collisions.
• PPE Requirements: Always use the proper personal protective equipment (PPE) for the task at hand.

Operator Tips for Efficiency

Pre-Staging Materials:

• Ensure pallets, labels, and stretch film rolls are ready and properly aligned before starting operations.

Task Sequencing:

• Group similar tasks to minimize downtime between operations.

Using the HMI:

• Familiarize yourself with shortcut menus and diagnostic features for quick access during tasks.

Alarm Resolution:

• Prioritize alarms based on severity and follow recommended troubleshooting steps on the HMI.

Troubleshooting Overview

Purpose

This module equips operators with the tools and knowledge to identify, address, and escalate common system issues. By following these troubleshooting protocols, operators can minimize downtime and maintain system safety and efficiency.

Common Issues and Resolutions

Robot Arm (CP500L)

Symptom: Arm fails to move to the home position.

• Possible Cause: Misaligned sensors or obstructions in the robot’s range of motion.
• Resolution:
  1. Inspect the workspace for physical obstructions, such as loose materials or pallet overhangs.
  2. Use the HMI to recalibrate the arm’s position sensors.
  3. Restart the system and test arm movement.
  • Escalation: If recalibration fails, contact maintenance for advanced diagnostics.

Symptom: EOAT loses suction or fails to grip objects.

• Possible Cause: Clogged suction ports or disconnected pneumatic lines.
• Resolution:
  1. Clean suction ports using compressed air.
  2. Inspect pneumatic connections for leaks or disconnections.
  3. Test EOAT functionality via the HMI’s manual control mode.

Pallet Dispenser (IBOB)

Symptom: Pallets jam or fail to feed correctly.

• Possible Cause: Misaligned pallet stacks or a malfunctioning lifting arm.
• Resolution:
  1. Engage LOTO and manually clear the jam.
  2. Realign the pallet stack for proper sensor detection.
  3. Test the system using the HMI’s manual cycle option.
  • Escalation: If jams persist, check sensor alignment and contact maintenance if issues remain unresolved.

Symptom: Sensors fail to detect pallets.

• Possible Cause: Dust or debris on photo eyes.
• Resolution:
  1. Clean photo eyes with a microfiber cloth.
  2. Check and adjust sensor alignment if needed.

Stretch Wrapper (WRTA200)

Symptom: Film tears during wrapping.

• Possible Cause: Incorrect tension settings or damaged film roll.
• Resolution:
  1. Re-thread the film roll to ensure smooth feeding.
  2. Adjust tension settings on the HMI to match the load type.
  3. Inspect the rollers for damage and clean any debris.

Symptom: Wrapper stops mid-cycle.

• Possible Cause: Film misfeed or sensor error.
• Resolution:
  1. Clear the film path and reinitialize the wrapping cycle.
  2. Test sensor functionality via the HMI’s diagnostics.

Pallet Labeler (FoxIV)

Symptom: Labels are misaligned or fail to adhere.

• Possible Cause: Misaligned label rolls or dirty application surfaces.
• Resolution:
  1. Realign the label roll in the print path.
  2. Clean the printhead and the pallet surface to ensure proper adhesion.
  3. Test the labeler with a sample print before resuming operations.

Symptom: Printer displays error messages.

• Possible Cause: Jammed printhead or low label supply.
• Resolution:
  1. Clear the printhead of obstructions.
  2. Replace label rolls and reset the printer via the HMI.

AMR (Quicktron M150)

Symptom: AMR stops unexpectedly or fails to complete a route.

• Possible Cause: Navigation errors due to sensor misalignment or obstructions.
• Resolution:
  1. Inspect the AMR’s path for obstructions and clear them.
  2. Use the HMI to recalibrate the AMR’s LiDAR sensors.
  3. Test the navigation system with a short manual route.

Symptom: AMR does not respond to commands.

• Possible Cause: Low battery or communication fault with the Mujin Controller.
• Resolution:
  1. Check battery status on the HMI and recharge if necessary.
  2. Restart the AMR and verify connectivity with the Mujin Controller.

Alarm Management via HMI

The HMI is a critical tool for identifying and addressing system faults:

View Alarms:

• Navigate to the “Alarms” tab to review active or historical error messages.

Identify Causes:

• Use the alarm code and description to determine the fault’s cause.

Resolve Faults:

• Follow on-screen guidance or the troubleshooting steps provided in this module.

Clear Alarms:

• Once resolved, use the “Reset” function to clear the alarm and restart operations.

When to Escalate

Operators should escalate issues under the following conditions:

• Recurring Alarms: If a fault persists after attempting the provided resolutions.
• Physical Damage: Any visible damage to sensors, EOAT, or mechanical components.
• Critical Faults: Errors marked as critical on the HMI that affect system safety or performance.
• Unresponsive Equipment: If components do not respond to HMI commands despite troubleshooting.

Summary and Resources

Purpose

This module consolidates key learning points from the training program and provides essential resources for operators to reference during day-to-day tasks. These tools will empower operators to maintain system performance and resolve issues confidently.

Key Takeaways

System Overview

• The Mujin system integrates advanced robotics, AMRs, and peripheral equipment to optimize material handling processes.
• Key components include the CP500L robot arm, stretch wrapper, pallet labeler, and the Mujin Controller, all managed through the HMI.

Safety Guidelines

• Always adhere to Lockout/Tagout (LOTO) protocols before performing any maintenance.
• Use Personal Protective Equipment (PPE) appropriate for the task, such as gloves, goggles, and hearing protection.
• Familiarize yourself with the locations of emergency stops (E-stops) and follow proper evacuation protocols in emergencies.

Operating Procedures

• Perform pre-operation checks on all components to ensure readiness.
• Use the HMI to monitor task progress, resolve alarms, and manage equipment configurations.
• Follow systematic shutdown procedures to prepare the system for the next operational cycle.

Troubleshooting Basics

• Common issues like pallet jams, film tearing, or sensor misalignments can be resolved using the steps outlined in the troubleshooting module.
• For persistent or critical faults, escalate to maintenance promptly to avoid prolonged downtime.

Resources

Operator Manual

• A detailed reference covering:
  • Component descriptions and functionality.
  • Operating procedures.
  • Troubleshooting techniques for common alarms.

HMI Alarm Guide

• Available on the HMI under the “Help” menu, the alarm guide includes:
  • Descriptions of active and historical alarms.
  • Suggested resolutions for each fault code.
  • Severity levels to prioritize responses.

Maintenance Contact Information

• On-Site Maintenance Team: For immediate support with mechanical, electrical, or software issues.
• Mujin Technical Support Line: For advanced troubleshooting or system upgrades.

Preventive Maintenance Logs[AK4] 

• Maintain a checklist for operator-level maintenance tasks:
  • Daily: Sensor cleaning, EOAT inspections, and pallet alignment checks.
  • Weekly: E-stop testing, AMR battery status checks, and lubrication of moving parts.

Continuous Learning and Improvement

Stay Updated

• Operators should attend periodic refresher courses to stay informed about system upgrades and new features.
• Updated manuals and training resources will be distributed as changes occur.

Feedback Loop

• Report system inefficiencies, recurring faults, or training gaps to your supervisor.
• Operator feedback ensures continuous improvements in system performance and support tools.

Collaborative Workflows

• Engage with maintenance teams and fellow operators to share insights, troubleshoot collaboratively, and streamline workflows.

Quick-Access References

Glossary

• EOAT (End of Arm Tool): The gripper used by the robot arm for lifting and positioning materials.
• AMR (Autonomous Mobile Robot): A mobile robot that autonomously transports pallets between system zones.
• IBOB (Inbound-Outbound Buffer): The staging area where pallets are queued for processing.
• E-Stop (Emergency Stop): A safety feature that halts system operations immediately.

Recommended Tools

• Operator Toolkit:
  • Microfiber cloths for cleaning sensors and vision systems.
  • Wrenches for securing loose connections.

• Consumables:
  • Replacement suction cups for EOAT.
  • Label rolls for the FoxIV labeler.
  • Pre-stretch film for the WRTA200 stretch wrapper.

Final Note
 The Mujin automation system is designed to enhance efficiency, safety, and accuracy in material handling operations. By following the guidelines and leveraging the resources provided, operators can confidently maintain high system performance and minimize downtime. Remember, safety and proactive problem-solving are key to successful operations.

Preventive Maintenance

Purpose

This module outlines daily and weekly operator-level preventive maintenance (PM) tasks. Regular PM ensures that the Mujin system operates efficiently, minimizes downtime, and prevents potential failures.

Daily Maintenance Tasks

Operators should perform the following checks and tasks at the start and end of each shift:

Robot Arm (CP500L):

• Inspect the EOAT for:
  • Secure attachment to the robot arm.
  • Wear or debris in suction ports and gripping surfaces.
• Verify that the arm is free from physical obstructions and moves smoothly.

Stretch Wrapper (WRTA200):

• Confirm the stretch film is loaded correctly and the film path is clear.
• Check the rollers for debris or wear that could affect film feeding.

Pallet Dispenser (IBOB):

• Ensure pallets are stacked correctly in the dispenser.
• Clean photo eyes to maintain accurate pallet detection.

Pallet Labeler (FoxIV):

• Inspect the printhead for dirt or buildup; clean as needed.
• Verify label alignment and test print a sample label for quality.

AMR (Quicktron M150):

• Inspect LiDAR sensors and bumpers for dust or damage.
• Check the battery status via the HMI and ensure AMRs are docked properly at the charging station when not in use.

General Safety Systems:

• Test E-stop buttons at accessible points to ensure they function correctly.
• Confirm that all safety gates and interlocks engage properly.

Weekly Maintenance Tasks

In addition to daily tasks, operators should perform the following tasks on a weekly basis:

Robot Arm (CP500L):

• Inspect joints and axes for smooth operation; report any unusual noises or resistance to maintenance.
• Clean vision system lenses to maintain accuracy during operations.

Stretch Wrapper (WRTA200):

• Test the film tension settings to ensure they match load specifications.

• Inspect the tensioning mechanism for wear or misalignment.

Pallet Dispenser (IBOB):

• Check for signs of wear on moving parts such as rollers and conveyor belts.
• Verify sensor alignment and recalibrate if necessary using the HMI.

AMR (Quicktron M150):

• Perform a full diagnostic scan using the HMI to identify potential issues.
• Inspect and clean wheels to ensure smooth navigation.

Safety Systems:

• Test all interlock mechanisms and ensure safety gates halt system operations when opened.
• Confirm that emergency pathways and exits remain unobstructed.

Operator PM Checklist

Operators should maintain a record of completed PM tasks. Below is an example template:

Escalating Maintenance Needs

Operators should escalate the following to the maintenance team:

• Persistent alignment issues or recurring alarms.
• Physical damage to critical components like EOATs, rollers, or sensors.
• Irregular noises or movements during operation.
• Any unresponsive safety mechanisms, including E-stops and interlocks.

Appendices

Appendix A:

Glossary of Terms

Appendix B:

Troubleshooting Quick Reference

Appendix C: 

Preventive Maintenance Checklist: 

Daily PM Tasks

Weekly PM Tasks

Appendix D: [AK5] 

Practical Examples

Exercise 1: Jogging the Robot Arm

• Task: Manually jog the CP500L robot arm using the HMI.
• Steps:
  1. Activate manual mode on the HMI or pendant.
  2. Use Cartesian Mode to move the arm in X, Y, and Z directions.
  3. Align the EOAT with a designated target zone.
• Outcome: Operators will demonstrate proficiency in precise arm control.

Exercise 2: Clearing a Pallet Jam

• Task: Simulate and resolve a pallet jam in the IBOB dispenser.
• Steps:
  1. Engage LOTO to isolate the dispenser.
  2. Inspect the jam and clear it safely using tools.
  3. Restart the dispenser and test functionality via the HMI.
• Outcome: Operators will practice safe and efficient jam resolution.

Exercise 3: Adjusting Stretch Wrapper Tension

• Task: Inspect and adjust film tension on the WRTA200 stretch wrapper.
• Steps:
  1. Confirm that the film is threaded correctly.
  2. Adjust tension settings via the HMI.
  3. Test-wrap a pallet and verify tension quality.
• Outcome: Operators will optimize film application for load stability.

Exercise 4: Recalibrating the AMR

• Task: Perform basic diagnostics and recalibration of the AMR.
• Steps:
  1. Access the HMI diagnostics menu.
  2. Verify sensor alignment and perform a LiDAR recalibration.
  3. Test navigation using a manual route assignment.
• Outcome: Operators will understand how to interpret and resolve AMR faults.

Exercise 5: Label Alignment and Quality Control

• Task: Align the label roll and test print quality on the FoxIV labeler.
• Steps:
  1. Reload the label roll, ensuring proper alignment.
  2. Clean the printhead and test print a label.
  3. Inspect adhesion and barcode clarity.
• Outcome: Operators will maintain consistent label quality and alignment.

Appendix E: Safety Diagram Placeholder

(Placeholder for system safety diagram, including E-stop locations, LOTO points, and interlock zones.)