Separate adjustment from tooling
During changeover, some items are adjusted and some are replaced. Confusing the two creates repeatability problems. A good record states which chuck, rail, support or guide is fitted and which scale position, stop, recipe or mechanical setting was used for the approved sample.
| Area | Changeover record | Maintenance check |
|---|---|---|
| Press head and chuck | Chuck identity, head height, press travel or setting and contact method. | Wear, loose fasteners, contamination and marking on the closure top. |
| Bottle support | Base support, side guides, stops and centring method. | Guide damage, build-up, scuffed contact surfaces and repeatability of the setting. |
| Feeder and rail | Bowl tooling, track, rail, escapement and sensor settings. | Cork fragments, track pressure, sensor cleanliness and any damage from jams. |
| Controls | Recipe, reset method, low-level warning and stop/start sequence. | Interlocks, alarms, switches and recovery sequence after stoppages. |
First-off and last-off samples
Keep an approved first-off sample and record the same measurement method at the end of a batch. This helps identify whether a change has occurred during production rather than discovering drift at the next setup. If the finished height changes during the run, inspect closure batches, air or drive settings, bottle variation, head condition and feeder pressure before assuming one isolated cause.
Spare parts and evidence
For support, keep photographs of the machine setup, the fitted change parts and the failed sample. State when the issue appeared, which format was running, whether it followed a changeover and what corrective action has already been attempted.
The feeder guide, troubleshooting guide and service page provide the best next routes when a repeatability issue appears.