Recovery behaviour is part of useful output and machine acceptance
Most production lines spend some time stopping, refilling, clearing or waiting for adjacent equipment. A machine that performs only during an uninterrupted demonstration has not proved the states that operators will encounter. FAT should therefore challenge low feeder level, missing bottles, missing closures, downstream stops and controlled restart.
| Test state | Expected evidence |
|---|---|
| No closure ready | Bottle is held or diverted according to the agreed sequence; no uncapped bottle is released as accepted. |
| Interrupted press cycle | The bottle and closure are identified as suspect and cannot be cycled twice without inspection. |
| Downstream stop | Accumulation remains controlled and decorative closures are not damaged by contact or pressure. |
| Controlled restart | Feeder, bottle spacing and press resume without double feed, empty cycle or loss of traceability. |
What should happen when no T‑cork is ready at the escapement?
The press should not complete a normal capping cycle on a bottle without a confirmed closure. The agreed sequence may hold the bottle, stop upstream supply or divert it, depending on the line design. The controls should identify the condition clearly and prevent the uncapped bottle from being counted or released as accepted product.
How should a T‑corker restart after an emergency stop or guard opening?
Restart should require the hazard to be cleared, guards and safety functions restored, the machine state reviewed and a deliberate reset. Any bottle or closure left in the feeder, escapement, chuck or press position must be identified before motion resumes. The exact procedure belongs in the machine instructions and the user’s site-specific risk assessment; a restart must not occur automatically from reset alone.
What should happen to a bottle with a partly inserted closure?
A bottle with a partly inserted closure should be treated as suspect and removed to the agreed inspection or reject route. Pressing it a second time without understanding the state can hide damage, alter retention or double-load the glass. Record the interruption, bottle and closure batch, then inspect the neck, top, finished position and any machine contact before deciding disposition.
Which control signals should pass between the T‑corker and adjacent machines?
The required signals depend on the line, but the interface normally needs clear run-permit, ready, fault, stop-request and downstream-available states, together with any reject or low-feeder information needed by the process. Define signal ownership, safe state, response time and restart sequence. A controls list should match the physical bottle buffer and accumulation available.
How can reject handling be proven during a factory acceptance test?
Create controlled conditions such as missing closure, mispresented closure, interrupted cycle or failed quality check, then follow the bottle through detection, stop or reject, record and restart. Confirm that the rejected item cannot rejoin accepted product and that the operator can identify the reason. Use safe simulated faults where creating the real fault would be hazardous.
Why should good output be measured after deliberate stoppages?
Deliberate stoppages reveal whether the feeder re-establishes orientation, bottle spacing recovers, suspect parts are controlled and the line returns to stable accepted output. Counting only uninterrupted cycles can hide losses that dominate real production. Report the number and type of stops, recovery time, rejected bottles and accepted output over the full test period.
UK machinery-use reference: HSE guidance on PUWER and work equipment explains the user’s duties for suitability, guarding, controls, maintenance, information and training. Final safeguards and procedures require a competent application-specific assessment.