GuideAppendix D
Start-Up Sensor & Safety Test Checklist
Complete before the first bottle of every batch and after any stop longer than the SOP allows. Do not start production with any test failed.
| Test | Pass condition | Ref. | OK |
|---|---|---|---|
| Emergency stops (all machines) | Each stops its machine | 2.3 | ☐ |
| Unscrambler bowl level sensor | Bulk feeder stops at full level, restarts when low | F-12 | ☐ |
| Wrong-way bottle sensor | Inverted test bottles blown back; correct bottles pass | F-09 | ☐ |
| Conveyor bottle stop sensor | Feeder stops when queue reaches sensor | F-07 | ☐ |
| Counter main hopper level sensor | Elevator starts when low, stops when full | F-15 | ☐ |
| Counter bottle presence sensor | No bottle: counter stops, releases nothing | N-11 | ☐ |
| Hand count | 10 bottles correct | N-01 | ☐ |
| Desiccant cutting sensor | Red spot on cut point; 10 clean cuts | D-01 | ☐ |
| Cap chute sensor / infeed wheel | Chute empty: capper infeed stops | K-10, K-18 | ☐ |
| Cap torque | 5 bottles within specification | 6.12 | ☐ |
| Cap height sensor | Loose/crooked test cap rejected | K-19 | ☐ |
| Foil detection sensor | No-foil test cap rejected | I-07 | ☐ |
| Induction seal | 2–3 test bottles fully sealed, no burns | 6.11 | ☐ |
| Inkjet code | Batch and expiry correct, second-person checked, QA approved | 6.2 | ☐ |
| Metal detector | All test pieces detected and rejected | 6.13 | ☐ |
| Checked by | Date / time |
|---|
Did this solve the problem?