Friction Driven Winder Operation And Safety Procedures Training

Objectives:
• Understand the purpose and applications of friction driven winders in industry
• Identify key components and their functions
• Recognize the importance of safety in winder operations
• Learn basic terminology and concepts
• Comply with relevant SAQA and OHS Act requirements

Topics:
• Overview of friction driven winders: types and uses
• Key components: drums, rollers, brakes, clutches, and control systems
• Introduction to operational safety principles
• Understanding relevant legislation: OHS Act, SANS codes
• Roles and responsibilities of operators and supervisors
• Basic risk assessment concepts

Objectives:
• Describe the mechanical systems of friction driven winders
• Perform pre-operational inspections systematically
• Identify common mechanical faults
• Understand lubrication and maintenance schedules
• Document inspection findings correctly

Topics:
• Detailed study of mechanical components: bearings, gears, couplings
• Pre-operational inspection checklist
• Lubrication points and types of lubricants
• Identifying wear, misalignment, and damage
• Maintenance schedules and record keeping
• Practical demonstration of pre-start checks

Objectives:
• Understand basic electrical circuits and control panels
• Identify safety devices: emergency stops, interlocks, overloads
• Perform visual inspection of electrical components
• Recognize common electrical faults
• Follow lockout/tagout procedures

Topics:
• Introduction to electrical diagrams and symbols
• Control panel components: PLCs, VFDs, relays
• Safety devices: emergency stop, limit switches, guarding
• Lockout/tagout procedures for electrical work
• Troubleshooting common electrical issues
• Practical exercise: identifying components

Objectives:
• Explain the role of hydraulic and pneumatic systems in winder operation
• Identify components: pumps, valves, cylinders, accumulators
• Perform basic pressure checks and adjustments
• Recognize leaks and malfunctions
• Apply safe work practices for hydraulic/pneumatic systems

Topics:
• Fundamentals of hydraulics and pneumatics
• System components and their functions
• Reading schematics
• Pressure testing and adjustment procedures
• Common faults: leaks, contamination, seal failure
• Safety precautions: pressure release, fluid handling

Objectives:
• Describe standard operating procedures for starting, running, and stopping winders
• Operate control interfaces: manual, semi-automatic, automatic modes
• Adjust speed, tension, and torque settings
• Monitor operational parameters
• Respond to alarms and warnings

Topics:
• Start-up sequence and shutdown procedures
• Control modes: local vs remote, manual vs automatic
• Setting and adjusting winding parameters
• Monitoring displays: speed, tension, current, temperature
• Alarm management and fault finding
• Practical exercise: simulated operation

Objectives:
• Understand material properties affecting winding
• Manage web tension, alignment, and edge control
• Perform splicing and threading procedures
• Handle roll changes and core preparation
• Minimize waste and defects

Topics:
• Material characteristics: thickness, strength, stretch
• Tension control principles and devices
• Web guiding systems: sensors, actuators
• Splicing techniques and adhesive selection
• Core preparation and roll removal
• Defect identification: wrinkles, telescoping, breaks

Objectives:
• Identify all safety systems on friction driven winders
• Test safety devices: light curtains, pressure mats, guards
• Execute emergency stop and evacuation procedures
• Conduct risk assessments for specific tasks
• Apply incident reporting protocols

Topics:
• Safety system overview: guarding, interlocking, emergency stops
• Testing and verification of safety devices
• Emergency response: fire, chemical spill, injury
• Task-specific risk assessment (JSA)
• Incident reporting and investigation basics
• Practical drill: emergency stop scenario

Objectives:
• Develop systematic troubleshooting approaches
• Diagnose mechanical, electrical, and control system faults
• Use diagnostic tools: multimeters, pressure gauges, software
• Interpret error codes and alarm logs
• Implement corrective actions safely

Topics:
• Troubleshooting methodology: observe, analyze, isolate, correct
• Common mechanical faults: vibration, noise, overheating
• Electrical fault finding: continuity, voltage, signal testing
• Control system diagnostics: PLC indicators, HMI messages
• Use of manuals and schematics
• Practical fault-finding scenarios

Objectives:
• Perform routine maintenance tasks according to schedule
• Inspect critical components: brakes, clutches, bearings
• Replace wear parts: belts, filters, seals
• Record maintenance activities accurately
• Identify when specialized maintenance is required

Topics:
• Preventive maintenance schedule
• Inspection of braking systems: pad wear, adjustment
• Clutch maintenance: slipping, adjustment
• Bearing inspection and replacement
• Filter and seal replacement
• Maintenance documentation and CMMS entry

Objectives:
• Optimize winding parameters for different materials
• Manage multiple winder configurations (center, surface, combo)
• Implement tension profiling and taper tension
• Handle special materials: film, paper, nonwovens
• Improve productivity and quality

Topics:
• Advanced tension control: taper, inertia compensation
• Winding curves and roll hardness
• Center vs surface winding techniques
• Handling delicate or stretchy materials
• Performance optimization: speed, tension, lay-on pressure
• Practical exercise: parameter optimization

Objectives:
• Inspect finished rolls for quality defects
• Measure roll hardness, diameter, and edge quality
• Analyze defect causes and implement corrective actions
• Apply continuous improvement principles (Kaizen)
• Document quality data and trends

Topics:
• Quality standards for wound rolls
• Measurement tools: hardness tester, micrometer, taper gauge
• Common defects: gauging bands, telescoping, core slips
• Root cause analysis techniques (5 Whys, fishbone)
• Process improvement: speed adjustments, tension changes
• Data collection and SPC basics

Objectives:
• Demonstrate competency in all aspects of winder operation and safety
• Complete practical assessments: pre-op checks, operation, troubleshooting, shutdown
• Pass written knowledge assessment
• Apply all safety procedures consistently
• Receive feedback and certification guidance

Topics:
• Review of key concepts and procedures
• Practical assessment: full operational cycle
• Written exam covering theory and safety
• Feedback session and gap analysis
• Certification requirements and portfolio of evidence
• Course evaluation and next steps