Punch list Extrusion line · SAT · rev. 3

14 open

  • 01 Infeed photocell inverted (DI 12.4) Stops loading D&D open closed
  • 02 Axis 2 drive: enable with no feedback Locks up on restart D&D open closed
  • 03 Pressure transducer: wrong full scale Reading out of range D&D open closed
  • 04 Zone 3 E-stop not wired Safety Customer open closed
  • 05 Unwinder encoder: count direction Wrong length D&D open closed
  • 06 Reset sequence after E-stop Manual restart D&D open closed
  • 07 Recipe 4: preheat set to zero Scrap Customer open closed
  • 08 Oil level alarm has no text Slow diagnosis D&D open closed
  • 09 Profinet node 14 dropping out Random stops D&D open closed
  • 10 Light curtain muting not tested Safety D&D open closed
  • 11 Panel thermostat set to 55 °C Alarms in summer D&D open closed
  • 12 Terminal labels, pump area Maintenance D&D open closed
  • 13 HMI backup not updated to v2.4 Recovery D&D open closed
  • 14 Load cell calibration with test weight Accuracy Customer open closed
Owner · 11 D&D · 3 customer No open items

A sample punch list, in the format we keep on site · not data from a real job

Testing and start-up · since 1996

Testing is done
when the list is empty.

Anything that doesn’t check out gets its own row: what’s wrong, how much it matters, who closes it. The line goes live when that list hits zero, not when the date comes around.

Plan your testing See what we test

Technical reply in 1–2 business days · No commitment

Scroll: watch the list empty

Companies that have trusted us

FAT and SAT

The same panel,
tested twice.

In our workshop we test everything that can be tested without the process. At your plant, all that’s left is what only the process can tell us.

3D reconstruction: the control panel with its doors open, still on its casters. On the left, on a stool, the simulation box wired to the terminal blocks; on the floor, the temporary power cable with its plug; on the right, a cart with the laptop, connected to the PLC by the network cable, and a multimeter.
FAT · Mesero, test bench

Here the signals are simulated.

  • Temporary power, a laptop connected to the PLC, a box of toggle switches in place of the field.
  • Protection, safety, controls and operator screens are verified here.
  • What doesn’t check out gets fixed where we have bench, spares and drawings.
3D reconstruction: the same panel, from the same viewpoint, at the plant. Doors open, feet anchored to the floor in place of the casters; the field cables arrive in a wire mesh cable tray and are terminated at the terminal blocks; on the left, a gearmotor connected by its power cable.
SAT · At your plant, on the line

Here the signals are real.

  • The panel is bolted down and the field gets connected: motors, sensors, valves, network.
  • Whatever is left goes on the list, with a name and a date.

FAT saves you days.
SAT saves you downtime.

Testing

336 signals.
One at a time.

An input can be inverted, an analog signal off scale, a drive enabled with no feedback. On the test bench that’s ten minutes; on site it’s hours.

Each square is one signal

336 of 336 tested

Force the field device, watch the PLC. If the bit doesn’t change, the problem isn’t in the software.

DI 12.4 infeed photocell. Expected 1, read 0. The signal comes in inverted.

DI 12.4 fixed at the terminal block. Retested, closed. On site it would have been two hours and a stopped line.

336 tested, 336 passed. Now we can talk about start-up.

3D reconstruction: the simulation box up close. A row of toggle switches labeled DI 12.1 to DI 12.7: only DI 12.4 is up, and its LED is lit.

From field to PLC

Every input.

A toggle switch stands in for the sensor. If the bit doesn’t move, the problem is somewhere between cable, terminal and power supply.

3D reconstruction: the two probes of a multimeter on the terminals of terminal block -X1; the display reads “24.0 V” DC.

From PLC to field

Every output.

We drive it from the PLC and measure at the terminal. The right thing has to move: that contactor, that valve, that lamp. Not the one next to it.

3D reconstruction: a loop calibrator connected by two alligator clips to the wires of a pressure transmitter; the display reads “12.00 mA”, mid-scale.

With the instrument

Every analog.

Zero and full scale. A badly scaled 4–20 mA signal goes unnoticed until it ruins product, and by then it’s scrap.

Start-up

“Running” isn’t
“producing.”

A machine can dry-cycle perfectly and stop at the first changeover. Start-up is over when the line makes product, at the right rate, run by the people who use it every day.

3D reconstruction: the same panel in operation. Doors closed, anchored to the floor, field cables connected; on the roof, the stack light with the green lit; on the left, the gearmotor.
The same panel, tested twice. Now it’s closed, and working.

  • With real material

    Until material goes
    through, the cycle
    is still a guess.

    Real product exposes what an empty run never will: tension, temperatures, settling times, start‑up scrap.

  • At the real rate

    8 hours
    straight.

    A single cycle almost always works. Eight hours straight is another story: that’s when overloads trip, timings run at the limit, false alarms show up and parts pile up where nobody was looking.

  • With the people who run it

    A line only two
    people can run
    stops with those two.

    We walk the people on shift through it, not just whoever followed the project.

Service

When the line starts,
we don’t disappear.

The part that isn’t in the quote: what happens the day after the acceptance report is signed.

The first hours

We stay until it runs on its own.

We watch them with you: that’s when the last issues surface.

The first year

Support is free.

Call whenever you need to, without wondering what the question will cost.

Always

We always answer.

For anyone who has bought from us, every day.

+39 02 97289083

If the plant has secure, authorized remote access, we run most post-start-up checks from Mesero, without waiting for a trip. How our remote support works

Handover

What you keep
when we leave.

Not a binder to file away: the things you need the first time the line stops and we’re not there.

3D reconstruction: on the bench, the acceptance report, the I/O report, the punch list with every item closed, the backup drive, the operating notes and the as-built drawings.

  • The acceptance report.

    What was tested, with the result, the date and the signature of whoever was there.

  • The I/O report.

    Every signal, its address, the expected value and the value read.

  • The open items list.

    Closed items, with the date and who closed them. Yours included.

  • The backups.

    PLC, HMI, drives and parameters: the version left in the machine, with the date on it.

  • The operating notes.

    Alarms, resets, limits, recipe changes: what the people on shift need to know.

  • The as-built drawings.

    Updated with the changes made on site, not the ones we started from.

Everything in formats you can still open ten years from now, without calling us to do it. When a change is ours, we redraw the schematics ourselves: see how we draw them.

First step

Got a date?
Let’s start there.

Tell us when the line has to produce and what needs testing. We’ll tell you what’s worth testing on the bench, what can only be tested on site, and how many days it really takes.

Plan your testing

An engineer reads it, and the first reply comes within 1–2 business days.

Already in start-up and the line is down? Call +39 02 97289083: that’s when it pays to skip the form. Or email info@dedautomazione.it.