Packaging LumenPnP V3.1

Reviewing packaging layout

The following components are packaged into the lower-foam-tray:
- y-gantry-left
- y-gantry-right
- x-gantry
- getting-started-kit
- Tool-kit
- feeder-blade-harness-set
- 2x front-leg-extension
- 2x back-leg-extension
The following components are packaged into the upper-foam-tray:
- primary-staging-plate
- static-camera-foot
- aux-staging-plate
- aux-staging-plate-foot
- bagged-10x-extrusion-cable-clips
- drag-chain-assembly
- front-drag-chain-mount
- 24v6A-power-supply
- power-cable
- front-feeder-rail
- rear-feeder-rail

Package `lower-foam-tray`

The following steps must be conducted by someone other than the original assembler.

Packaging `tool-kit`

Perform tool-kit QC
- Confirm QC PASS sticker is present on lumen-v3.1-hardware-kit bag
- Confirm bottom-camera-cable was added to zipped pouch
- Confirm squaring-bracket was added to zipped pouch
- Confirm feeder-programmer was added to zipped pouch
- Confirm DRIVE-WHEEL-ASM Adjustment Hex Key was added to zipped pouch
If all checks pass, continue onward
Add tool-kit into the middle region of lower-foam-tray
- Orient the tool-kit so the Opulo logo faces towards the x-gantry

Packaging `getting-started-kit`

Insert getting-started-kit into the lower region of the tray
- Only pull these items from a green QC-Pass bin.

Packaging `x-gantry`

Perform x-gantry QC
- GT2-belt has been trimmed to appropriate length (flush on 1 side, ~1/2" - 3/4" on the other)
- Camera is installed with two bolts
- Camera lens cap is present
- The wire connectors on both NEMA-11-stepper-motor units face away from each other, sitting adjacent to their respective cable strain relief points
- Each CP40-holder has been lubricated and fit-tested with a nozzle
- Z-belt-loop feels appropriately tensioned when plucked
- Each z-gantry moves smoothly when actuated back-and-forth by hand
- 2x M5-hex-nut are installed in x-gantry-back for use with drag-chain attachment
- NEMA-17-stepper-motor wire connector faces towards drag-chain mounting location on x-gantry-back
- Linear-rail is centered atop aluminum-extrusion
- x-idler-mount and x-motor-mount are secured to 600mm-alu-extrusion with 2x M5x10-bolt per side
- 2x M5-hex-nut are installed in x-motor-mount for use with the x-motor-cable-guide
- Tensioner-arm is installed on x-idler-mount in the correct orientation (IE acorn-nut facing touches print)
- Timing-pulley is tightened down and at proper height
- GT2-belt lays flat and is roughly centered in the 600mm-alu-extrusion channels
- GT2-belt has been correctly tensioned
- X-gantry-toolhead moves smoothly when actuated back and forth by hand
  
  If all checks pass, continue onward
- Package x-gantry into lower-foam-tray, in the region shown below

Packaging `y-gantry-right`

Perform y-gantry-right QC
- Confirm M5 bolts are installed in every counterbored region
- M5-hex/square-nut installed where required:
  - 2x M5-hex-nut pressed into bottom of front-right-leg
  - 1x M5-hex-nut pressed into bottom of back-leg
  - 2x M5-hex-nut pressed into y-gantry
- GT2-belt has been trimmed to appropriate length (flush on 1 side, ~1/2" - 3/4" on the other)
- GT2-belt has been correctly tensioned
- Tensioner-arm is installed on front-right-leg in the correct orientation (IE acorn-nut facing touches leg)
- Linear-rail is centered atop aluminum-extrusion
- y-gantry sits flat on linear-rail-carriage
- y-gantry feels smooth and free of friction across the y-min to y-max travel range when actuated by hand
- GT2-belt lays flat in the 600mm-alu-extrusion channels
- 3x extrusion-cable-clip have been installed onto the y-gantry-left's lower 600mm-alu-extrusion
- Timing-pulley is tightened down and at proper height
- Y2 cable is secured with a zip-tie and exits the port labeled Y2
If all checks pass, continue onward
Package y-gantry-right into lower-foam-tray, in the region shown below

Packaging `y-gantry-left`

Perform y-gantry-left QC
- Confirm M5 bolts are installed in every counterbored region
- M5-hex/square-nut installed where required:
  - 2x M5-hex-nut pressed into bottom of front-left-leg
  - 1x M5-square-nut pressed into side of front-left-leg for use with front-drag-chain-mount
  - 1x M5-hex-nut pressed into bottom of back-leg
  - 2x M5-hex-nut pressed into y-gantry
- GT2-belt has been trimmed to appropriate length (flush on 1 side, ~1/2" - 3/4" on the other)
- GT2-belt has been correctly tensioned
- Tensioner-arm is installed on front-right-leg in the correct orientation (IE acorn-nut facing touches leg)
- Linear-rail is centered atop aluminum-extrusion
- y-gantry sits flat on linear-rail-carriage
- y-gantry feels smooth and free of friction across the y-min to y-max travel range when actuated by hand
- GT2-belt lays flat in the 600mm-alu-extrusion channels
- 3x extrusion-cable-clip have been installed onto the y-gantry-left's lower 600mm-alu-extrusion
- Timing-pulley is tightened down and at proper height
- Y1 cable is secured with a zip-tie and exits the port labeled Y1
If all checks pass, continue onward
Package y-gantry-left into lower-foam-tray, in the region shown below

Packaging `front/back-leg-extension`

Insert 2x back-leg-extension into the tray in the region shown below
- Confirm both pieces have rubber-feet installed
Insert 2x front-leg-extension into the tray
- Confirm both pieces have rubber-feet installed

Packaging `feeder-blade-harness-set`

Insert feeder-blade-harness-set into the tray in the region shown below

This photo is out of date

Be sure to use the new version of this cable, feeder-blade-harness-set, rather than the earlier version shown above.

Confirm the contents of `lower-foam-tray`

Confirm the lower-foam-tray matches the image shown below before continuing:

Package `upper-foam-tray`

The following steps must be conducted by someone other than the original assembler.

Begin by laying out empty upper-foam-tray pieces

Packaging misc. parts

Insert the following items into the right-side cavity of upper-foam-tray

Package each of the following items while inspecting them for their given QC inspection criteria
- front-drag-chain-mount - confirm 2x M5-hex-nut installed into print
- aux-staging-plate-foot - confirm top-side M3 bolt and bottom-side rubber-foot
- static-camera-foot - confirm bottom-side rubber-foot
- Bagged-10x-extrusion-cable-clips
  - Only pull these items from a green QC-Pass bin.
Insert the following into the left-side cavity of the foam tray:
- 24v6A-power-supply
- power-cable

Packaging `primary-staging-plate` and `aux-staging-plate`

Inspect primary-staging-plate before packaging it into the foam tray
- Confirm QC PASS sticker is present underneath the staging-plate
- Confirm mobo QC receipt is present
- Confirm adhered machine SN label matches box-sn-label clipped to primary-staging-plate
- Review the primary-staging-plate for the presence of all major components (checking to see if the original QC inspector missed anything):
  - 2x vacuum-pump
  - 2x solenoid-valve
  - 1x nozzle-rack w/6 nozzles
  - mobo-top-cover
  - bottom-camera assembly
- Confirm tubing is installed correctly:
  - Red Vac1 line appears unkinked and runs to LH y-coupler
  - Blue Vac2 line appears unkinked and runs to RH y-coupler
If all checks pass, continue onward
Unclip the box-sn-label from primary-staging-plate and loosely add it to the power supply side-pocket
Place the primary-staging-plate into upper-foam-tray in the region shown below

The Opulo logo should face away from the feeder-rail pocket
Insert a foam block above each side of primary-staging-plate
Insert aux-staging-plate on top of primary-staging-plate

The Opulo logo should face away from the feeder-rail pocket

Packaging `front/rear-feeder-rail`

It is much easier to check the entire batch at once for a given inspection, rather than checking each one rail at a time against this entire checklist

Perform QC inspection on the front of front-feeder-rail and rear-feeder-rail pieces
- Front-feeder-rail:
  - Slot #1 - #Slot 25 are installed sequentially from left to right when examined visually
  - Slot #1 - #Slot 25 are installed sequentially from left to right when checked with a slot-programmer-jig that is set to read mode
  - The 2x installed corner-bracket pieces each have a spare M5x8-bolt and M5-t-nut installed into the unused holes
    - Total 2x M5x8-bolt and M5-t-nut
  - Wiggle all of the installed slots to ensure none are loose, retightening any if needed
- Rear-feeder-rail:
  - Slot #26 - #Slot 50 are installed sequentially from left to right when examined visually
  - Slot #26 - #Slot 50 are installed sequentially from left to right when checked with a slot-programmer-jig that is set to read mode
  - Wiggle all of the installed slots to ensure none are loose, retightening any if needed
  - The 4x installed corner-bracket pieces each have a spare M5x8-bolt and M5-t-nut installed into the unused holes
    - Total 4x M5x8-bolt and M5-t-nut
  - Confirm that #Slot 50 is printed in yellow plastic
Perform QC inspection on the back of front-feeder-rail and rear-feeder-rail pieces:
- Front-feeder-rail:
  - Confirm the slit in every 2x3-idc-connector faces towards the left of each feeder-slot
  - The 2x installed corner-bracket pieces are flush to the 2020-alu-extrusion
- Rear-feeder-rail:
  - Confirm the slit in every 2x3-idc-connector faces towards the left of each feeder-slot
  - The 4x installed corner-bracket pieces are flush to the 2020-alu-extrusion
If all checks pass, continue onward
Place the finished feeder rails into the upper-foam-tray
1. Orient the rails back-side upward, with rear-feeder-rail in the lower pocket and slot #50 on the right

Packaging `drag-chain`

Perform drag-chain QC
- Inspect the drag-chain for missing or loose drag-chain-cover pieces
- Confirm each drag-chain-end-link has been reworked with the drill jig
- Inspect the x-gantry side of drag-chain to confirm the following cables are present and installed in the correct direction:
  
  A quick way to tell which side of the drag-chain is the x-gantry side: it is the side where the cables are shorter exiting the drag-chain
  - LM cable: 6-pin connector with LM label
  - RM cable: 6-pin connector with RM label
  - ZM cable: 6-pin connector with NO label
  - ZL cable: 3-pin connector with NO label
  - DL cable: 3-pin connector with NO label, exits drag-chain between end-link and final cover
  - USB cable: 4-pin connector with NO label, exits drag-chain between end-link and final cover
- Confirm the following vacuum tubes are present and labeled correctly at both ends:
  - Red 4mm-pneumatic-tubing with LH label
  - Blue 4mm-pneumatic-tubing with RH label
- Confirm zip-tie's are trimmed flush and present in the following locations:
  - 2x on x-cable-chain-bracket where XM cable leaves the drag-chain
    - While here, confirm that XM cable exits drag-chain in place of the 12th drag-chain-cover
  - 2x connecting x-motor-cable-guide to end of XM cable
    - While here, confirm the end of XM cable features a 6-pin connector with NO label
  - 3x evenly spaced between drag-chain and umbilical-cable-strain-relief
  - 2x on umbilical-cable-strain-relief
If all checks pass, continue onward
Install a 2" x 9" bag over both sides of drag-chain
1. Confirm no vacuum tubes are pinched closed by the bagging process
Place the drag-chain into the upper-foam-tray

Confirm the contents of `upper-foam-tray`

Confirm the upper-foam-tray matches the image shown below
Tuck the box-sn-label into the accessory prints pocket after confirming the contents of upper-foam-tray

Package LumenPnP Box

Perform this process 1 machine at a time

It's OK for this work to be performed by the original machine assembler

Gather the following items:
- Empty LumenPnP box
- Packaged and QC'd upper-foam-tray
- Packaged and QC'd lower-foam-tray
- All relevant shipping paperwork, including packing slip, shipping label, and any international forms
Adhere shipping documents to box
- Adhere all relevant shipping documentation to the top left side of the LumenPnP box flap
- Set the packing slip aside if it lists product pricing information, otherwise it can be adhered below the shipping label
Remove the box-sn-label from the upper-foam-tray and adhere it to the LumenPnP box in the region shown below

It is critical that this label matches the serial number listed on the underside of the primary-staging-plate
Examine the packing slip and take note of what (if any) additional items must be packaged
Open the OQC Checklist
- Fill out this checklist as you package the LumenPnP
Complete the first page of the OQC Checklist page
Examine the contents of the lower-foam-tray and complete the corresponding OQC Checklist page
Place the packaged lower-foam-tray into the LumenPnP packaging
- Orient the tray so that the packaged x-gantry is closer to the Opulo logo side of the box
Examine the contents of the upper-foam-tray and complete the corresponding OQC Checklist page
Place the packaged upper-foam-tray into the LumenPnP packaging
- Orient the tray so that the staging plates are closer to the Opulo logo side of the box
Complete the corresponding OQC Checklist page
Reference the order's packing list to determine if the box must include any additional items
- If the order includes additional items, select Yes to this page's last question before proceeding
- If the order does not include additional items, select No to this page's last question before proceeding
If you answered Yes to the previous question you will be directed to the Extra Items Checklist page
- Package any additional items required into the open void regions of the LumenPnP's packaging
- If the order includes feeders or items suitable for a feeder-accessory-tray package them above the upper-foam-tray like so:
- After adding any additional items to the order, check-off any additional items this order contains before proceeding
Proceed to the Finalize Shipment page of the OQC Checklist and work your way through alongside following these last 6 steps
Install a top-foam-sheet above the upper-foam-tray

Is this LumenPnP being shipped with feeders?

Use feeder trays and a top-cardboard-pad instead of a top-foam-sheet if the LumenPnP order includes either feeders and/or items that use a feeder-accessory-tray.
Fill out a getting-started-card with the machine's version number
Use double-sided tape to attached the getting-started-card to the top-foam sheet
- Orient the card so that it's bottom edge faces toward the Opulo logo side of the box
If the packing slip had pricing info listed on it, please tape it next to the getting-started-card at this time
Tape the LumenPnP box shut
Adhere an orange sticker to the top-right corner of the box.
Click Submit on the final page of OQC Checklist page