The Corrugator Control page fulfills two main purposes:
In the corrugator control room it functions as the online connection between corrugator and Planning. The Corrugator Control page lets the corrugator operator transfer runs to the Dry End controller and change the run sequence while keeping Program Memory and Dry End controller synchronized.
Furthermore, the Corrugator Control page lets the corrugator crew print out a variety of production documents like corrugator programs, cutting and material lists or pallet labels right at the machine.
Elsewhere in the plant, e.g. at the Wet End, the Corrugator Control page allows printing corrugator schedules and material requirements but without the possibility to make sequence changes or to transfer runs to the Dry End controller.
More Control for the Corrugator Crew, Program Memory Always Up to Date
The Corrugator Control Page changes PC-Topp's approach to the link between Planning and the corrugator: Originally, the On-line Link program was run on a PC in the planning office. When new schedules were ready, the planners used it to transfer them to the corrugator.
Now, the Corrugator Control Page is used by the corrugator crew, directly in the corrugator control cabin, for the same purpose. This not only gives the crew much more control over what programs are downloaded to the corrugator, it also allows PC-Topp to follow corrugator production more closely.
Before, new programs were sent by Planning always to the end of the queue of schedules waiting to be produced. If such a new schedule needed to be run earlier, the corrugator crew had to make the necessary sequence change at the Dry End controller computer, which had the advantage that they maintained full control over what was happening at the machine. Planning could not simply make a sequence change without informing them, or without their okay. The disadvantage was that the schedules in PC-Topp's Program Memory usually stayed in the old, now obsolete sequence.
Now, Planning simply releases new schedules for production, and they appear at the end of the queue of schedules waiting for production. If a sequence change is needed, the corrugator crew makes it right there in the Corrugator Control Page, which is usually much easier than using the corrugator's own user interface. The sequence at the Dry End controller computer is automatically kept in sync with the changes done on the Corrugator Control page.
Moreover, the Corrugator Control page automatically synchronizes Program Memory with the new sequence. This way, the actual program sequence is always visible in Planning as well as at the corrugator.
With the Corrugator Control page, runs can be transferred to the Dry End controller computer either manually or automatically. The automatic mode always keeps enough programs in the queue to maintain a smooth production flow. Optionally, the Corrugator Control page can only be used for displaying and printing programs and paper requirements, without the functionality for modifying the run sequence.
Changing the Production Sequence
The Corrugator Control page displays the runs in the corrugator queue marked with padlock symbols. They show the status of each run and allow you to change it.
| ||Runs whose position can't be changed anymore because they are either already being produced or very close to production. |
| ||Runs that have already been transferred to the Dry End controller computer. |
Those runs are locked, i.e. their sequence can't be changed. If you want to modify the position of those runs you can unlock them with a mouse click on the green padlock. Unlocking a run means that it is temporarily deleted from the Dry End controller computer. The run is retransferred as soon as the desired sequence has been established.
| ||Runs that are in Program Memory but haven't been transferred to the Dry End controller computer yet. You can change their position anytime. |
| ||Runs whose position in the queue of the Dry End controller computer is different from their position in Program Memory. This happens when runs are manually inserted or when the sequence is modified at the Dry End controller computer. These runs can be changed after unlocking them with a click on the padlock. |
The queue always starts with one or several red padlocks, followed by runs with a locked padlock symbol (ideally all green, after changes done at the Dry End controller some of them may be orange). The last run with a locked padlock marks the end of the schedule that has already been downloaded to the Dry End controller. After that point, all runs have open padlock icons.
Sequence changes in the section marked with open padlocks can be done directly. If however a change is needed in the locked part of the queue, then the corresponding runs must be unlocked first by clicking on the padlock symbol of the first run in the locked part of the schedule.