PC-Topp.NET prints pallet labels in real time at the machine: Ideally, the person at palletisation will find just one label in the printer when he needs it, the label for the pallet he is just finishing. This is ensured by printing the label when the pallet is half full (or alternatively at the beginning or at the end of the pallet).
This gets desynchronized by waste during production: The counter shows the pallet as half full, but in fact that quantity is not reached yet. Small differences are not a problem, but when the waste goes near the quantity on a pallet the user will find two labels in the printer, the right label and – on top of it - the label for the next pallet. Of course, this can lead to errors.
Therefore, we created buttons to enter waste during production to re-synchronize the label printing in such a case. And while we were at it, we added a few more buttons, to make the solution complete.
Sheets used during set-up are usually waste, and the terminal can be configured to count set-up waste automatically (the number can be corrected manually during or after set-up). Set-up waste is entered in sheets (and not in finished goods, e.g. on a die-cutter).
Waste occurring after set-up is entered as the number of faulty products taken out before palletisation.
Waste Before the Machine
Sheets sorted out before feeding them into the machine have no influence on label printing synchronisation. But if a high quantity must be sorted out, then PC-Topp's estimated ending time should be adjusted. To do so, enter the waste before the machine using the corresponding button (quantity is entered in sheets).
Sheets From / to Stock
Like waste occurring before the machine, sheets added from stock (or excess quantities not converted but moved to stock instead) can change production time quite dramatically. Therefore, we added a button that lets you change the quantity that will go through the machine by entering the number of sheets going to (or coming from) stock.
This information is not stored at this time. We have future plans to keep quantities moved into stock in memory so that the terminal can later suggest what quantities (and from which production orders) could be added from stock for a given article.
Products Moved to Stock
A final button added at the end of the machine lets the crew reduce the quantity going to Shipping or to the next machine. This is useful if e.g. printing is done for a big overrun coming from the corrugator, but because the customer accepts only exact quantities, only a smaller number must go to the die-cutter.
The reduced quantity gives the order a correct duration on the next machine and thus allows more precise planning.
The entries are not stored, however: Again, we have future plans to create a memory of quantities of an article (or semi-finished goods) moved into stock, so that they can later be identified and retrieved.