As a part of improving the flexibility of automatic scrap we have introduced the functionality to assign different signal quantity values to good and scrap sensor inputs. To get more information or enable this feature, please contact our Support at [email protected].
This feature is used when the number of units registered by sensor counting production does not match the number of units registered by another (scrap) sensor. In order to register the correct amount of scrap, it is now possible to set a multiplier for scrap quantities for each product and station.
For example, in the image below, the total ("all products"), scrap and good quantity ("only good products") all have the same signal quantity value assigned. In this example every signal equals one bottle and scrap can be calculated simply by deducting the good quantity from the total quantity.
So, if the total quantity is, for example, 600 bottles and good quantity is 594 bottles, scrap would be 600 - 594 = 6 bottles.
However, sometimes good quantity is not counted in the same unit as total. For example in the image below, total ("all products") is counted as individual cans, but good quantity is counted as sets - meaning 6 individual cans make 1 set. And to calculate scrap, good quantity would have to be multiplied with the "scrap signal unit", which in this example is 6.
So, if the total quantity is 600 and the good quantity is 99 and we know that scrap signal quantity is 6, scrap would be 600 - 99*6 = 6 cans.
The feature needs to be enabled before these steps (contact Support).
Go to Settings - Products
Find the product and click on the edit button
Open product settings for station (route settings)
Set the number of scrap units for one sensor signal
Hint: If we take the example with the cans (packed as a set of 4 cans), then this value would be 4.
Click “Apply” to apply the settings and confirm by clicking "Save".
Note: This does not affect ongoing batches, it will be enabled from the next product changeover.