PC-Topp.NET News (en)

New PDF Order Production Card

PcTopp — Thu, 23 Feb 2012 11:37:00 +0200

The PC‑Topp.NET Production Card accumulates all information that PC‑Topp has about an order in one single document. You can have all the order details that you always had to search for in different parts of the system at your fingertips now.

The Production Card consists of three main sections:

Basic order data
E.g. order number, customer name, due date, format, ordered vs. shipped quantity etc.
A compact overview of the order’s production steps
One block of production data per machine that the order and all of its parts have already run on shows the most relevant figures like production date and time, the number of products into and out of the machine, quantities, area produced, downtime, set-up and run time etc.
In-depth production information by machine for the order
Starting with the corrugator, the third section lists detailed production figures including shift and crew information, scheduled vs. good quantities, waste, downtimes and their causes, quality checks with execution times and results etc. for all of an orders runs on the respective machines.

You can access the PC‑Topp.NET Production Card via the “Find Orders in Production History” link. If you prefer to use the old Look Up Orders in Statistics program instead of the Production Card just click the link in the bottom of the page (below “Save as Excel File”).

Machine Terminal: Option to Enforce Completing all Quality Checks before Shift Change

PcTopp — Wed, 07 Dec 2011 12:00:00 +0200

At the Machine Terminal, operators have a set time limit to do a quality check from the moment it has become due.

As it can happen that one or several quality checks become due just minutes before the shift change, PC-Topp allows those checks to be entered by the next crew, after the shift change.

In some environments, however, it may be preferable to force the crew to finish all pending quality checks before they are able to close the shift, so a new setting has been created to do so.

Define Downtime Cause for Machine Stops at Order End

PcTopp — Thu, 01 Dec 2011 12:00:00 +0200

When a machine stops, the crew has two activities:

Prepare the machine for the next order in order to start production again as quickly as possible,
Finalize palletizing and counting the order that has ended and enter the result into the terminal.

By default, PC-Topp assumes that the set-up for the next order starts at the exact moment when the machine stops for the last time in an order. The crew can press the End of Order button (and also the Start Set-Up button) at any time, the ending time of the order is always recorded as the moment when the machine has stopped, and the starting time of the next order equals that time.

However, some customers have a different view:

At the end of the order, the crew takes some time to “remove the old order from the machine”, a time that varies from order to order and should not be counted as part of the next order’s set-up. The next order’s set-up should only start at the exact moment when End of Order is pressed for the preceding one. The time between the moment the machine has stopped and End of Order is considered as a downtime (with always the same cause, e.g. "Downtime at the end of the order").

By entering a "Default Downtime Cause* at Order End" in the PC-Topp.NET DataSet Parameters, that new behavior can be activated. The time between the stop of the machine and the moment the crew presses End of Order is then recorded as a downtime with the corresponding downtime cause taken from that parameter.

* This downtime cause at order end is different from the optional Default Downtime Cause which is automatically assigned to all unspecified downtimes.

New Report on Ink Color Requirements

PcTopp — Wed, 30 Nov 2011 11:42:00 +0200

The report gives an overview of orders to produce for the respective ink color codes for the next month, showing day details for the fortnight to come and totals for week 3 and 4.

With this report it is easy to see when there are orders to produce for the respective ink color codes, the quantities to produce and the required ink quantities. In descending order, the figures in the cells give the number of orders, the orders’ total surface area to produce (in 1000 m²) and the weight of the necessary amount of ink (in kg) for the corresponding period.

PC-Topp.NET Event Messaging System with New Events

PcTopp — Mon, 31 Oct 2011 10:12:00 +0200

Since the introduction of the PC-Topp.NET Event Messaging system one year ago several new event types have been implemented to further increase the scope of situations the system can monitor. PC-Topp.NET can now also send alerts for the following situations.

New Events

Supervisor Required
A user is executing an action requiring supervisor approval, e.g. certain types of quality checks.
Call Supervisor
If a user executes an action that requires authorization by a supervisor a button saying “Call Supervisor” is displayed in the upper left corner of the PC-Topp.NET authentication dialog. Clicking this button triggers a message to the supervisor calling him to the machine where the action has been executed.
Overrun of Available Quantity
More sheets than available have been fed into a machine.
No Shift Open But Machine Is Running
PC-Topp receives a machine counter signal even though there is no open shift on the specified machine(s).
User Signs in Who Has to Read the Safety Instructions
A crew member who is obliged to read the safety instructions signs in at the specified machine(s). For more details on this functionality see the post Protect Yourself from Damages Claims with Safety Instructions Functionality
Shift Record Broken
A machine crew has surpassed a given record value defined in the settings of one of the machines. This can be an interesting incentive to spur the staff’s competitive spirit.
Pallet Label Reprinted
A pallet label which has already been printed is printed again. An authorized person must confirm that it actually replaces the original label to ensure that there aren’t two identical labels attached to different pallets.
Periodical Event
This event can be used like a scheduler, i.e. you can make the system automatically execute an action at certain intervals, e.g. send the latest shift report at shift end.
Communication Control Events
A Communication Control task cannot be executed, i.e. there is a potential system problem.

(For a full list of all PC-Topp events please refer to PC-Topp.NET Events & Actions: Event Types)

New Option for Sending Event Messages

In addition to the new events, you can now specify if a PC-Topp.NET alert message should only be sent if the recipient is signed into PC-Topp. This prevents urgent messages or messages that are interesting only within a certain time frame from being sent even though currently there is no one to react.

New Events on Demand

By now the PC-Topp.NET event Messaging system has become a powerful instrument for monitoring a broad range of critical or interesting events in production or in the system. Moreover it can easily be made to meet customer needs by creating specific events tailored to a customer’s requirement. We gladly take any suggestions on further event types at info@pctopp.com or tel. ++49 (911) 994000

New Report on Work in Progress

PcTopp — Mon, 24 Oct 2011 12:22:00 +0200

There is a new report that gives you a detailed overview over the current work in progress for the conversion machines sorted by flute type. The report shows all orders that currently are in production, i.e. not fully finished.

It contains information about previous machine, order start date, article number, board grade, ordered quantity, number of finished goods and sheets, area and weight, with price per piece and value.

That way you can see at a glance where you need to take action to reduce work in progress.

Workaround for PC-Topp.NET Issues Caused by Internet Explorer 9 Memory Problem

PcTopp — Tue, 18 Oct 2011 16:25:52 +0200

As a temporary workaround for the Internet Explorer 9 memory hogging problem described earlier, PC-Topp Terminal pages will automatically refresh every 60 minutes, causing a momentary flicker, and potentially displaying the start page of the terminal (and not the page that was last being viewed). We do however watch out for ongoing user interaction and delay the refresh until we are have not seen any user interaction with the page for a reasonable time.

This workaround now makes it possible to use Internet Explorer 9 with PC-Topp's terminal pages without suffering the effects of long term memory loss inside Internet Explorer 9.

However, any other problems Internet Explorer 9 still has will not disappear with this trick, so users may still experience browser failures and similar effects in PC-Topp under IE9, the same effects Internet Explorer 9 users experience in popular Internet services like Google's www.gmail.com.

Optional Automatic Sign-In for Crew Leaders

PcTopp — Mon, 17 Oct 2011 10:46:00 +0200

From now on PC‑Topp can automatically sign in the crew leader at the beginning of a shift. This saves him the trouble of having to sign in explicitly which is sometimes forgotten.

This optional feature can be activated in the Dataset Parameters.

PC-Topp.NET Issues Caused By Internet Explorer

PcTopp — Mon, 10 Oct 2011 12:09:34 +0200

Internet Explorer 9

When working with PC-Topp.NET in Internet Explorer 9 you may face difficulties like unexpectedly high memory usage or browser crashes.

These are Internet Explorer 9 specific problems; in Internet Explorer 8 PC-Topp.NET is stable and runs with the usual reliabilty.

Microsoft has admitted the memory hogging problem in Internet Explorer 9 (see http://support.microsoft.com/kb/2572253/en-us); concerning the browser crashes a Microsoft statement is still pending.

Our developers are currently trying to find a workaround. However, in the meantime resp. as long as there is no official Microsoft fix we recommend using PC-Topp.NET with Internet Explorer 8. We will inform you via this blog as soon as there is a solution available.

Internet Explorer Add-Ons

No matter which version of Internet Explorer you are using, Internet Explorer add-ons can cause performance and stability problems in PC-Topp.NET.

Therefore, we advise you to disable all Internet Explorer add-ons like search engine toolbars, social networking tools etc., except those you absolutely need.

You can find instructions on how to disable add-ons here:
http://windows.microsoft.com/en-US/windows-vista/Internet-Explorer-add-ons-frequently-asked-questions

Downtime Cause Analysis Report

PcTopp — Fri, 30 Sep 2011 11:21:00 +0200

The Downtime Cause Analysis report offers a graphical overview of a selected downtime cause or group on corrugator and conversion machines during a selectable period, including figures as well as total and average downtime duration. It can be grouped by shift, day, week or month. You can select either one specific downtime cause or a group of downtime causes to be displayed.

New Reports on Machine and Crew Leader Performance

PcTopp — Tue, 27 Sep 2011 15:30:00 +0200

For getting a better overview of the overall performance of machines and crew leaders the following four new reports have been implemented:

Overall Machine Performance

This report shows performance indicators by machine over a period of one year, with performance per month, totals, and target for the selected year. Performance diagrams illustrate the figures.

Overall Machine Performance by Crew Leader

This report is almost identical to the Overall Machine Performance report but it additionally shows figures for the crew leaders.

Overall Crew Leader Performance

The Overall Crew Leader Performance report shows performance indicators by crew leader for the selected period compared with average values since the beginning of the year. The report contrasts the crew leader’s monthly performance values with the average of the year. Graphical indicators show if the crew leader performance has improved or changed for the worse.

Protect Yourself from Damages Claims with Safety Instructions Functionality

PcTopp — Mon, 12 Sep 2011 11:36:00 +0200

Imagine one of the machine operators in your plant has an accident due to issues warned against in the safety instructions provided to the crew. How to prove to your insurance company that he has disregarded or failed to read them?

What It Is Good for

This is where the new Safety Instructions functionality at the PC-Topp.NET Machine Terminal and Multi Machine Terminal comes into play:

It forces crew members who haven't signed in at a machine for a certain period of time to take note of important information (e.g. reminders to wear safety clothes, hints on things to keep in mind or changes in the workflow etc).
It allows you to prove that a crew member has acknowledged important information so you aren't liable for damages incurred through non-observance.

How It Works

If a crew member who hasn’t signed in at a machine for the specified number of days signs in at the Machine Terminal a dialog prompts him to read the safety instructions for this machine.
This dialog appears if the safety instructions file has been modified, too. Everybody who signs in at the machine for the first time after the modification is prompted to read the changed safety instructions.
At the same time the feature demands confirmation by a superior that the person in question has done so, thus guaranteeing that users really view relevant information and don't just skip the dialog.
The Safety Instructions feature is best used in conjunction with the PC-Topp.NET Messaging functionality. It can alert the supervisor by email or text message in real time that a crew member has to read the safety instructions, thereby automatically creating written evidence of the procedure.
Moreover, when the supervisor comes to the workstation of the person in question to give his confirmation he can print out two copies of the safety instructions, have the person in question sign both, and file one copy in the crew member's personal record.

If the new feature is used as outlined above, your personnel is kept up-to-date on important information, and at the same time the fact that staff members have received this information is fully documented to protect you against unjustified claims.

How to Switch It On

To activate this feature you have to:

Upload a safety instructions file to the PC-Topp server via the Machine Settings page (Machine Terminal tab),
Define how much time has to pass after the last sign-in of a crew member for the safety instructions to be displayed (in the DataSet Parameters, Machine Terminal tab).

New Plant Wide Waste Report Available

PcTopp — Mon, 29 Aug 2011 14:02:00 +0200

We have created a new report which summarizes waste by corrugator and conversion machines, with totals for the whole plant.

It gives production key figures and all incurred waste in finished goods and m² or kg, including detailed waste reasons (if configured).

Calculate Exact Die-Cut Waste with New Machine Terminal Option

PcTopp — Fri, 05 Aug 2011 12:27:00 +0200

PC-Topp now gives you close control of the amount of die-cut waste occurred during production at the PC-Topp.NET Machine Terminal.

This optional new feature prompts the user to enter the sheet weight before and after production before allowing him to close an order. From the difference between these two figures you can easily calculate the die-cut waste of this order.

In the production statistics, the die-cut waste appears in the PC-Topp.NET Plant Performance Report.

To enable this feature, some PC-Topp parameters have to be modified so if you want to use it please contact the PC-Topp team.

Capacity Reservations in PC-Topp.NET

PcTopp — Fri, 05 Aug 2011 12:14:00 +0200

In corrugated plants, a high percentage of all orders comes from a small number of customers who place orders in a regular pattern, but often very late, only a short time before production starts.

Obviously, Sales must keep capacity free for those guaranteed orders until they arrive. With Capacity Reservations, the known required capacity can be reserved machine by machine, and the reserved capacity is automatically released when the actual orders arrive. The TGV Machine Load then shows the remaining free capacity for other orders, and does not create a false impression of too little work where machines are actually almost fully loaded.

Capacity Reservations can be made in several different categories:

Customer Reservations are the most relevant of those categories. The system knows the number of hours to be blocked per week (or per day) for each customer and each machine, and automatically applies the same standard reservations for each new week.

Stock Reservations are an example of other categories for which capacity can be reserved.

The Planning Reservation finally allows Planning to keep a safety margin on selected (or all) machines. Contrary to the other reservations, that number of hours is never released automatically, but Planning must do so manually when they feel the time has come.

To let PC-Topp know for which orders it must release a corresponding part of the reservation when the order arrives, the order must be marked by a Reservation Code in the order data transfer. That code can be, for example, S for the Stock Reservations, and C for the Customer Reservations: An order that has a reservation code C for one of the special customers for which there can be reservations (the "Service Customers") reduces the capacity reserved for that customer, an order with an S reserves the Stock Reserve.

(That means that an order for a service customer without the C will not affect the reservation, which is exactly right when a Service Customer places some extra order, which should not reduce the room reserved for the regular orders of that customer.)

The Capacity Reservations page visualizes the reservations and the resulting machine load in a TGV-like timeline as well as in a bar diagram to make it as easy as possible to identify bottlenecks and available capacity.