How to add a manual scrap counter

Updated July 02, 2026 09:57

SUMMARY

Use this guide to add a manual scrap counter to a sensor-based production line. Manual scrap counters allow operators to record scrap that cannot be detected automatically and optionally categorize it using scrap reasons.

WHEN TO USE THIS

Use this guide if:
- You want operators to manually record scrap.
- Your production line already uses an automatic bottleneck sensor.
- You want to track scrap reasons during production.

PREREQUISITES

Before starting:
- A virtual device is available in Administration > Devices.
- You have permission to configure devices and lines.
- A production line has already been created.

STEPS

Navigate to Administration > Devices.
Locate your virtual device. If one is not available, you can create one as explained here.
Open the virtual device.
Create a new sensor on the virtual device.
Wait approximately 60 seconds, then refresh the page until the new sensor appears.
Open the production line and access the line settings.
Add the new sensor as an Additional Sensor.
Specify whether the scrap counter is located before or after the bottleneck sensor.
Save the line settings.
Open the Register Stops tab to verify that the manual scrap counter is available.

EXPECTED RESULT

After completing these steps:
- Operators can manually record scrap using the new counter.
- Scrap counts are associated with the production line.
- Scrap is handled according to the configured sensor placement relative to the bottleneck sensor.

TROUBLESHOOTING

Issue: The scrap counter does not appear on the line.

Try: Wait up to 60 seconds after creating the sensor and refresh the page.
Try: Confirm the sensor has been added as an Additional Sensor in the line settings.

Issue: Scrap counts are not affecting the Produced count as expected.

Try: Verify whether the scrap sensor is configured before or after the bottleneck sensor.
Try: Confirm the sensor placement matches where scrap is removed from the production process.

STILL NEED HELP?

Contact Support and include:
- The production line name.
- Whether the scrap counter is configured before or after the bottleneck sensor.
- A screenshot of the line configuration and virtual device.