With a manual scrap counter, you can add manual scrap counting to your automatic sensor-based lines.

The image below shows an example of a sensor-based line where a manual scrap counter has been added on top:

Setting up a manual scrap counter

• Go to Administration > Devices. Find your virtual device by searching for “virtual”. If you don’t see one, contact your local sales person to get one.

Open the virtual device by clicking on it:

• Create a sensor on the device. Wait about 60 seconds for the sensor to be created (refresh the page)

• Once created, you should see your new scrap counter as a sensor:

• To add the scrap counter to a line, go to the line and open up line settings:

• Find the new sensor and add it as an “additional sensor” by pressing it:

• Specify the scrap sensor placement relative to the bottleneck sensor. If you do not specify a placement, the sensor values will not be counted as scrap on the line. Think: Where are you scrapping on the line - is it before or after the bottleneck counter?
• Scrap sensors placed after the bottleneck: The counts made here will be subtracted from the line’s “Produced” as the part was scrapped after it was counted by the bottleneck sensor
• Scrap sensors prior to the bottleneck: Will not affect the “Produced” value.

• Save the line settings and go the register stops tab. Here you should see the new scrap counter.

Scrap reasons

It is possible to use the scrap counter to count scrap reasons. When a counting button is pressed, the operator will be prompted to choose which reason (see image below)

How to add scrap reasons

• To add scrap reasons, simply add more scrap sensors on the virtual device and make sure they are added to the line as scrap in the line settings.
• The system will interpret multiple scrap counters as different reasons for scrap. The name of each sensor will automatically become the name of the scrap reason.

Below, you can see what the line configuration looks like for the scrap reasons shown above

Changing the primary quantity

The primary counting quantity (+1) can be changed depending on the needs of the workstation. This is done by clicking the settings icon on the counter itself

Local Counter Field

When you add a count, it can take up to 30 seconds before it’s visible in any other place in the system (e.g. the LIVE tab or the batch tab). To provide operators with a more user-friendly experience, we have made the counter field (see highlighted on the image below) a local value, meaning that it will show the value changing immediately on the operators' screen. This way, the operator gets real-time feedback on how much has been counted, but the database will only have the value up to 30 seconds later.

The local counter field currently does not show the amount counted within the selected timeframe (as the other KPIs in the system do). It only shows the amount counted since the counter was locally reset. That means that when you reset the counter, the value shown is visually and locally set to 0. This does not delete any data in the database, but is a way for operators to know how much they have produced since the beginning of a shift or batch.

How to undo and edit counts

Press the “EDIT INPUT” button to see previously submitted counts. In the dialog, you can change or delete counts. Please note that it may take up to 30 seconds before new data is shown.