System User's Guide

Version 4.3x

SYSCON International, Inc. © 2009

 SYSCON - PlantStar
System User's Guide
SYSCON International, Inc.
April 2009

For your reference, our contact information is:

SYSCON - PlantStar
1108 South High Street
South Bend, IN 46601
USA
Phone - (574) 232-3900
FAX - (574) 287-5916
SYSCON-PlantStar Help System

SYSCON International, Inc. © 2009

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indirectly by this document.
Printed: April 2009 in South Bend, IN 46601 USA
 Contents i

1 Welcome to PlantStar ........................ 25

1.1 Getting Started ....................................................................... 26
1.2 PlantStar Products ................................................................. 26
1.3 System Overview ................................................................... 27
1.4 System Features .................................................................... 28
1.5 Features Summary ................................................................. 30
1.6 What’s new in PlantStar 4.20 ................................................. 32
1.7 What's new in PlantStar 4.10.................................................. 33
2 Shop Floor Configuration ................... 36
2.1 File Menu ............................................................................... 36
2.1.1 Save Session 36
2.1.2 Restore Session 36
2.1.3 User Preferences 37
2.1.4 Logout 38
2.1.5 Exit 38
2.2 User Menu.............................................................................. 39
2.2.1 User Accounts 39
2.2.2 User Defined Labels 40
2.3 Sets Menu .............................................................................. 41
2.3.1 Down Reason Sets 41
2.3.2 Assist Reason Sets 42
2.3.3 Reject Reason Sets 43
2.3.4 Boot Sets 44
2.4 Groups Menu ......................................................................... 45
2.4.1 Work Center Setup 45
2.4.2 Display Group Setup 46
2.5 Labor Menu ............................................................................ 48
2.5.1 Labor Setup 48
2.6 Shop Floor Menu .................................................................... 49
2.6.1 Comm Processor Setup 49
2.6.2 DCM Setup 50
2.6.3 Machine Setup 51
2.6.4 REU Setup 53
2.7 Window Menu ........................................................................ 54
2.7.1 Arrange Icons 54
2.7.2 Arrange Windows 54
2.8 Help Menu .............................................................................. 54
2.8.1 Help Contents 54
2.8.2 Help Index 54
2.8.3 Help Search 55
 2.8.4 Help Active Window 55
2.8.5 About PlantStar 55
3 Shop Floor Monitor ............................ 57
3.1 File Menu ............................................................................... 58
3.1.1 User Preference 58
3.1.2 Logout 59
3.1.3 Exit 59
3.2 Monitor Menu ......................................................................... 60
3.2.1 Display Group Status 60
3.2.2 Machine Status 61
3.2.3 Labor Status 62
3.2.4 Exception Summary 63
3.2.5 Production Summary 64
3.2.6 Job Summary 65
3.2.7 Material Usage 66
3.2.8 Pareto/Pie Charts 67
3.2.8.1 Down Pareto / Pie ................................................................................................. 67
3.2.8.2 Assist Pareto / Pie ................................................................................................ 68
3.2.8.3 Reject Pareto / Pie ................................................................................................ 69
3.2.9 Machine Performance 71
3.2.10 Machine Exception 72
3.2.11 Machine Usage73
3.2.12 Machine Log 74
3.2.13 Overlay Profile 75
3.2.14 Process Trend / SPC 77
3.2.15 Process Summary 78
3.3 Schedule Menu ...................................................................... 80
3.3.1 Job Schedule Board 80
3.3.2 Current / Queue Jobs 82
3.3.3 Work Orders 84
3.3.4 Product Standards 86
3.3.5 Shift Schedule 88
3.3.6 Material Forecast 89
3.3.7 Labor Forecast 90
3.3.8 Tool Change 92
3.4 History Menu .......................................................................... 93
3.4.1 SPC History 93
3.4.2 Labor History 94
3.4.3 Material Lot Tracking 96
3.4.3.1 Material Lot Detail................................................................................................. 97
3.4.4 Pareto/Pie Charts 98
3.4.4.1 Down_Pareto_Pie ................................................................................................. 98
3.4.4.2 Assist_Pareto_Pie ................................................................................................ 99
3.4.4.3 Reject_Pareto_Pie .............................................................................................. 100
3.4.5 Down Time Editor 101
3.4.6 Assist Time Editor 102
 Contents iii

3.4.7 Parts Count Editor 103

3.5 Window Menu ...................................................................... 104
3.5.1 Arrange Icons 104
3.5.2 Arrange Windows 104
3.6 Help Menu ............................................................................ 106
3.6.1 Help Contents 106
3.6.2 Help Index 106
3.6.3 Help Search 106
3.6.4 Help Active Window 106
3.6.5 About PlantStar 107
4 Voice Output .................................... 109
4.1 File Menu ............................................................................. 109
4.1.1 Exit 109
4.2 Monitor Menu ....................................................................... 110
4.2.1 Exception Summary 110
4.2.2 Machine Exception 111
4.3 Configure Menu .................................................................... 112
4.3.1 System Parameters 112
4.3.2 Attention Announcement 112
4.3.3 State Announcement 113
4.3.4 Down Announcement 114
4.3.5 Assist Announcement 115
4.3.6 Process Announcement 116
4.3.7 Machine Announcement 117
4.4 Options Menu ....................................................................... 117
4.4.1 Silence Mode 117
4.4.2 Changing Text Sizes 118
4.5 Window Menu ...................................................................... 118
4.5.1 Arrange Icons 118
4.5.2 Arrange Windows 118
4.6 Help Menu ............................................................................ 119
4.6.1 Help Contents 119
4.6.2 Help Index 119
4.6.3 Help Search 119
4.6.4 Help Active Window 119
4.6.5 About PlantStar 120
5 View and Print .................................. 122
5.1 Custom Reports ................................................................... 122
5.1.1 View 122
5.1.2 Schedule 123
5.1.3 Exit 124
 5.2 Help Menu ............................................................................ 124
5.2.1 Help Contents 124
5.2.2 Help Index 124
5.2.3 Help Search 125
5.2.4 Help Active Window 125
5.2.5 About PlantStar 125
6 Design Manager .............................. 128
6.1 Design Manager ................................................................... 129
6.2 Help Menu ............................................................................ 130
6.2.1 About PlantStar 130
6.2.2 Exit 130
7 DCM Browser Interface .................... 132
7.1 Menu Frame ......................................................................... 133
7.1.1 Machine Navigation 134
7.1.2 Child Navigation 134
7.1.3 Menu Clock 134
7.1.4 Logo Link 134
7.2 Main Frame .......................................................................... 135
7.2.1 Job Summary 135
7.2.2 Down Select 136
7.2.3 Assist Select 138
7.2.4 Reject Update 138
7.2.5 Process Summary 141
7.2.5.1 Process Select .................................................................................................... 142
7.2.5.2 Process Table ..................................................................................................... 143
7.2.5.3 Process Graph .................................................................................................... 144
7.2.5.4 Process SPC ...................................................................................................... 144
7.2.5.5 Profile Tiled ......................................................................................................... 146
7.2.5.6 Profile Overlay .................................................................................................... 146
7.2.5.7 Profile Cross ....................................................................................................... 147
7.2.5.8 Profile Store ........................................................................................................ 149
7.2.5.9 SQC Sample ....................................................................................................... 150
7.2.6 Production Summary 151
7.2.6.1 Job Setup ........................................................................................................... 152
7.2.6.2 Job Update ......................................................................................................... 153
7.2.6.3 Labor Login ......................................................................................................... 154
7.2.6.4 Material Lot ......................................................................................................... 156
7.2.6.5 Machine Logs ..................................................................................................... 158
7.2.7 Journals 159
7.3 Lights Frame ........................................................................ 159
8 System Administration ..................... 161
8.1 Configuring the Host ............................................................. 161
8.1.1 Software Configuration 161
8.2 Administering the Host ......................................................... 166
8.3 Archiving Data ...................................................................... 171
 Contents v

8.4 Backing Up the System ........................................................ 174

8.5 Host Log Files ...................................................................... 176
8.6 Software Upgrades............................................................... 177
8.7 Product Standards Import..................................................... 178
8.8 Work Orders Import .............................................................. 179
8.9 Production and/or Process Data Export................................ 179
8.10 Job Schedule Data Export .................................................. 180
8.11 Material Lot Data Export ..................................................... 181
9 Knowledge Base ............................. 184
9.1 Application Notes ................................................................. 184
9.2 Arranging Windows and Icons .............................................. 186
9.2.1 Arange Icons 186
9.2.2 Arrange Windows 186
9.3 Changing View Options ........................................................ 187
9.4 Colors ................................................................................... 187
9.5 Creating Work Orders .......................................................... 188
9.6 FAQ - Frequently Asked Questions ...................................... 188
9.7 Getting A Screen Capture .................................................... 190
9.8 JIT - Product Standard Matching .......................................... 190
9.9 Job Schedule Board Overview ............................................. 190
9.10 Job Scheduling Concepts ................................................... 191
9.11 Loading a Product Standard onto a Job ............................. 194
9.12 Logging into your PlantStar system .................................... 195
9.13 Material Lot Tracking Concepts .......................................... 195
9.14 O.E.E. ................................................................................ 196
9.15 OSI Model .......................................................................... 198
9.16 Process and Production Monitoring .................................... 202
9.17 Saving Jobs as a Product Standard ................................... 205
9.18 Setting up your System ...................................................... 206
9.19 Shift Scheduling ................................................................. 206
9.20 Shop Floor Configuration.................................................... 209
9.21 SPC Statistics Concepts..................................................... 210
9.22 System Architecture ........................................................... 213
9.23 Understanding Machine States........................................... 213
9.24 User Preferences ............................................................... 216
9.25 Using PlantStar Help .......................................................... 217
9.25.1 About PlantStar 217
9.25.2 Help Active Window 217
 9.25.3 Help Contents 218
9.25.4 Help Index 218
9.25.5 Help Search 218
10 Functions ....................................... 220
10.1 Activating an attention announcement ................................ 220
10.2 Adding a DCM .................................................................... 220
10.3 Adding a labor category...................................................... 220
10.4 Adding an employee ........................................................... 220
10.5 Adding an employee to labor history................................... 220
10.6 Adding child jobs ................................................................ 221
10.7 Adding machines to a display group ................................... 221
10.8 Adding machines to an REU list ......................................... 222
10.9 Adding users ...................................................................... 222
10.10 Adding/editing multiple materials ...................................... 223
10.11 Adjusting gross or net pieces............................................ 223
10.12 Adjusting reject counts ..................................................... 223
10.13 Adjusting start/end date .................................................... 223
10.14 Adjusting start/end time .................................................... 223
10.15 Adjusting times ................................................................. 223
10.16 Anchoring selected job ..................................................... 224
10.17 Assigning a report file name ............................................. 224
10.18 Assigning an employee to a labor category ...................... 224
10.19 Assigning child jobs .......................................................... 224
10.20 Assigning weekly schedules ............................................. 225
10.21 Changing a comm processor's name ............................... 225
10.22 Changing a machine's name ............................................ 225
10.23 Changing a report ............................................................. 225
10.24 Changing an existing work center's name ........................ 226
10.25 Changing child jobs .......................................................... 226
10.26 Changing com port settings .............................................. 226
10.27 Changing contact input settings........................................ 226
10.28 Changing display groups .................................................. 227
10.29 Changing down, assist and reject data ............................. 227
10.30 Changing end date ........................................................... 228
10.31 Changing forecast start date............................................. 228
10.32 Changing forecast views .................................................. 228
10.33 Changing general DCM settings ....................................... 229
10.34 Changing graph types ...................................................... 229
10.35 Changing jobs .................................................................. 229
10.36 Changing labor categories ................................................ 229
 Contents vii

10.37 Changing machines .......................................................... 230

10.38 Changing material components ........................................ 230
10.39 Changing number of plotted values .................................. 230
10.40 Changing number of reasons displayed ........................... 230
10.41 Changing number of shifts ................................................ 230
10.42 Changing passwords ........................................................ 230
10.43 Changing preferences ...................................................... 231
10.44 Changing process graph modes ....................................... 231
10.45 Changing process variables name ................................... 231
10.46 Changing profile graph modes.......................................... 231
10.47 Changing profile variables name ...................................... 232
10.48 Changing rescaling options .............................................. 232
10.49 Changing RIO settings ..................................................... 233
10.50 Changing shifts................................................................. 233
10.51 Changing start date .......................................................... 233
10.52 Changing the x-axis .......................................................... 233
10.53 Changing tools ................................................................. 234
10.54 Changing user-defined labels ........................................... 234
10.55 Changing work centers ..................................................... 234
10.56 Clearing machines ............................................................ 234
10.57 Clearing process history information................................. 234
10.58 Clearing search fields ....................................................... 234
10.59 Clipping the graph ............................................................ 234
10.60 Closing the window-Close ................................................ 234
10.61 Closing the window-OK-Cancel ........................................ 235
10.62 Coldstart a DCM ............................................................... 235
10.63 Committing a schedule ..................................................... 235
10.64 Copying a product standard ............................................. 235
10.65 Copying an announcement ............................................... 236
10.66 Creating a comm processor.............................................. 236
10.67 Creating display groups .................................................... 236
10.68 Creating machines ........................................................... 237
10.69 Creating new standards.................................................... 237
10.70 Creating process variables ............................................... 237
10.71 Creating product standards .............................................. 237
10.72 Creating profile variables .................................................. 237
10.73 Creating reason sets ........................................................ 238
10.74 Creating REUs ................................................................. 238
10.75 Creating unassigned child jobs ......................................... 238
10.76 Creating weekly schedules ............................................... 239
10.77 Creating work center schedules ....................................... 239
10.78 Creating work centers....................................................... 239
10.79 Creating work orders ........................................................ 240
10.80 Customizing the work order list......................................... 240
10.81 Deleting a comm processor .............................................. 241
10.82 Deleting a custom report from PlantStar ........................... 241
10.83 Deleting a DCM ................................................................ 242
10.84 Deleting a labor category .................................................. 242
10.85 Deleting a labor record ..................................................... 242
10.86 Deleting a scheduled report .............................................. 242
10.87 Deleting an employee ....................................................... 243
10.88 Deleting display groups .................................................... 243
10.89 Deleting jobs from the schedule board ............................. 243
10.90 Deleting machines ............................................................ 243
10.91 Deleting process variables ............................................... 244
10.92 Deleting profile variables .................................................. 244
10.93 Deleting reason sets ......................................................... 244
10.94 Deleting REUs .................................................................. 245
10.95 Deleting schedules ........................................................... 245
10.96 Deleting unassigned child jobs ......................................... 245
10.97 Deleting users .................................................................. 245
10.98 Deleting work centers ....................................................... 245
10.99 Deleting work orders and product standards .................... 246
10.100 Discarding a schedule .................................................... 246
10.101 Displaying standard spc statistics ................................... 246
10.102 Editing child parameters ................................................. 247
10.103 Editing employee records ............................................... 247
10.104 Editing jobs from the schedule board.............................. 248
10.105 Editing labor categories .................................................. 248
10.106 Editing labor manning factors ......................................... 249
10.107 Editing machine parameters ........................................... 250
10.108 Editing parent parameters .............................................. 250
10.109 Editing process and profile limits .................................... 251
10.110 Editing process variables ................................................ 252
10.111 Editing production parameters ........................................ 253
10.112 Editing profile variables .................................................. 254
10.113 Editing report definitions ................................................. 254
10.114 Editing setup sheets ....................................................... 255
 Contents ix

10.115 Enable a DCM ................................................................ 255

10.116 Enabling a RIO on a machine ......................................... 255
10.117 Exporting data ................................................................ 256
10.118 Forcing a machine down ................................................ 257
10.119 Freezing profiles ............................................................. 257
10.120 Getting a voice file .......................................................... 257
10.121 Identifying machines with Product Standards ................. 257
10.122 Ignore criteria in a report ................................................ 258
10.123 Including boot files from a boot set ................................. 258
10.124 List All product standards ............................................... 258
10.125 Logging in an employee ................................................. 259
10.126 Logging out an employee ............................................... 260
10.127 Moving jobs around the schedule board ......................... 260
10.128 Ordering machines in the list .......................................... 261
10.129 Playing an announcement .............................................. 261
10.130 Printing a report to the screen ........................................ 261
10.131 Rebuilding the display .................................................... 261
10.132 Recalling profiles ............................................................ 261
10.133 Recording an announcement.......................................... 262
10.134 Refreshing the display .................................................... 262
10.135 Refreshing the lists ......................................................... 262
10.136 Removing child jobs from a product standard ................. 262
10.137 Removing child jobs from a work order ........................... 262
10.138 Removing machines from a display group ...................... 263
10.139 Removing machines from a REU list .............................. 263
10.140 Renaming a reason set .................................................. 263
10.141 Resizing columns ........................................................... 263
10.142 Retrieve default product standard ................................... 263
10.143 Saving process variables ................................................ 264
10.144 Saving profile variables .................................................. 264
10.145 Saving reason sets ......................................................... 264
10.146 Saving your changes-Apply ............................................ 265
10.147 Saving your changes-Update ......................................... 265
10.148 Scheduling jobs by due date........................................... 265
10.149 Scheduling jobs by earliest start date ............................. 265
10.150 Scheduling selected jobs by due date ............................ 266
10.151 Search Product Standards ............................................. 266
10.152 Searching for a job ......................................................... 267
10.153 Searching material lots ................................................... 268
10.154 Selecting a machine state .............................................. 268
10.155 Selecting a period interval .............................................. 268
10.156 Selecting a time scale..................................................... 269
10.157 Selecting a year .............................................................. 269
10.158 Selecting criteria for a report........................................... 269
10.159 Selecting current/queue jobs .......................................... 270
10.160 Selecting display groups from the schedule board.......... 270
10.161 Selecting forecast intervals ............................................. 270
10.162 Selecting jobs from the schedule board .......................... 270
10.163 Selecting product standards ........................................... 271
10.164 Selecting Report Criteria ................................................ 271
10.165 Selecting specific machines............................................ 271
10.166 Selecting users ............................................................... 271
10.167 Selecting/viewing tote details.......................................... 272
10.168 Sending a report to the printer ........................................ 272
10.169 Set report to display in HTML format .............................. 272
10.170 Setting down reason flags .............................................. 272
10.171 Setting report criteria ...................................................... 272
10.172 Sorting columns .............................................................. 273
10.173 Storing profiles ............................................................... 274
10.174 Toggling auto size and normal size ................................ 274
10.175 Toggling Process and Profile view .................................. 274
10.176 Toggling tool change view .............................................. 274
10.177 Undoing your changes.................................................... 274
10.178 Updating a comm processor ........................................... 274
10.179 Updating a DCM ............................................................. 274
10.180 Updating default Product Standard ................................. 275
10.181 Updating existing standards ........................................... 275
10.182 Updating machines ......................................................... 275
10.183 Updating schedules ........................................................ 275
10.184 Updating users ............................................................... 276
10.185 Viewing job summary information ................................... 276
10.186 Viewing machine detail ................................................... 277
10.187 Viewing machine exceptions .......................................... 278
10.188 Viewing machine status .................................................. 278
10.189 Viewing min and max values .......................................... 278
10.190 Viewing production hours ............................................... 278
10.191 Viewing the shift schedule .............................................. 278
10.192 Zooming selected profiles ............................................... 279
 Contents xi

11 Glossary ...................................... 281

11.1 Actual multiplier .................................................................. 281
11.2 Actual rate .......................................................................... 281
11.3 Actual setup time ................................................................ 281
11.4 Actual shot weight .............................................................. 281
11.5 ADC option ......................................................................... 281
11.6 Administration privilege ...................................................... 281
11.7 Analog filter ........................................................................ 281
11.8 Analog inputs ..................................................................... 281
11.9 Announce flag .................................................................... 281
11.10 Announce machine flag .................................................... 282
11.11 Announcement delay ........................................................ 282
11.12 Assist state ....................................................................... 282
11.12.1 Assist period 282
11.12.2 Assist reason 282
11.12.3 Assist state colors 282
11.12.4 Assist time 282
11.13 Auto clear flag .................................................................. 282
11.14 Auto logout ....................................................................... 283
11.15 Available triggers .............................................................. 283
11.16 Average cycle ................................................................... 283
11.17 Average value .................................................................. 283
11.18 Backup internet path ........................................................ 283
11.19 Base model ...................................................................... 284
11.20 Baud ................................................................................. 284
11.21 Bias .................................................................................. 284
11.22 Bits ................................................................................... 284
11.23 Block number ................................................................... 284
11.24 Boolean set ...................................................................... 284
11.25 Boot files .......................................................................... 285
11.26 Boot set ............................................................................ 285
11.27 Calendar board................................................................. 285
11.28 CAMAC address............................................................... 285
11.29 Case sensitive matching................................................... 285
11.30 Channel ............................................................................ 286
11.31 Child count ....................................................................... 286
11.32 Child job ........................................................................... 286
11.33 Column number ................................................................ 286
11.34 Comm port ....................................................................... 286
11.35 Comm option .................................................................... 286
11.36 Comment.......................................................................... 286
11.37 Communications processor .............................................. 286
11.38 Component percent .......................................................... 287
11.39 Contact duration ............................................................... 287
11.40 Contact input .................................................................... 287
11.41 CONV_VEC#.................................................................... 287
11.42 Convert index ................................................................... 287
11.43 Cost per hour.................................................................... 288
11.44 Cp .................................................................................... 288
11.45 Cpk ................................................................................... 288
11.46 Critical process variable ................................................... 288
11.47 Current job ....................................................................... 288
11.48 Current shift ...................................................................... 288
11.49 Currently running jobs privilege ........................................ 288
11.50 CV .................................................................................... 288
11.51 Cycle time ........................................................................ 288
11.52 Cycle tolerance................................................................. 288
11.53 Cycle window ................................................................... 289
11.54 Data number .................................................................... 289
11.55 Date range scheduled usage ............................................ 289
11.56 Date range usage ............................................................. 289
11.57 DCM ................................................................................. 289
11.58 DCM base address ........................................................... 289
11.59 Debounce ......................................................................... 289
11.60 Decimals .......................................................................... 290
11.61 Delay Timer ...................................................................... 292
11.62 Derivative ......................................................................... 292
11.63 Derivative smoothing ........................................................ 292
11.64 Descriptor ......................................................................... 292
11.65 Device address................................................................. 292
11.66 Digital inputs ..................................................................... 292
11.67 Display group ................................................................... 292
11.68 Display option ................................................................... 292
11.69 Display type ...................................................................... 293
11.70 Down state ....................................................................... 293
11.70.1 Down cycles 293
11.70.2 Down period 293
11.70.3 Down reason 293
 Contents xiii

11.70.4 Down state colors 293

11.70.5 Down threshold 294
11.70.6 Down time 294
11.71 Drag and drop options ...................................................... 294
11.72 Duration............................................................................ 294
11.73 Element number ............................................................... 295
11.74 Embedded matching......................................................... 295
11.75 Employee id ..................................................................... 295
11.76 Employee name ............................................................... 295
11.77 End date ........................................................................... 295
11.78 End time ........................................................................... 295
11.79 Estimated completion time ............................................... 295
11.80 Event type ........................................................................ 296
11.81 Exact matching ................................................................. 296
11.82 Exception state ................................................................. 296
11.83 Exception time .................................................................. 296
11.84 Excess material ................................................................ 296
11.85 Exit privilege ..................................................................... 296
11.86 Extended down and reject reasons .................................. 296
11.87 Family job ......................................................................... 296
11.88 Fast state ......................................................................... 296
11.89 File number ...................................................................... 297
11.90 File type............................................................................ 297
11.91 FN code............................................................................ 297
11.92 Force down flag ................................................................ 297
11.93 Force scrap flag................................................................ 297
11.94 Forecast interval ............................................................... 298
11.95 Forecast types .................................................................. 298
11.96 Free text ........................................................................... 298
11.97 Full access privilege ......................................................... 298
11.98 Gain ................................................................................. 298
11.99 Gross pieces .................................................................... 298
11.100 High value ...................................................................... 298
11.101 Higher limit ..................................................................... 298
11.102 Historical job ................................................................... 298
11.103 Historical shift ................................................................. 298
11.104 Hours to go ..................................................................... 298
11.105 Hours worked ................................................................. 299
11.106 HTML ............................................................................. 299
11.107 Identifier ......................................................................... 299
11.108 Idle period ...................................................................... 299
11.109 Idle state......................................................................... 299
11.110 Idle time.......................................................................... 299
11.111 Ignore cycle flag ............................................................. 299
11.112 Index number (JSW source type) ................................... 299
10.113 International support ....................................................... 300
11.114 IP address ...................................................................... 300
11.115 Isolated A to D ................................................................ 300
11.116 Job ................................................................................. 300
11.116.1 Job board 300
11.116.2 Job changes 301
11.116.3 Job history size 301
11.116.4 Job key 301
11.116.5 Job name 301
11.116.6 Job parameters 301
11.116.7 Job primary label 301
11.116.8 Job start time 301
11.116.9 Job-to-date 301
11.117 Job queue ...................................................................... 301
11.118 Job queue size ............................................................... 301
11.119 Job Summary - graph view ............................................. 302
11.120 Job Summary - grid view ................................................ 302
11.121 Labor category ............................................................... 303
11.122 Labor data privilege ........................................................ 303
11.123 Labor Forecast - graph view ........................................... 303
11.124 Labor Forecast - grid view .............................................. 303
11.125 Labor history size ........................................................... 304
11.126 Language ....................................................................... 304
11.127 Last value ....................................................................... 304
11.128 Left matching .................................................................. 304
11.129 Linearization type ........................................................... 305
11.130 Login privilege ................................................................ 305
11.131 Lot end time ................................................................... 305
11.132 Lot start time................................................................... 305
11.133 Low value ....................................................................... 305
11.134 Lower limit ...................................................................... 305
11.135 Lower spec ..................................................................... 305
11.136 Machine.......................................................................... 305
11.136.1 Machine cycle .............................................................. 306
 Contents xv

11.136.2 Machine index 306

11.136.3 Machine parameter 306
11.136.4 Machine running state 306
11.136.5 Machine state 306
11.136.6 Machine state colors 306
11.136.7 Machine usage 308
11.137 Maintenance job ............................................................. 308
11.138 Manning factor................................................................ 308
11.139 Material component ........................................................ 308
11.139.1 Material formula 308
11.139.2 Material lot history size 309
11.139.3 Material lot ID 309
11.139.4 Material name 309
11.139.5 Material required 309
11.139.6 Material used 309
11.140 Max assist time ............................................................... 309
11.141 Max cycle time................................................................ 309
11.142 Maximum family size ...................................................... 310
11.143 Memory .......................................................................... 310
11.144 Memory area .................................................................. 310
11.145 Memory required ............................................................ 310
11.146 Module address .............................................................. 310
11.147 Monitor number .............................................................. 310
11.148 Moving average cycle ..................................................... 310
11.149 Multiple login .................................................................. 310
11.150 Net parts counting .......................................................... 310
11.151 Net parts multiplier ......................................................... 311
11.152 Net pieces ...................................................................... 311
11.153 No access privilege ........................................................ 311
11.154 Non-family job ................................................................ 311
11.155 Offline state .................................................................... 311
11.156 One RIO for all machines ............................................... 311
11.157 Operator efficiency ......................................................... 312
11.158 Operator start options ..................................................... 312
11.159 Operator utilization ......................................................... 312
11.160 Ordered histogram ......................................................... 312
11.161 Other status .................................................................... 312
11.162 Overrun .......................................................................... 312
11.163 Parameter number ......................................................... 312
11.164 Parameter type ............................................................... 312
11.165 Part weight ..................................................................... 313
11.166 Parts per minute ............................................................. 313
11.167 Percent down ................................................................. 313
11.168 Percent process exception ............................................. 313
11.169 Percent production exception ......................................... 313
11.170 Percent rejects ............................................................... 313
11.171 Percent slow cycles ........................................................ 313
11.172 Percent variance ............................................................ 313
11 .173 Pieces required ............................................................. 313
11.174 Pieces to go ................................................................... 313
11.175 PLC ................................................................................ 314
11.176 Polarity ........................................................................... 314
11.177 Port number.................................................................... 314
11.178 Post-down delay ............................................................. 314
11.179 Primary contact .............................................................. 314
11.180 Primary internet path ...................................................... 314
11.181 Print reports privilege...................................................... 314
11.182 Process trend privilege ................................................... 315
11.183 Process variable ............................................................. 315
11 .183.1 Process exception 315
11.183.2 Process exception state colors 315
11.183.3 Process index 316
11.183.4 Process log 316
11.183.5 Process variable parameter 316
11.184 Product ........................................................................... 316
11.184.1 Product parameter 316
11.184.2 Product key 316
11.185 Product standard ............................................................ 316
11.186 Product standard privilege .............................................. 317
11.187 Production data .............................................................. 317
11.188 Production efficiency ...................................................... 317
11 .189 Production exception ..................................................... 317
11.189.1 Production exception state colors 317
11.190 Production performance ................................................. 317
11.191 Production time .............................................................. 318
11.192 Profile ............................................................................. 318
11.192.1 Profile parameter 318
11.192.2 Pseudo end 318
11.192.3 Pseudo start 318
11.192.4 Pseudo variable 318
11.193 PVAR History ................................................................. 318
 Contents xvii

11.194 Queued job ..................................................................... 318

11.195 RAM size ........................................................................ 319
11.196 Range............................................................................. 319
11.196.1 Range control limits 319
11.196.2 Range max 319
11.196.3 Range mean 319
11.196.4 Range min 319
11.197 Real-time ........................................................................ 319
11.198 Reason set ..................................................................... 319
11.199 Re-feed runners ............................................................. 320
11.200 Re-feed scrap ................................................................. 320
11.201 Register number ............................................................. 320
11.202 Reject reason ................................................................. 320
11.202.1 Reject count 320
11.202.2 Reject exception 320
11.202.3 Reject multiplier 320
11.202.4 Reject percent 320
11.202.5 Reject threshold 320
11.202.6 Reject state colors 320
11.203 Required by .................................................................... 321
11.204 REU ............................................................................... 321
11 .205 RIO ................................................................................ 321
11.206 Running state ................................................................. 321
11.206.1 Running state colors 321
11 .207 Scale factor ................................................................... 322
11.208 Schedule factory ............................................................. 322
11.209 Schedule jobs and shifts privilege .................................. 323
11.210 Schedule now ................................................................. 323
11.211 Schedule reports privilege .............................................. 323
11.212 Schedule selected job by due date ................................. 323
11.213 Scheduled idle time ........................................................ 324
11.214 Scheduled jobs ............................................................... 324
11.215 Scheduled machine usage ............................................. 324
11.216 Scheduled up time .......................................................... 324
11.217 Set name ........................................................................ 324
11.218 Setup sheet .................................................................... 324
11.219 Setup time ...................................................................... 324
11.220 Shift ................................................................................ 324
11.220.1 Shift count 324
11.220.2 Shift history size 325
 11.220.3 Shift ID 325
11.220.4 Shift idle period 325
11.220.5 Shift length 325
11.220.6 Shift schedule 325
11.220.7 Shift-to-date 325
11.221 Shop floor privilege ......................................................... 325
11.222 Shot size ........................................................................ 325
11 .223 Shuttle boot set ............................................................. 325
11.224 Slow state ....................................................................... 326
11.225 Source ............................................................................ 326
11.226 SPC ................................................................................ 326
11.226.1 SPC alarms 326
11.226.2 SPC Graph Area 326
11.226.3 SPC history size 326
11.226.4 SPC interval 327
11.226.5 SPC subgroup 327
11.226.6 SPC subgroup size 327
11.227 Specification limits .......................................................... 327
11.228 Standard completion time ............................................... 327
11.229 Standard cycle................................................................ 327
11.230 Standard deviation ......................................................... 327
11.231 Standard multiplier ......................................................... 327
11.232 Standard production time ............................................... 327
11.233 Standard rate.................................................................. 328
11.234 Standard rate factor ........................................................ 328
11.235 Standard setup time ....................................................... 328
11.236 Standard shot weight ...................................................... 328
11.237 Start date ........................................................................ 328
11.238 Start time ........................................................................ 328
11.239 Suspend ......................................................................... 328
11.240 Switch code .................................................................... 328
11.241 System icon .................................................................... 328
11.242 Tool ................................................................................ 329
11.243 Total cycles .................................................................... 329
11.244 Total rejects .................................................................... 329
11.245 Tote box ......................................................................... 329
11.245.1 Tote box size 329
11.245.2 Tote end time 329
11.245.3 Tote history size 329
11.245.4 Tote ID 329
11.245.5 Tote pieces 330
11.245.6 Tote reject 330
 Contents xix

11.245.7 Tote start tim330

11.246 Trigger delay .................................................................. 330
11.247 Trigger event .................................................................. 330
11.248 Ty-Decimal ..................................................................... 330
11.249 Unassigned child jobs..................................................... 330
11.250 Units ............................................................................... 330
11.251 Up cycles ........................................................................ 331
11.252 Up time ........................................................................... 331
11.253 Upper spec ..................................................................... 331
11.254 User name ...................................................................... 331
11.255 Value .............................................................................. 331
11.256 Variable long name......................................................... 331
11.257 Variable short name ....................................................... 331
11.258 View only privilege .......................................................... 331
11.259 Voice file name ............................................................... 331
11.260 Weekly schedules list ..................................................... 331
11.261 Weekly shift chart ........................................................... 331
11.262 Weight per part ............................................................... 332
11.263 Work center .................................................................... 332
11.264 Work order ..................................................................... 332
11.265 Work order privilege ....................................................... 332
11.266 X-axis ............................................................................. 332
11.267 X-axis Value ................................................................... 332
11.268 X-bar .............................................................................. 332
11.268.1 X-bar Control Limits332
11.268.2 X-bar Max 332
11.268.3 X-bar Mean 332
11.268.4 X-bar Min 332
11.269 Y-axis ............................................................................. 333
12 Release Notes ............................... 339
13 Technical Support Contact ............. 368
SYSCON - PlantStar System
User's Guide

Part

I
 Welcome 25

1 Welcome to PlantStar

SYSCON-PlantStar produces four levels of shop floor data collection systems. These
systems are sized and targeted to meet customer's needs. For additional information about
these levels see on line help.

The goal of your PlantStar system is to provide you with a data collection and monitoring
apparatus that enables you to make informed decisions on the factory floor in Real-Time. It
defines the shop floor, schedules jobs on the floor, and monitors those jobs.
There are a number of PlantStar applications within your system:

· Shop Floor Configuration - The Shop Floor Configuration program enables you to
define the physical descriptions of machines on the shop floor in terms of down
reasons, reject reasons, assist reasons, display groups, and data collection modules
(DCMs). Once defined, these shop floor characteristics provide the foundation upon
which jobs are scheduled. The Shop Configuration program also lets you define
users, their privileges and passwords.
· Shop Floor Monitor - The Shop Floor Monitor program provides information on
current shop floor activity. Within Monitor, real-time monitoring is presented as a
"moving window" of recent events. Information on the current shift, the current job,
or the most recent machine cycle is presented in a variety of windows. A scheduling
component, accessible through the SCHEDULE menu, utilizes the Shop
Configuration program's definitions in order to facilitate planning activities. These
planning activities take the form of job scheduling. Jobs, their priorities and
placement in a job queue, provide the work schedule for the shop floor.
· Browser Interface - All the shop-floor information is available throughout the plant
(and even the world, if so configured) through any computer with a Firefox browser
and a network connection. This functionality gives end users the ability to monitor
specific machines from remote locations. It also enables machine operators to
access multiple machines from a single location.
· Label Printing - A PlantStar system (option for Snapshot and above) configured with
the print option can be used to create and print labels at the production machine.
· Voice Output - A PlantStar system (option for Snapshot and above) configured with
the Voice Output Option is able to broadcast messages relating to currently monitored
exception conditions such as Down, Idle, Fast, Slow, and Production Exception.
These messages can be heard on speakers or public address systems.
· Family Molding - A PlantStar system (option for Snapshot and above) configured
with the Family Molding software can add to your ability to track multiple cavity jobs
or other parallel processes.
· Process Journal - A PlantStar system (option for Snapshot and above) configured
with the Process Journal software can track any changes made to the system on the
shop floor. Supports 21CFR1 1 data recording.
· View and Print - The View and Print program provides up-to-date shift and job
history information in the form of on-line and paper-generated reports. Your system
26 SYSCON-PlantStar Help System

provides a variety of pre-existing reports from which to choose.

· Design Manager - The Design Manager program is an add-on feature for your
system that enables you to create your own reports. The Custom Reports
Manager program transfers custom reports designed in Crystal Reports into
PlantStar. It provides editing capabilities for these reports, deletion capabilities,
and provides for the selection of report search criteria.

1.1 Getting Started

The goal of your PlantStar system is to provide you with a data collection and monitoring
apparatus that enables you to make informed decisions on the factory floor in Real-Time. It
defines the shop floor, schedules jobs on the floor, and monitors those jobs.

What do you want to know about?

System Overview
Logging into your PlantStar system
Setting up your System
Shop Floor Configuration
Shift Scheduling Concepts
Job Scheduling Concepts
Monitoring Concepts
Material Lot Tracking Concepts
Technical Support
FAQ

1.2 PlantStar Products

SYSCON-PlantStar produces four levels of shop floor data collection systems. Two of these
systems support plant floor production information and two support both production and
process information. These systems are sized and targeted to meet customer's needs.

QUICKSHOT – a basic system that supports 12 to 48 production machines; used by

manufacturers interested in basic shop-floor metrics; twenty pre-configured reject and down
reasons; very limited upgrade capability.
SNAPSHOT - an upgradeable, mid-entry level system for shop-floor production information
commonly used as a starting point by many manufacturers interested in basic shop floor data
metrics.

PORTRAIT - our medium-sized company product; an expansion to the SnapShot

environment that incorporates many new functions not available in SnapShot such as
SPC data collection.

PANORAMA - our enterprise level product that is commonly used to integrate multi-site, multi-
process environments; used by manufacturers to organize all of their world wide manufacturing
assets under one system.
 Welcome 27

Our contact information is:

SYSCON-PlantStar
1108 South High Street
South Bend, IN 46601 USA

Phone - 574-232-3900
FAX - 574-287-5916
For more information visit us on the web at www.plantstar.org.

1.3 System Overview

The goal of your PlantStar system is to provide you with a data collection and monitoring
apparatus that enables you to make informed decisions on the factory floor in Real-Time. It
defines the shop floor, schedules jobs on the floor, and monitors those jobs.

PlantStar Applications
There are five primary PlantStar applications within your system:

· Shop Floor Configuration - The Shop Floor Configuration program enables you to
define the physical descriptions of machines in terms of down reasons, reject reasons,
assist reasons, boot sets, display groups, DCMs, and communications processors. Once
defined, these shop floor characteristics provide the foundation upon which jobs are
scheduled. The Shop Floor Configuration program also lets you define users, their
privileges and passwords.
· Shop Floor Monitor - The Shop Floor Monitor program provides information on current
shop floor activity. Within Monitor, real-time monitoring is presented as a "moving window"
of recent events. Information on the current shift, the current job, or the most recent
machine cycle is presented in a variety of windows. A scheduling component, accessible
through the Schedule menu, utilizes the Shop Floor Configuration program's definitions
in order to facilitate planning activities. These planning activities take the form of job
scheduling. Jobs, their priorities and placement in a job queue, provide the work schedule
for the shop floor.

· Voice Output - A PlantStar system configured with the Voice Output option is able to
broadcast messages relating to currently monitored exception conditions such as Down,
Idle, Fast, Slow, and Production Exception. These messages can be heard on speakers
or public address systems.

· Print and View Reports - The Print and View Reports program provides up-to-date
shift and job history information in the form of on-line and paper-generated reports. Your
system provides a variety of pre-existing reports from which to choose.

· Design Manager - The Design Manager program is an add-on feature for your system,
which enables you to create your own reports. The Custom Reports Manager program
transfers custom reports designed in Crystal Reports into PlantStar. It provides editing
capabilities, deletion capabilities, and provides for the selection of report search criteria.
Each of these components includes numerous windows that display and manipulate
28 SYSCON-PlantStar Help System

shop floor information.

1.4 System Features

There are many features included within your system. Some systems have optional
features configured at the time of purchase. Most of these options can be added to any of
our process-level products: Portrait or Panorama. The descriptions that follow are brief
summaries. Within the operational sections of this document, you'll find more detail on how
the specifics of the optional feature works in your system.
High Speed Profile - HSPO
This option allows collection and display of high speed process variable profiles. These
profiles are displayed in line graph format. Up to four profiles can be displayed
simultaneously. This allows analysis of interdependent process phenomena and analysis
of potential to optimize the process.
Statistical Process Control - SPC
A simple to use analytical tool is available in this option. It allows process variable
summary display (average, last, low values), process variable history display (table, graph,
X bar & R bar charts), averages and exceptions. A more advanced third party SPC
package is an available option.
Sound Track Automated Public Address - VOO
Sound Track alarms and events to be announced automatically over the plant public address
system. Messages are custom recorded by the system owner and can be tailored to the
operations and terminology used in the plant. Voice PC not included.

Single Material Lot Tracking - MATL-LOT/S

Single Material Lot Tracking allows tracking of consumption of one material per machine
using the operator input at a touch screen DCM. The lot number identifies the material.
Consumption tracking, is supported and forecasting is enabled as well.

Multiple Material Tracking - MULT-MTL

Multiple materials (up to four) can be tracked with this option. Use of each material can be
tracked and forecasting of material demand is supported to improve operations and control.
Multiple Material/Multiple Lot Tracking - MAT-LOT/M
Up to four component materials and four lot numbers can be tracked with this option. Use of
each material and lot can be tracked and forecasting of material demand is supported to
improve operations and control.
Labor Tracking - LBR-TRKG
Labor tracking is designed to forecast, collect, and report labor hours by machine, job, shift
or employee. Labor is collected and tracked by personnel logging in and out at a DCM.
Login/logout can be; RFID, barcode, or manual touch screen entry. The same person or
people may be logged onto one or many machines at the same time depending on the work
being done. For these reasons, it is not a time and attendance system. It will provide a
window to where and how labor is used on the shop floor. It can also report time spent at the
machine by support personnel. As a job history is developed the job history labor reports can
be used to forecast staffing requirements on a shift or weekly basis.
Process Journals - PRO-JOURN
 Welcome 29

This feature adds to our already extensive web browser interface to allow operators and
shop floor people to record problems and corrective actions. This feature is used in
conjunction with our labor tracking option. The data is time-stamped and associated with an
individual job, shift and employee. It also has an all browser based user interface so anyone
on your network will be able to view the data.
Machine Control Data Interface - (MODL)-I/F
This option provides a special data interface between a machine equipped with a data port
from the control system to the DCM. The DCM, depending on the capabilities of the
machine's control system to generate the data, can collect temperatures and other process
parameters. Additional sensors are not required for monitoring purposes for the parameters
delivered by the machine's serial data port. Currently, SYSCON-PlantStar has interfaces for
Allen Bradley PLC5, Advantech DL06, Arburg Selogica, Cincinnati Camac VLC/VEL,
Cincinnati Camac VSX Century Controller/486/ XLT, Cincinnati Camac XTA, Cincinnati
Milacron Roboshot (SPI or OPC), Cincinnati Milacron Xtreem/Mosaic , Van Dorn CRT-C,
Engel CC-80/CC-90/EC-88/CC-100, HPM CMD-III/CMD-90, Husky OI TCP/IP, JSWuPACS-
3000/uPACS-5000, Maco 4000, 6000, Maco 8000, Netstal Sylink (Sijaard card), Nissei
NC9300T, OPC Clients, SPI interface, Van Dorn Pathfinder (Siemens 1 15u), RKC
F900/F400, Square D Powerlogic Series 2000 SY/Max 802.3 Protocol, TI 545, Toshiba
Injectvisor 5 series/10 series, Toshiba V10.V21/V30, Toyo PLCS Part-6, Battenfeld Unilog
9000 B, Kawaguchi B & B2, Hekuma, and more are added regularly.
Gauge Interface - GAGE-I/F
Currently, SYSCON-PlantStar has interfaces for A&D Companies EK-G or EW-G series
scales, AC 9000, Beta Tech MiniMUX, Branson, Kaman Kuda, Ohaua Trooper, Peet
Brothers Ultimeter 2100, Sartorius QC series The DCM can be equipped with serial
communications compatible with a wide variety of digital gage equipment. Measurements
can be made with the gauge and tabulated by the system allowing reports and analysis of
dimensional data along with process variable measurements.
Printer Interface –
Currently, SYSCON-PlantStar has interfaces for Zebra tote label printers, HP laser
printers, and all printers supported by T-Former software.

Scale Interface - SCALE-I/F

The DCM can be equipped with serial communications compatible with a wide variety of
digital weigh scale equipment. Measurements can be made with the weigh scale and
tabulated by the system allowing reports and analysis of part weight data along with process
variable measurements.
Other Interface
Interfaces to moisture meters, humidity sensors, etc. also have been written.
Set-Up Sheet Software - SET-UP
Hard copy set up sheets can be replaced by this software option. The option allows set-up
instructions to be typed into the system and displayed at a touch screen DCM for each job to
be run at a specific machine. Questions about how to set up specific jobs will be put to an
end.

Bar Code Interface - BAR-COD

The interface between the DCM and bar code printer is enabled by this option. Labels can
be printed out by the system according to a variety of requirements. Integration of the
30 SYSCON-PlantStar Help System

TFORMer runtime package allows for rapid development of customized labels. Separate
purchase of the Windows- based TFORMer Designer package gives the user the ability to
create label templates for use with PlantStar, and to print labels independently. A Bar Code
printer may be connected to the DCM by either a serial or USB port. Bar Code Printer not
included.

Interface to DataStream MP2 Software - MP2 I/F

Interface enabling data exchange between the system and DataStream MRP2 production
planning software. A fully integrated system that enables both production monitoring and
production planning is ensured with this option and the emplacement of the DataStream
software.
Remote Modem and Set-Up Service - REMOTE-ACC
To provide remote data access or remote log-on, this option can be selected. It consists of
two modems and set-up service from SYSCON-PlantStar. Minimum personal computer
configuration requirements apply and the customer must provide direct telephone line
access to the modem at the plant site.
Shot Tracker - SHOT-TRACK-2
Shot by shot archiving of all data collected for every shot. This feature does not provide tools
to sort or analyze the data collected. The user must use a database tool such as ACCESS to
analyze the collected data.
Host E-mail capabilities –
We have added a new feature to our host that allows the system to send e-mails from most
programs running on the PlantStar server. We can configure this program to send information
to any e-mail address in your domain. The e-mails that can be sent include success/failure of
any automated tasks like backups, imports, and exports. We can, if requested, have an e-mail
address created so these messages can be forwarded to PlantStar customer support. Our
support department can use this information about your server status to provide you more
timely and proactive system support.
Backup
The system is normal backed up by FTP transferring of files to a customer supplied file server.
Optionally a CD or CDRW drive can be supplied with the PlantStar host for backup purposes.

1.5 Features Summary

Welcome 31
32 SYSCON-PlantStar Help System

1.6 What’s new in PlantStar 4.20

PlantStar 4.20 has incorporated many new features including:

· Process Journaling - This feature adds to our already extensive web browser interface to
allow operators and shop floor people to record problems and corrective actions. This
feature is used in conjunction with our labor tracking option. The data is time-stamped and
associated with an individual job, shift and employee. It also has a totally browser-based
user interface. So anyone on your network will be able to view the data.
· RTLDCM Flash Drives - The RTL based data collection modules now come in a diskless
version. This feature uses flash memory cards instead of a hard drive. Hard drives are
susceptible to mechanical failure and we have eliminated the problem of hard drive
failure by removing the hard drive. The flash drive allows for thousands of read/writes
before needing replacement. In addition, replacement flash cards can be made for a
fraction of the cost of a hard drive.

· Journaling File System - The structure of the data contained on the flash/hard drive
has, in the past, been prone to data corruption. We have found that in almost all cases
the corruption can be traced to a power failure or inappropriate shutdown of the data
collection module. We have converted from the Linux based EXT2 file system to the
newer Reiser journal file system. This new file system will automatically restore itself to
its previous state in the event of an uncontrolled shutdown.
· Host E-mail capabilities - We have added a new feature to our host that allows us to send
e-mails from most programs running on the PlantStar server. We can configure this
program to send information to any e-mail address in your domain. The e-mails that can be
sent include success/failure of any automated tasks like backups, imports, and exports. We
can, if requested, have an e-mail address created to forward these messages to PlantStar
customer support. Our support department can use this information about your server
status to provide you more timely and proactive system support.
· Import/Export Options - PlantStar has extended its options for importing and exporting
data to ERP systems. We now provide multiple machine specific standards to be imported
in any one import file. Our end-of-shift export utility can now notify you of any machines that
have failed to report the end-of-shift event. This is usually a sign of network problems
between the host and the data collection module. In conjunction with the previous feature,
we can export only data for late reporting machines. So once the initial communications
problem has been resolved, the data that was missed in the first end-of-shift will be
exported. Our export utility can now be set to perform an incremental export. That is,
instead of one export per shift, it can now do an export on a set interval. This will allow your
ERP system to more accurately reflect the current production status of your shop floor.
· Automated Archiving - The archiver program can now be automated to perform an
archive at set interval. For instance you can maintain a six-month record active in the
PlantStar database by setting the archiver to run once a month. The archiver program will
store the archived data on the PlantStar server or FTP it to a location of your choice.
Eliminating the delay associated with archiving multiple months worth of data after a
performance decrease has been noted.

· Labor Required Displayed on the Schedule Board - If you have purchased the labor
tracking option, the total labor hours required for a given shift can be displayed on the
 Welcome 33

Job Schedule Board. This option can be enabled from the User Preferences screen
in the Monitor program.
· Maco 6000 Host Interface - PlantStar has expanded its already extensive collection of
machine interfaces by providing support for the Maco 6000 host interface. The protocol
uses 485 based serial communications to collect process data direct from the machine's
controller.
· International Support - The date, currency, and decimal numeric fields used for input
and display in all PlantStar monitor screens and reports now use the locale settings that
have been configured in Windows control panel.
· Crystal Reports v11.0 - All PlantStar reports have been updated to the latest version
of Crystal Reports. This makes integrating your own custom reports even easier.

· Voice Program - PlantStar's voice program has been modified to eliminate delays in
making announcements. Now when any event occurs that requires a voice announcement,
the response will be immediate.

1.7 What's new in PlantStar 4.10

PlantStar 4.10 has many new and exciting features, including:

· Family Tooling - Family Tooling is designed to allow the collection and tracking of data
by child job. Management will receive a much more detailed picture of production, rejects,
history, and pieces made for each family job. Family Tooling allows up to twelve child
jobs running, at one time, on a machine.
· Labor Tracking - Labor Tracking is designed to forecast, collect, and report labor hours
by machine, job, shift, or employee. Labor is collected and tracked by personnel logging in
and out at a DCM. The same person or people can be logged onto one or many machines
at the same time depending on the work being done. For this reason, it is not a time and
attendance system. It will provide a window to where and how labor is used on the shop
floor. It can also report time spent at the machine support personnel. As a job history is
developed the job history labor reports can be used to forecast staffing requirements on a
shift or weekly basis.
· Shot Tracker - PlantStar is pleased to introduce Shot Tracker. This new
tracking feature timestamps and logs information for each cycle of the machine.
· OPC Client - PlantStar has joined the OPC era with the introduction of an OPC client. This
client will connect to any OPC certified server to deliver data to the PlantStar system.
· Increased Performance - Because of PlantStar improved capabilities; retrieval of job data
is more robust than previous versions. The most noticeable areas are the loading of the Job
Schedule Board and retrieval of Product Standards.

· Improved Job Editing Capabilities - All job editing screens (Job Schedule Board,
Current/Queue Jobs, Work Orders, and Product Standards) have been recreated. The
result has given a more powerful job editor. A partial list of features includes: enhanced field
editing, pop up date calendars, integrated job list, and family tooling capabilities.
· Column Resizing - Most PlantStar screens now allow you to resize the columns the
34 SYSCON-PlantStar Help System

way that you see fit.

· Column Sorting - Some of the Shop Floor Monitor screens now allow the sorting of the
columns of data. This can be achieved by clicking the column heading you wish to sort.
The following screens have column sorting capabilities:

Material Lot Tracking

Material Lot Detail
Labor Status
Labor Forecasting
· Job Queue Editing - Queue jobs can now be edited from the Current/Queue Job
window, as well as the Job Schedule Board. Previous versions only allowed
editing, of queue jobs, from the Job Schedule Board.
· Case Insensitive Search - Searches no longer require the search criteria to match the
case of the expected result. This is most noticeable in the Job Schedule Board,
Product Standards, and the Material Lot Tracking screens.

· Job Schedule Board Search - The search capabilities within the Job Schedule
Board have been expanded to search on more fields. Now all the available fields from
the filtering function are included in the search function.
· HTML Help - Previous versions of PlantStar used Win Help.
SYSCON - PlantStar System
User's Guide

Part

II
36 SYSCON-PlantStar Help System

2 Shop Floor Configuration

There are numerous steps to setting up and defining a shop floor. Each step entails providing
specific information. The information on one element of the shop floor directly relates to and is
associated with a second element. Communication Processor information, for example,
needs boot set information. Machine definitions need Communications Processor and Data
Collection Module (DCM) information. Changes to some shop floor definitions force a re-
initialization of a DCM. This, in turn, affects the currently running job.
The following sections discuss some basic relationships between specific shop floor
components. These relationships are presented here to facilitate the entering of
information.

What do you want to know about?

User Defined Labels

Reason Sets
Work Centers
Display Groups
Labor Categories
Communications Processors DCMs
Machines
Process Variables

2.1 File Menu

2.1.1 Save Session
Defining and updating your shop floor definitions is an extremely important part of PlantStar.
When shop floor definitions change, the new information is loaded down to a DCM and the
database.

Many shop floor characteristics are inter-related. Communications Processor information

needs boot set information. Machine definitions need Communications Processor and
DCM information. Since changes that you make to shop floor definitions are so inter-
related and immediate, PlantStar provides a feature to edit multiple shop floor
characteristics before you send them down, all at once, to the shop floor.
The Save Session menu command under the File menu lets you decide when new or
updated shop floor definitions should be sent to a DCM. You can edit any number of setup
windows. No action is taken with regard to actually sending information to the shop floor
until you click the Save Session menu item.

2.1.2 Restore Session

The Restore Session command button restores any changes that have been made on
the following windows to the way it was before you started editing. These windows
include:
Assist Reason Sets
Down Reason Sets
Reject Reason Sets
Boot Sets
 Shop Floor Configuration 37

Work Center Setup

Display Group Setup
Labor Setup
Comm Processor Setup
DCM Setup
Machine Setup
REU Setup

To restore your information, click on the Restore Session command under the File menu.

2.1.3 User Preferences

The User Preference window enables you to customize the PlantStar environment in terms of:
Font Size -- Changing Text Sizes sets the font size for all PlantStar windows.
Job Primary Label -- The label to use for all jobs displayed on the Job Schedule Board
window can be selected. The job label field lists all jobs on the Gantt chart by job name.
The product label shows all jobs by product name.
Default When Moving a Job - You can select what will happen by default when moving
38 SYSCON-PlantStar Help System

work orders or jobs from one machine to another on the Job Schedule window.
Screen Load Behavior - This option enables the quick loading of screens. When the
quick load option is enabled, a screen is loaded without retrieving the data for the
selection criteria. Data is loaded after window is opened and selection is made.
Search Criteria - The search method used on the Job Schedule Board window can be
selected. There are three search methods: left, embedded, and exact. Left matching
searches for records that start with a specified text. Embedded matching finds all
occurrences of a text wherever it is located. Exact matching finds exact matches only.
(Specific examples are provided under each method's field help topics.)
Show labor Hours – This displays the total number of man-hours required for each shift.
Language - This allows the users to select their language preference.
These preferences are saved from session to session and will not change until the next
modification.
Where can you find it?

· Choose the File menu on the Monitor window.

· Choose the User Preference option.
What do you want to know about?

Changing Preferences
Saving Your Changes
Undoing Your Changes
Closing the Window

2.1.4 Logout
The Logout menu option closes all the current opened PlantStar windows and returns you
to the main Login window.

2.1.5 Exit
To exit the program, choose one of the following methods:

· Select the Exit option under the File menu

· Click your mouse button while it is positioned over the 'x' in the upper right hand
corner of the window.
NOTE: You must have the “Exit Panorama” privilege to exit the Monitor program.
 Shop Floor Configuration 39

2.2 User Menu

2.2.1 User Accounts

The User Accounts window lets you add, change or delete users and their privileges. This
window is one of the primary security features within PlantStar. There are three levels of
privileges which can be granted to users: no access, view only, or full access.

No Access - Does not allow the user to open the specified window.
View Only - Allows a user to view any PlantStar window associated with the granted
privilege
Full Access - Enables the user to add, delete and edit all information associated
with the granted privilege.
All known PlantStar users are displayed upon the opening of this window. If you want to
change a user's information, place your mouse pointer over the user's name or the
relevant field.

NOTE: If you do not have administrator privileges, then only your name appears in the user
name list. You cannot view other people's privileges. You can change your password but not
your assigned privileges.
40 SYSCON-PlantStar Help System

Where can you find it?

Choose the User menu on the main Shop Configuration window.

Choose the User Accounts option.

What do you want to know about?

Selecting Users
Adding Users
Updating Users
Deleting Users
Changing Passwords
Saving your Changes
Undoing your Changes
Closing the Window

2.2.2 User Defined Labels

The User Defined Labels window lets you customize the title of a free text field. Up to four
free text fields appear on the Product Standard, Work Order, Current/Queued Jobs, and
Material Lot Tracking windows within the Monitor program and related reports. These
fields can be used as customized searching keys or site-specific pieces of information.
The top field on this window displays the free text field selected. Below it is the title currently
displaying on the above-mentioned windows. This second field is editable.

Where can you find it?

Choose the User menu on the main Shop Configuration window.

Choose the User Defined Labels option.

What do you want to know about?

Selecting a Free Text Field

Changing User-Defined Labels
Setting User-Defined Labels to Default
Saving your Changes
 Shop Floor Configuration 41

Undoing your Changes

Closing the Window

2.3 Sets Menu

2.3.1 Down Reason Sets

The Down Reason Sets window lets you add, change or delete a down reason set.
Defining down reason sets enables PlantStar to report a machine's down time and down
frequency by a defined reason. Down time statistics are collected using shift-to-date data
for a current job or historical job. Down reason sets are associated with a machine from
the Machine Setup window.
You can define up to twenty (20) down reasons for each down set. Down reason number one
and two are pre-defined by PlantStar in terms of what they do and mean.

NOTE: An extended down and reject reason option can be purchased from PlantStar.
This will extended the down/reject limit to one hundred and sixty (160) down/reject
reasons for each set.
Down Reason One: The first reason is the default down reason. Time is accrued to this
reason when a machine is down and the operator has not selected a specific reason. A post-
down delay period can be set, though, from the Machine Setup window that delays the
accruing of "unspecified" down time to Down Reason #1.

Down Reason Two: The second down reason clocks actual setup time. PlantStar compares
this time with a job's standard setup time.
NOTE: A machine is considered down under the following conditions:
· The machine is cycling so slowly that the actual cycle time is longer than the down time
threshold specified in the current job.
42 SYSCON-PlantStar Help System

· The operator has selected a down reason that 'forces' the machine into a down state.

Where can you find it?

Choose the Sets menu on the main Shop Configuration window.

Choose the Down Reason Sets option.
What do you want to know about?

Selecting Reason Sets

Creating Reason Sets
Renaming a Reason Set
Deleting Reason Sets
Saving Reason Sets
Undoing Your Changes
Setting Down Reason Flags

2.3.2 Assist Reason Sets

The Assist Reason Sets window lets you add, change or delete an assist reason set.
Defining assist reasons enables PlantStar to report a machine's assist time and assist
frequency by each defined reason. Assist time statistics are collected using shift-to-date
data for a current jobs or historical jobs.

A list of defined assist reason sets is displayed upon the opening of this window. The first
defined reason set and its reason definitions are visible initially. You can define up to
twenty (20) assist reasons for each set. Reason sets are assigned to a machine from the
Machine Setup window.
Where can you find it?
 Shop Floor Configuration 43

Choose the Sets menu on the main Shop Configuration window.

Choose the Assist Reason Sets option.

What do you want to know about?

Selecting Reason Sets

Creating Reason Sets
Renaming a Reason Set
Deleting Reason Sets
Saving Reason Sets
Undoing Your Changes
·

2.3.3 Reject Reason Sets

The Reject Reason Sets window lets you add, change or delete a reject reason set. Defining
reject reason sets enable PlantStar to report on the number of rejects for a machine. It also is
able to calculate reject percentages for each defined reject reason. Reject counts are
collected using shift-to-date data of a current job or historical job.
You can define up to twenty (20) reject reasons for each reason set. The first defined
reason set and its reason definitions are visible initially. Reason sets are attached to a
machine from the Machine Setup window.
NOTE: An extended down and reject reason option can be purchased from PlantStar.
This will extend the down/reject limit to one hundred and sixty (160) down/reject
reasons for each set.

NOTE: Reject Reason number two has a special meaning attached to it. PlantStar uses the
second reject reason to accumulate the difference between gross and net pieces when Net
Parts Counting is in effect.
44 SYSCON-PlantStar Help System

Where can you find it?

Choose the Sets menu on the main Shop Configuration window.

Choose the Reject Reason Sets option.

What do you want to know about?

Selecting Reason Sets

Creating Reason Sets
Renaming a Reason Set
Deleting Reason Sets
Undoing Your Changes

2.3.4 Boot Sets

The Boot Sets window lets you add, change or delete a boot set. Defining boot sets
enables PlantStar to start-up and load information into a communications processor
or a DCM.
Defining boot sets for Communications Processors and DCMs are mandatory. A boot set
lists the files that are downloaded to a Communications Processor or DCM. These files are
required for communication and data collection. The boot set must correspond to your
hardware configuration. A boot set is assigned to a Communications Processor or a DCM
from the Comm Processors Setup or the DCM Setup windows.
A list of defined boot sets is displayed upon the opening of this window. The boot files included
in each boot set are marked by a check box to the left of their file name. You may use the
default boot sets provided or create your own boot sets.
 Shop Floor Configuration 45

Where can you find it?

Choose the Sets menu on the main Shop Configuration window.

Choose the Boot Sets option.

What do you want to know about?

Selecting Reason Sets

Creating Reason Sets
Renaming a Reason Set
Deleting Reason Sets
Saving Reason Sets
Undoing Your Changes
Including Boot Files from a Boot Set

2.4 Groups Menu

2.4.1 Work Center Setup

The Work Center Setup window lets you add, change or delete a work center. Defining work
centers is optional although this parameter offers you a way to group your machines into
logical work groups.
It is important to note that shift schedules are created for and assigned to individual work
centers.
All defined work centers are displayed upon the opening of this window. If there is no work
center defined, the window appears with the default 'All' work center. This work center
includes all defined machines.

Machines are assigned to a work center from the Machine Setup window. A machine can
belong to one and only one work center.
46 SYSCON-PlantStar Help System

Where can you find it?

Choose the Groups menu on the main Shop Configuration window.

Choose the Work Center Setup option.

What do you want to know about?

Changing Work Centers

Creating Work Centers
Deleting Work Centers
Changing An Existing Work Center's Name
Saving your Changes
Undoing your Changes
Closing the Window

2.4.2 Display Group Setup

The Display Group Setup window lets you add, change or delete display groups. Defining
display groups is optional although this parameter offers you a way to group your machines
into logical work groups for later monitoring and selection on multi-machine windows within
PlantStar Monitor (for example, the Exception Summary window).
Display groups are defined by work centers. Work centers define the shift schedule that a
machine follows. Therefore, each machine within a display group has the same shift
schedule.
Existing display groups are displayed upon the opening of this window. On the right-hand side
 Shop Floor Configuration 47

is a list of machines currently assigned to the "group" visible in the Display Group field. On
the left-hand side of the window is a list of existing machines within the selected work center.
Any of the machines in this list can be added to the current display group. The up and down
arrows on the window move a highlighted machine up or down the list, changing the order in
which machines are displayed on all multi-machine windows.
NOTE: A machine can exist in multiple display groups in any one work center.
Where can you find it?

Choose the Groups menu on the main Shop Configuration window.

Choose the Display Group Setup option.
What do you want to know about?

Changing Display Groups

Creating Display Groups
Deleting Display Groups
Adding Machines to a Display Group
Removing Machines from a Display Group
Ordering Machines in the List
Saving your Changes
Undoing your Changes
Closing the Window
48 SYSCON-PlantStar Help System

2.5 Labor Menu

2.5.1 Labor Setup

The Labor Setup window lets you add, change or delete Labor Categories and Employees
for a given work center. Defining Labor Categories is optional although this parameter offers
you a way to group labor requirements for Labor Forecasting.
Defining an Employee is necessary before that employee can be logged in and out.
Where can you find it?

Choose the Labor menu on the main Shop Configuration window.

Choose the Labor Setup option.
What do you want to know about?

Changing Work Centers

Editing Labor Categories
Editing Employee Records
Saving Your Changes
Undoing Your Changes
Closing the Window
 Shop Floor Configuration 49

2.6 Shop Floor Menu

2.6.1 Comm Processor Setup

The Comm Processor Setup window lets you add, change or delete a Communications
Processor (Comm Processor) definition. The Comm Processor is the link between a
DCM on the production floor and the PlantStar host computer. At least one Comm
Processor must be defined.
It is recommended that the shop floor be configured in the following sequence:

Set up the Comm Processor.

Set up DCMs.
Set up Down, Reject or Assist reasons.
Set up Work Centers.
Set up Machines.

Each DCM must be associated with a Comm Processor. This is done from the DCM
Setup and Machine Setup windows.

Where can you find it?

Choose the Shop Floor menu on the main Shop Configuration window.
Choose the Comm Processor Setup option.

What do you want to know about?

Selecting a Comm Processor

Creating a Comm Processor
Deleting a Comm Processor
Updating a Comm Processor
Changing a Comm Processor's Name
50 SYSCON-PlantStar Help System

Saving your Changes

Undoing Your Changes
Closing the Window

2.6.2 DCM Setup

The DCM Setup window lets you add, change or delete DCM information. This window
configures a DCM to suit the shop floor environment. The software configuration must match
the physical components within the unit. For instance, a DCM can only be configured for 16
analog channels if the optional analog board was purchased and installed. This window also
allocates the on-board memory (RAM Size).
At least one DCM must be defined for your plant. All defined DCMs are displayed upon the
opening of this window. If no DCMs have been defined, then the window appears blank.
NOTE: Machines are assigned to DCMs from the Machine Setup window.
Where can you find it?

Choose the Shop Floor menu on the main Shop Configuration window.
Choose the DCM Setup option.
 Shop Floor Configuration 51

What do you want to know about?

Selecting a DCM to View

Adding a DCM
Updating a DCM
Deleting a DCM
Enable a DCM
ColdStart a DCM
Changing General DCM Settings
Changing COM Port Settings
Changing Contact Input Settings
Changing RIO Settings
Saving your Changes
Undoing Your Changes
Closing the Window

2.6.3 Machine Setup

The Machine Setup window lets you add, change or delete a machine definition. It is
52 SYSCON-PlantStar Help System

used to configure a machine to match a unique monitoring environment. Down reason

sets, assist reason sets, and reject reason sets are assigned, along with analog inputs
and digital inputs.
Monitoring machines in Real-Time is the primary goal of PlantStar. Machines are the main
data collection point. In order to create work orders and scheduled jobs, at least one
machine must be already defined and its information downloaded to the shop floor.
A list of defined machines is displayed upon the opening of this window. If no machines
have been defined, the window appears blank. If machines have been defined, they can be
selected for viewing from the machine field in the upper left corner. Once selected, a
machine's general parameters, as well as its process variables and profiles appear. The
process variables and profiles are located on the bottom portion of the window.
Where can you find it?

Choose the Shop Floor menu on the main Shop Configuration window.
Choose the Machine Setup option.

What do you want to know about?

Changing a Machine's Name

Creating Machines
Deleting Machines
Updating Machines

Editing Process Variables

Creating Process Variables
Deleting Process Variables
Changing Process Variables Name
Saving Process Variables

Editing Profile Variables

Creating Profile Variables
Deleting Profile Variables
Changing Profile Variables Name
Saving Profile Variables

Saving your Changes

Undoing Your Changes
Closing the Window
Undoing your Changes
 Shop Floor Configuration 53

2.6.4 REU Setup

NOTE: REU’s are not supported in the current release of PlantStar. This window is only
available for the deletion of REU's.
Upon the opening of this window, a list of existing REU's is displayed -- along with
its list of corresponding machines.
Where can you find it?

Choose the Shop Floor menu on the main Shop Configuration window.
Choose the REU Setup option.
What do you want to know about?

Selecting a REU
Deleting REU's
Saving your Changes
Undoing Your Changes
Closing the Window
54 SYSCON-PlantStar Help System

2.7 Window Menu

2.7.1 Arrange Icons

To arrange the iconized windows into straight rows or columns, select the Window menu
on the main menu bar. Choose the Arrange Icons option.

2.7.2 Arrange Windows

The windows can be arranged in three ways

Cascading:

Vertical Tiles:

Horizontal Tiles:

To choose one of these styles, select the Window menu from the main system window. Select
one of the options displayed

2.8 Help Menu

2.8.1 Help Contents

General content help provides a table of contents for virtually all topics within this
application. The Contents window can be used to jump to topics that explain various
windows or how to get quick access to key reference topics. This help is available by
selecting the Contents on the Help menu item.
Use the scroll bar to the right side of the Help window to view the next page of the Table of
Contents.

2.8.2 Help Index

The Index list is directly accessible from the Index on the Help menu item or from the Index
tab within the on-line help utility. Index terms consist of:

Definitions
Formulas, if applicable
Recommended values, if applicable.
 Shop Floor Configuration 55

To access an item from the Index list:

Use the scroll bar on the right hand side to scroll the window to the desired item.
Point to the term or phase desired.
Double-click on the highlighted word to open.

-Or-
Use the keyword field to search for the desired item.
Once found, double-click on the highlighted word to open.

2.8.3 Help Search

Another method to find a particular topic in Help is to use the Search option. To display the
Search window, either choose Search from the Help menu on the application window or
click the Search tab on the Help topic screen.

Select a topic by:

· Use the keyword field to search for the desired item.
· Click on the List Topics button to search on the keyword entered
· A list of related topics then appears on the screen.
· Once found, double-click on the highlighted topic to open.

2.8.4 Help Active Window

Window level help provides information on the display that currently has focus. Information
for each window includes:
· Purpose of the window
· Specific field descriptions
· Window button explanations
This type of help is available by selecting and opening a desired window. Once opened,
select the Help-Active Window menu on the application window or press the F1 key.

NOTE: If there are currently no PlantStar windows open, this menu item will not display any
help.

2.8.5 About PlantStar

For up-to-date resource information, the application provides a window with the following
information:
· PlantStar Software Version
· PlantStar Copyright Date
· Microsoft Windows Version
· Amount of free memory

To see this information:

· Select the Help menu on the main menu.

· Choose the About PlantStar menu item.
SYSCON - PlantStar System
User's Guide

Part

III
 Shop Floor Monitor 57

3 Shop Floor Monitor

PlantStar's goal is to provide you with a data collection and monitoring apparatus that
enables you to make informed decisions on the factory floor in real-time. It defines the shop
floor, schedules jobs on the floor, and monitors those jobs.
The Monitor program provides information on current shop floor activity. Within Monitor,
real-time monitoring is presented as a "moving window" of recent events. Information on
the current shift, the current job, or the most recent machine cycle is presented in a variety
of windows. A scheduling component, accessible through the Schedule menu, utilizes the
Shop floor Configuration program's definitions in order to facilitate planning activities.
These planning activities take the form of job scheduling. Jobs, their priorities and
placement in a job queue, provide the work schedule for the shop floor.
What do you want to know about?

Machine States
Shift Scheduling
Creating Work Orders
Creating Work Orders from a Standard Job Scheduling
Process and Production Monitoring Displaying SPC Statistics
Material Lot Tracking
58 SYSCON-PlantStar Help System

3.1 File Menu

3.1.1 User Preference

The User Preference window enables you to customize the PlantStar environment in terms
of:
Font Size - Changing Text Sizes sets the font size for all PlantStar windows.
Job Primary Label - The label to use for all jobs displayed on the Job Schedule Board
window can be selected. The job label field lists all jobs on the Gantt chart by job
name. The product label shows all jobs by product name.
Default When Moving a Job - You can select what will happen by default when moving
work orders or jobs from one machine to another on the Job Schedule window.
Screen Load Behavior - This option enables the quick loading of screens. When the
quick load option is enabled, a screen is loaded without retrieving the data for the
selection criteria. Data is loaded after window is opened and selection is made.
Search Criteria - The search method used on the Job Schedule Board window can
be selected. There are three search methods: left, embedded, and exact. Left
 Shop Floor Monitor 59

matching searches for records that start with a specified text. Embedded matching
finds all occurrences of a text wherever it is located. Exact matching finds exact
matches only. (Specific examples are provided under each method's field help
topics.)

Show labor hours displays the total number of man hours required for each shift.
Language - This allows the users to select their language preference.
These preferences are saved from session to session and will not change until the next
modification.
Where can you find it?

Choose the File menu on the Monitor window.

Choose the User Preference option.
What do you want to know about?

Changing Preferences
Saving Your Changes
Undoing Your Changes
Closing the Window

3.1.2 Logout
The Logout menu option closes all the current opened PlantStar windows and returns you to
the main Login window.

3.1.3 Exit
To exit the program, choose one of the following methods:

Select the Exit option under the File menu

Click your mouse button while it is positioned over the 'x' in the upper right hand
corner of the window.
NOTE: You must have the Exit Panorama privilege to exit the Monitor program.
60 SYSCON-PlantStar Help System

3.2 Monitor Menu

3.2.1 Display Group Status

The Display Group Status window contains a rectangle for each defined display group. For
each display group, the percent of machines in a down state, percent of machines in
process exception, and the percent of machines in a production exception are calculated.
Your system computes these percent values using current shift or job-to-date data or data
collected during recent shifts. The color of the box reflects the display group's machine
state. The machine with the highest priority state is reflected for the display group. See the
Machine State Colors on-help section for further information.
Where can you find it?

Choose the Monitor menu on the main your system window.

Choose the Display Group Status option.
What do you want to know about?

Toggling Auto Size and Normal Size

Viewing Machine Status
Closing the Window
 Shop Floor Monitor 61

3.2.2 Machine Status

The Machine Status window contains a rectangle for each machine in a selected display
group. If you have not selected a display group, the initial default group 'All' is displayed.
The machine name appears in the upper left hand corner of the rectangle. Below the
machine is the product being produced. The standard multiplier and actual multiplier for
the current job are located in the upper right corner. The number of net pieces, reject
percent, and actual rate for each job on a machine is calculated using current shift or job-
to-date data or data collected during recent shifts.
The color of the box reflects the machine's state. See the Machine State Colors on-help
section for further information.
NOTE: If the machine displayed is running a family job, the data displayed is one of the
child jobs running. The child job displayed rotates to the next child job after each
machine cycle.
Where can you find it?

Choose the Monitor menu on the main your system window.

Choose the Machine Status option.
What do you want to know about?

Viewing Machine Detail

Toggling Auto Size and Normal Size
Changing Display Group
Closing the Window
62 SYSCON-PlantStar Help System

3.2.3 Labor Status

The Labor Status window allows the viewing of any employee’s labor record for the current
shift or any historical shift for the selected work center. It is also possible for employees to
login or logout from this window.

NOTE: You must have the proper privileges in order to view this window. See your
System Administrator if you do not have the Labor viewing privilege.
Where can you find it?

Choose the Monitor menu on the main your system window.

Choose the Labor Status option.
What do you want to know about?

Changing Work Centers

Changing Shifts
Logging in an Employee
Logging out an Employee
Exporting Data
Refreshing the display
Sorting Columns
Resizing Columns
Closing the Window
 Shop Floor Monitor 63

3.2.4 Exception Summary

The Exception Summary window highlights machines that are experiencing performance
problems. These are machines that are in an exception state for the selected display group.
There is one line of information for each machine within a display group. The color of the line
reflects the machine's running state. See the Machine State Colors on-line help section for
further information.
If a machine is in exception, the applicable column information is displayed. For example, if a
machine is in process exception, the process variable column displays the variable in
violation. If a machine is in assist state, the assist reason displays in the Assist Reason
column.

NOTE: More than one type of exception can be displayed at one time. The "Machine" and
"Exception Since" columns both display the highest priority machine running state.
Highlighted exception states are:

Down state
Idle state
Off-line state
Process exception
Production exception
Assist state
Where can you find it?

Choose the Monitor menu on the main your system window.

Choose the Exception Summary option.
64 SYSCON-PlantStar Help System

What do you want to know about?

Changing Display Groups

Changing View Options
Viewing Machine Exceptions
Closing the Window

3.2.5 Production Summary

The Production Summary window provides information on the selected display group's
current production on each machine. Production information is described in terms of machine
performance and progress toward completion of any current jobs. There is one line of
information for each job running on each machine within the display group. If there are
multiple jobs running on a machine (i.e. family job), there will be multiple lines displayed for
each child job.
The color of the line reflects the machine's running state. See the Machine State Colors
on-line help section for further information. PlantStar computes all statistics using shift-to-
date data for all current jobs.
Where can you find it?

Choose the Monitor menu on the main your system window.

Choose the Production Summary option.
What do you want to know about?

Changing Display Groups

Changing View Options
Exporting Data
Closing the Window
 Shop Floor Monitor 65

3.2.6 Job Summary

The Job Summary window displays current shift and historical shift information for a
selected job running on a machine.
The first row of the table provides shift-to-date information for the current shift and job. The
middle rows display shift data for up to four completed shifts, depending upon how long a job
has been running. The next row provides shift totals for the last four shifts available. Job-to-
date totals for all columns are then calculated in the last row of the table. The color of the
window background reflects the machine's running state. See the Machine State Colors on-
line help section for further information.
NOTE: If the job is a non-family job, the child job selection will display "No Family Jobs
Defined" and the child job selection would be disabled. If the machine selected is running a
family job, the child job selection will be enabled and the user can select from one of the
child jobs running.
Where can you find it?

Choose the Monitor menu on the main your system window.

Choose the Job Summary option.
What do you want to know about?

Changing Display Groups

Changing Machines
66 SYSCON-PlantStar Help System

Changing Jobs
Changing Child Jobs
Changing Number of Shifts
Exporting Data
Closing the Window

3.2.7 Material Usage

The Material Usage window provides a summary of the amount of material used, excess
material, and material requirements for each material component of a job. All calculations are
based upon the current job. Material usage statistics are primarily based upon net pieces or
gross pieces, part weight, and a job's standard multiplier. The handling of reject parts,
whether runners are re-fed, determines whether usage and excess material calculations must
take shot size into consideration.
There is one line of information for each material component attached to the current
running job on a machine. The window’s information can be filtered by display group,
machine state, and material component. The color of each line reflects machine states. See
the Machine State Colors on-line help section for color-coding.
Where can you find it?

Choose the Monitor menu on the main your system window.

Choose the Material Usage option.
What do you want to know about?

Changing Display Groups

Changing View Options
 Shop Floor Monitor 67

Changing Material Components

Closing the Window

3.2.8 Pareto/Pie Charts

3.2.8.1 Down Pareto / Pie

The Down Pareto/Pie window displays an ordered histogram of the down time for a selected
shift, job, and child job. There is one vertical bar per down reason. Bar height represents the
down time displayed. Bars are displayed from left to right in descending order, in effect
highlighting the main causes of any down time. The Y-axis represents down time in terms of
hours or minutes. The X-axis lists the down reasons as previously stated.
Where can you find it?

Choose either the Monitor or History menu items on the main system window.
Chose the Pareto/Pie Charts option.
Choose the Down Pareto/Pie option.
What do you want to know about?

Changing Display Groups

Changing Machines
Changing Jobs
Changing Child Jobs
Changing Shifts
68 SYSCON-PlantStar Help System

Changing Graph Types

Changing Number of Reasons Displayed
Scrolling the view
Viewing Next Shift
Viewing Previous Shift
Closing the Window

3.2.8.2 Assist Pareto / Pie

The Assist Pareto/Pie window displays an ordered histogram of the assist time for the
selected shift, job, and child job. The X-axis lists the assist reasons as defined for a machine.
There is one vertical bar per assist reason. Bar height represents the assist time displayed.
Bars are displayed from left to right in descending order, in effect highlighting the main
causes of any assist time. The Y-axis represents the amount of assist time in hours and
minutes.
The color of the bars reflects the current machine state of the selected machine.
See the Machine State Colors on-help section for further information.
Where can you find it?

Choose either the Monitor or History menu items on the main system window.
Chose the Pareto/Pie Charts option.
Choose the Assist Pareto/Pie option.
 Shop Floor Monitor 69

What do you want to know about?

Changing Display Groups

Changing Machines
Changing Jobs
Changing Child Jobs
Changing Shifts
Changing Graph Types
Changing Number of Reasons Displayed
Scrolling the view
Viewing Next Shift
Viewing Previous Shift
Closing the Window

3.2.8.3 Reject Pareto / Pie

The Reject Pareto/Pie window displays an ordered histogram of the reject counts for the
selected shift, job, and child job. The X-axis lists the reject reasons as defined for a machine.
There is one vertical bar per reject reason. Bar height represents the number of rejected
parts. Bars are displayed from left to right in descending order, in effect highlighting the main
causes of rejects. The Y-axis represents the number of rejects. The color of the bars reflects
the current machine state of the job running on a selected machine. See the Machine State
Colors on-help section for further information.
70 SYSCON-PlantStar Help System

The window's scroll bars shift the view of the Pareto chart, allowing you to see all reject
reasons defined for a machine. Click on the scroll bar to view reasons not immediately
visible.
NOTE: If the job selected is a non-family job, the child job selection will display "No Family
Jobs Defined" and the child job selection would be disabled. If the machine selected is
running a family job, the child job selection will be enabled and the user can select from one
of the child jobs running.
Where can you find it?

Choose either the Monitor or History menu items on the main system window.
Chose the Pareto/Pie Charts option.
Choose the Reject Pareto/Pie option.
What do you want to know about?

Changing Display Groups

Changing Machines
Changing Jobs
Changing Child Jobs
Changing Shifts
Changing Graph Types
Changing Number of Reasons Displayed
Scrolling the View
Viewing Next Shift
Viewing Previous Shift
Closing the Window
 Shop Floor Monitor 71

3.2.9 Machine Performance

The Machine Performance window provides a summary of a selected display group's

performance over time as it pertains to currently running jobs. There is one line of
information for each machine within the display group. The color of the line reflects the
machine's running state. See the Machine State Colors on-line help section for further
information.
Where can you find it?

Choose the Monitor menu on the main PlantStar window.

Choose the Machine Performance option.
What do you want to know about?

Changing Display Groups

Changing View Options
Closing the Window
72 SYSCON-PlantStar Help System

3.2.10 Machine Exception

The Machine Exception window provides a greater detailed description of a selected

machine's running state than the Exception Summary window. Any running state of the
machine is displayed along with an exception time. If a process variable is in exception, this
window shows whether it is a result of a higher limit or lower limit violation. Also, this window is
color-coded according to your system Machine State Colors.

NOTE: The Machine Exception window can also be accessed from the Exception
Summary window. While on the Exception Summary window, click on a machine's row of
information. Exception information for the selected machine appears.
Where can you find it?

Choose the Monitor menu on the main your system window.

Choose the Machine Exception option.
What do you want to know about?

Changing Display Groups

Changing Machines
Closing the Window
 Shop Floor Monitor 73

3.2.11 Machine Usage

The Machine Usage window displays the machine usage and scheduled machine
usage over a selected time period.
Also, the Machine Usage window provides a detailed description of the selected machine's
running state. Any running state that the machine is in is displayed along with an exception
time. If a process variable is in exception, this window shows whether it is a result of a higher
limit or lower limit violation. Also, this window is color-coded according to the system Machine
State Colors.
NOTE: For job-to-date calculations the current shift totals are also included.
Where can you find it?

Choose the Monitor menu on the main your system window.

Choose the Machine Usage option.
What do you want to know about?

Changing Start Date

Changing End Date
Rebuilding the Display
Printing
Changing Display Groups
Changing View Options
Closing the Window
74 SYSCON-PlantStar Help System

3.2.12 Machine Log

The Machine Log window displays a list of the most recent 1000 events relating to a
selected machine. These events are recorded at the DCM. Event types include:

Job Related Events - start/end of a job or a job change;

Shift Related Events - start of a new shift or a shift idle period;
Down Events - start and end of down time periods;
Assist Events - start and end of assist time periods;
Process Alarm Events - time of a process exception, the actual "exception" value,
and the limit it violated. Process exceptions are only logged, though, if the machine
is not in a down state. If a process exception begins while a machine is down, the
exception events are not logged for the machine.
Labor Events - login and logout of users on the selected machine
Material Events - material changes on the selected machine

For process alarms, the specific process variables that display on this window depend upon
how a machine is defined. The process log field on the Machine Setup window controls
which variables are included. There are three process log options:

All - Include all process variables for a machine

None - do not include any process variables
Critical - Include critical process variables only.

NOTE: The Machine Log window only updates if the scroll box is at the very bottom of the
scroll bar. Events are updated every 60 seconds.
Where can you find it?

Choose the Monitor menu on the main your system window.

Choose the Machine Log option.
 Shop Floor Monitor 75

What do you want to know about?

Changing Display Groups

Changing Machines
Changing Event Types
Exporting Data
Closing the Window

3.2.13 Overlay Profile

Profiles must be setup in the machine configuration before this graft is available.

The Overlay Profile window displays the current behavior of a profile for a selected machine,
overlays that profile on top of another profile or cross plots the profile with another profile. It
also allows you to zoom in on sections of a profile.
The window's graph area is blank until a profile is selected. Each profile is a collection of
points. Each point represents a value that was collected during a machine cycle. Up to 500
points may be shown. Actual values are plotted against the Y-axis. The X-axis represents the
time when the actual values were taken relative to the start time. The start time is always
zero, which is the point at which the collection of the profile began.
NOTE: Each profile consumes a considerable amount of system resources. For that reason,
only ten profiles may be displayed on the system at a given time.
Special graph controls are available for manipulating and tailoring the profiles:
76 SYSCON-PlantStar Help System

Freeze the profile

Store the profile
Clip the profile
Manual scaling option
Auto scale once option
Auto scale every cycle option
Overlay selected profiles
Cross plot selected profiles

The color of the window background reflects the machine’s running state. See the Machine
State Colors in the on-line help section for further information. All profiles are plotted using
the color code designated by the colored box to the left of each profile’s name.
Where can you find it?

Choose the Monitor menu on the main system window.

Choose the Overlay Profile option.
What do you want to know about?
General Functions:
Changing Display Groups
Changing Machines
Selecting Profiles
Exporting Data
Closing the Window

Graph Functions:
Clipping the graph
Freezing Profiles
Changing Profile Graph Modes
Changing Rescaling Options
Storing Profiles
Viewing Actual Values
Viewing Maximum and Minimum Values
Zooming Selected Profiles
 Shop Floor Monitor 77

3.2.14 Process Trend / SPC

The Process Trend/SPC window graphically displays the behavior of any defined process
variable for a machine. The selected number of most recent values for a variable is plotted.
Specific points to note are:

The X-axis is the cycle number. The most recent cycle is 1.

The Y-axis is the actual process variable value. The rightmost point is the most recent
value. For each machine cycle update, the new value enters from the right, moving the
older values to the left. Undefined values show up as blank spaces in the graph.
The dashed, colored lines represent the higher limit and lower limit for the variable. The
higher limit is red and the lower limit is blue.
The color of the window background reflects the machine's running state. See the
Machine State Colors on-help section for further information.
Where can you find it?
· Choose the Monitor menu on the main your system window.
· Choose the Process Trend/SPC option.
The Process Trend/SPC window can also be accessed from the Process Summary
window. While on the Process Summary window, click on a process variable's row of
information. A trend graph appears for the selected process variable and machine.
78 SYSCON-PlantStar Help System

What do you want to know about?

General Functions:

SPC Statistics Concepts

Changing Display Groups
Changing Machines
Selecting Process Variables
Displaying Standard SPC Statistics Exporting Data
Closing the Window
Graph Functions:

Clipping the Graph

Changing the X-axis
Clearing Process History Information
Changing Rescaling Options
Viewing Actual Values
Viewing Maximum and Minimum Values

3.2.15 Process Summary

The Process Summary window displays the high value and low value for a
machine's process variables measured during the last fifty complete machine
cycles.
 Shop Floor Monitor 79

The Process Summary window provides quick access to the Process Trend/SPC window
for a specified machine and process variable. To view a process trend graph, click on a
process variable name or any place on its row of information. A trend graph appears for the
selected process variable and machine.
If a process variable is above the higher limit or below the lower limit, that process
variable is highlighted according to the following default color scheme:

Red - value is above the higher limit

Blue - value is below the lower limit

There is one line of information in the table for each process variable defined. The color of
the window background reflects the machine's running state. See the Machine State Colors
on-help section for further information.
Where can you find it?

Choose the Monitor menu on the main your system window.

Choose the Process Summary option.
What do you want to know about?

Changing Display Groups

Changing Machines
Closing the Window
80 SYSCON-PlantStar Help System

3.3 Schedule Menu

3.3.1 Job Schedule Board

In order to collect process variables and production data for a machine, a job must be
assigned on that machine. The process of scheduling or queuing jobs is handled through
the Job Schedule window.
The Job Schedule window consists of a Gantt style scheduling board. Calendar time is
shown on the X-axis. Machines within a selected display group are shown on the Y-axis.
Each row represents a machine's job queue and each rectangular block is a scheduled job.
The first rectangular block for each machine is its current job. The block length indicates the
expected run time for the job. Block labels are selectable. The caption display on the block
labels can be either the job or product names for the selected job.
NOTE: If the job scheduled is a family job, the block length indicates the expected run
time of the longest running child job.
A job is scheduled by selecting a work order and placing it in the job queue of a given
machine. By default, jobs are scheduled sequentially from left to right. There are two
scheduling methods available within your system:
· Schedule jobs by earliest start date (default)
· Schedule jobs by required by (due date)
The default method on the Job Schedule window is for jobs to run immediately following
the completion of previously-queued jobs. The estimated completion time of a job becomes
the starting time for the next queued job. Under this method, jobs that are expected to be
 Shop Floor Monitor 81

completed on time are shown in green. A red rectangular block indicates that a job will not
complete by its estimated completion date. The default method is active unless the second
scheduling method has been activated and/or saved during a previous session.
The second method is to schedule jobs by required by due date. This method places a
selected job (or jobs) on the job board at the latest possible time which allows it to be
completed by its due date. Specifically, a job's required by date is used as the starting point.
The length of time to run a job is then used to walk backwards through the shift schedule to
estimate the start date. Using this method, gaps may occur between a job's starting time and
a previous job's ending time. These "gaps" are represented on the job board by gray blocks
and indicate slack time where new jobs can be scheduled. Under this method, jobs that are
expected to be completed on time are shown in green. If this method causes a subsequent
job to become late, the late job's rectangular block is colored orange.

The marker, located along the top of the job board area, indicates which jobs are
scheduled according to their due dates. All jobs to the left of this marker are scheduled
according to the earliest possible start -- a job starts immediately upon completion of the
previous job (method one). All jobs to the right of this marker are displayed on the job board
according to their due dates (method two).
(For more detailed explanations refer to the field help provided on the icon.)

The Job Schedule window also enables you to edit a work order, current job, or queued job.
NOTE: You must have the proper privileges in order to schedule jobs. See your System
Administrator if you do not have the scheduling privilege.

Where can you find it?

Open the Schedule menu within Monitor.

Click on the Job Schedule window.

What do you want to know about?

General Topics:
Job Schedule Board Overview
Job Scheduling Concepts
Creating Work Orders
Loading a Product Standard onto a Job
Saving Jobs as a Standard
Work Order Functions:
Creating Work Orders
Customizing the Work Order List
Refreshing the Work Order List
Job Functions:
Selecting Jobs from the Schedule Board
Editing Jobs from the Schedule Board
Deleting Jobs from the Schedule Board
Searching for a Job
Viewing Job Summary Information
82 SYSCON-PlantStar Help System

Scheduling Functions:
Moving Jobs Around the Schedule Board
Selecting a Time Scale
Selecting Display Groups from the Schedule Board
Scheduling Jobs by Earliest Start Date
Scheduling Jobs by Due Date
Viewing Production Hours
Viewing the Shift Schedule
Identifying Machines with Job Standards Committing a Schedule
Discarding a Schedule

3.3.2 Current / Queue Jobs

The Current/Queue Jobs window provides three functions:

Job parameters for a current job can be changed.

Job parameters for a queued job can be changed.
The current job and any queued jobs can be saved as product standards.
A list of existing jobs is displayed on the left side of the window and job parameters are on
the right. Additionally, the process variable, profile, setup sheets, and manning factor
parameters are available from the Limits, Setup Sheet, and Labor tabs, located in the top
 Shop Floor Monitor 83

portion of the window.

NOTE:
· Current and Queued Jobs can also be created and edited from the Job Schedule
Board window.
· Access to this window is limited. You must have the Edit Current Job or
Scheduling privilege in order to edit job parameters. If you do not have these
privileges, the window is viewable but no information can be edited.
Where can you find it?
· Choose the Schedule menu on the main your system window.
· Choose the Current/Queue Jobs option.
What do you want to know about?

Changing Display Groups

Changing Machines
Selecting Current/Queue Jobs
Editing Production Parameters
Editing Process and Profile Limits
Editing Setup Sheets
Editing Labor Manning Factors
Loading a Product Standard onto a Job
Saving Jobs as a Standard
Saving your Changes
Undoing your Changes
Closing the Window
84 SYSCON-PlantStar Help System

3.3.3 Work Orders

The Work Order window lets you add, change or delete work orders. A list of work orders is
displayed on the left side of the window upon opening. If no work orders have yet been
defined, the work order list will be empty.
Work orders are essentially jobs that have been defined but not yet scheduled. In order to
schedule jobs, you must first create a work order. A work order consists of a set of job
parameters. These parameters define the job. They include such things as the number of
pieces required and the standard rate at which the pieces will be produced.
A list of existing work orders is displayed on the left side of the window and job parameters
are on the right. Additionally, the process variable, profile, setup sheets, and manning factor
parameters are available from the Limits, Setup Sheet, and Labor tabs, located in the top
portion of the window.
A work order may be created manually by entering the parameters or by loading in a product
standard.
NOTE:
· Work orders can also be created and edited from the Job Schedule Board window.
· You must have the proper privileges to enter this menu option. (See your System
Administrator if you do not have the proper privileges.).
Where can you find it?

Choose the Schedule menu within Monitor.

Choose the Work Orders option.
 Shop Floor Monitor 85

What do you want to know about?

Creating Work Orders

Selecting Work Orders
Changing Machines
Editing Production Parameters
Editing Process and Profile Limits
Editing Setup Sheets
Editing Labor Manning Factors
Loading a Product Standard onto a Job
Saving Jobs as a Standard
Creating Unassigned Child Jobs
Deleting Unassigned Child Jobs
Adding Child Jobs to a Work Order
Removing Child Jobs from a Work Order
Assigning Child Jobs
Deleting Work Orders
Saving your Changes
Undoing your Changes
Refreshing the Lists
Closing the Window
86 SYSCON-PlantStar Help System

3.3.4 Product Standards

A job may be created manually entering all these types of parameters into a work order and
then scheduling the job. The process of entering all the parameters can be time consuming.
To facilitate this process, the Product Standards window is available. This window allows
you to build up a collection of product-based standards. Job scheduling then consists of
copying an existing product standard into a work order. The work order is placed into the
job schedule. This library of standards also aids in the development of pre-defined
standards for recurring jobs.
Every job in PlantStar consists of a set of parameters. These parameters are based upon the
type of product produced and the machines on which the product will run. They, in essence,
describe the job and set the standard for monitoring it. They define the line between the
normal operating mode and various exception states for a machine. All monitoring is based
upon these values. For instance, if the Standard Cycle parameter is set to 30 seconds and
the Cycle Tolerance is set to 10 percent, a machine would be considered slow if is cycle time
was currently 50 seconds. This same machine would be considered down if the down time
threshold parameter was set to less than 50 seconds.
Job parameters also determine the expected run time of a job. The pieces required, standard
setup time and the standard rate factor are used when computing the completion date of a job.
If 10,000 pieces are required and the standard rate is 50 pieces per hour, then the runtime of a
 Shop Floor Monitor 87

job would be 200 hours. Add this to the standard setup time and you have the expected
runtime of a job. The schedule now and schedule factory parameters also affect the calculated
completion date. These fields determine if the shift schedule should be followed when
computing the completion date. Specifically, the Product Standards window is used to add,
change or delete product standards. Job parameters are separated into two types (product
versus machine-specific). Machine-specific parameters are located in the bottom right corner.
Machine-specific parameters generally change from machine to machine. Product-specific
parameters generally do not change from machine to machine. They can, however, be
changed if needed.
A list of existing product standards is displayed on the left side of the window and job
parameters are on the right. Additionally, the process variable, profile, setup sheets, and
manning factor parameters are available from the Limits, Setup Sheet, and Labor tabs,
located in the top portion of the window.
NOTE: Once a product standard is saved for a machine, an asterisk appears next to the
machine in the machine field. This asterisk signifies that a product standard exists for the
specific machine and product.

NOTE: You must have the proper privileges to view or edit Product Standards. See
your System Administrator if you need this privilege.
Where can you find it?

Choose the Schedule menu within Monitor.

Choose the Product Standards option.
What do you want to know about?

Creating a Product Standard

Selecting Product Standards
Changing Machines
Editing Production Parameters
Editing Process and Profile Limits
Editing Setup Sheets
Editing Labor Manning Factors
Adding Child Jobs to a Product Standard
Removing Child Jobs from a Product Standard
Copying Product Standards
Deleting Product Standards
Saving your Changes
Undoing Your Changes
Refreshing the Lists
Closing the Window
88 SYSCON-PlantStar Help System

3.3.5 Shift Schedule

The Shift Schedule window is used to create, assign, delete and change work center
schedules. If no schedules have been defined, the window appears blank. To create a work
center's shift schedule, use the New button.
Shift schedules define the start time and end time for work shifts, idle times for holidays or
weekends, and any other events when jobs should not be running or have special needs.
Shift schedules are not required but they do provide the flexibility to control part of the job
process. If shift schedules are not created, all jobs run all the time.
Shift schedules are created for a work center. Each work center has multiple schedules --
one for each year desired. Each year’s schedule may have up to twelve different weekly
work schedules. There must be at least one work center defined before access to the
Shift Schedule window is possible.
NOTE: You must have the Scheduling privilege in order to access this window. See your
System Administrator if you need this privilege.
Where can you find it?

Choose the Schedule menu within Monitor.

Choose the Shift Schedule option.
 Shop Floor Monitor 89

What do you want to know about?

General Functions:
Shift Scheduling Concepts
Changing Work Centers
Selecting a Year
Closing the Window
Weekly Schedules:
Creating Weekly Schedules
Assigning Weekly Schedules
Yearly Schedules:
Creating Work Center Schedules
Deleting Schedules
Updating Schedules
Saving your Changes
Undoing your Changes

3.3.6 Material Forecast

The Material Forecast window provides a forecast of the amount of material required for both
current jobs and queued jobs. Forecasts are based upon scheduled jobs information. Job
parameters such as standard multiplier, actual multiplier, part weight, and component
percents are used to calculate forecast figures. The handling of reject parts and whether
90 SYSCON-PlantStar Help System

runners are re-fed determines whether material forecast figures are based upon pieces
remaining or whether shot size is taken into consideration. There is one row of information in
the table for each material component within a current job or queued job. The background
colors reflect the current machine state of the job running on a selected machine. See the
Machine State Colors on-help section for further information.
Queued jobs are displayed as white on dark grey and are listed after each machine's current
job.
NOTE: This window does not automatically update information with each machine cycle.
The Build button must be used to obtain the most current forecast figures.
Where can you find it?

Choose the Schedule menu on the main your system window.

Choose the Material Forecast option.
What do you want to know about?

Changing Display Groups

Changing Machines
Changing Material Components
Rebuilding the Display
Closing the Window

3.3.7 Labor Forecast

The Labor Forecast Window is used to accurately forecast, by work center and shift, the
number of employees needed in a given Labor Category. This forecast is based off current
jobs and queued jobs scheduled.
 Shop Floor Monitor 91

There are two different views to Labor Forecasting:

Grid View
Graph View

NOTE: This window does not automatically update information with each machine cycle.
The Build button must be used to obtain the most current forecast figures.
Where can you find it?

Choose the Schedule menu on the main your system window.

Choose the Labor Forecast option.
What do you want to know about?

Changing Work Centers

Changing Start Date
Changing Shifts
Changing Number of Shifts to Forecast
Changing Forecast Views
Changing Graph Types
Changing Labor Categories
Rebuilding the display
Exporting Data
Sorting Columns
Resizing Columns
Closing the Window
92 SYSCON-PlantStar Help System

3.3.8 Tool Change

The Tool Change window provides information on upcoming tooling changes for both current
jobs and queued jobs. The list of tooling changes can be filtered by display group, machine,
forecast interval or tool name. The type of tooling changes displayed is selectable. The Tool
Change Only and All Job Changes fields, located directly below the tool table, determine
which jobs are displayed in the tool table.
If Tool Change Only is selected, and if each job’s tool(s) are different, then current jobs and
the next job scheduled on the same machine are displayed. If a currently-running job and
upcoming queued job have the same tool, neither one is displayed. (The next job is color-
coded in blue on dark cyan.)
If All Jobs Only is selected, all jobs which meet the selection filters (display group,
machine, tool or forecast interval) are listed regardless of whether or not there are tooling
changes. Current jobs are listed first, followed by the next queued job.
Queued jobs can be listed twice in the tooling table -- once as a "next" job and once as a
queued job with its own "next" job. Queued jobs that are listed a second time are displayed
as white on dark grey.
NOTE: This window does not automatically update information with each machine cycle.
The Build button must be used to obtain the most current tool schedule.
Where can you find it?

Choose the Schedule menu on the main your system window.

Choose the Tool Change option.
 Shop Floor Monitor 93

What do you want to know about?

Changing Display Groups

Changing Machines
Changing Tools
Toggling Tool Change View
Selecting Forecast Intervals
Rebuilding the Display
Closing the Window

3.4 History Menu

3.4.1 SPC History

The SPC History window displays a line chart of the SPC values collected for a specific
process variable and job. It includes two graphs. The top graph is a plot of X-bar values
collected from the selected job and the bottom graph is a plot of the associated range values.
The X-axis is the time at which the SPC values were recorded. The number of values graphed
may be a subset of the total collected. On the top graph, the Y-axis is the X-bar value
collected for the selected job and process variable. On the bottom graph, the Y-axis is the
range value. The rightmost point is the most recent value for the process variable and job.
There is a scroll bar at the bottom of the graph that allows you to scroll through the SPC
values. As you slide the scroll bar, you see the X-axis change. The range of the scroll bar is
shown below the scroll bar. The value on the left is the time of the first SPC data (the oldest
data). The value on the right is the time of the latest SPC data collected for the process
variable and job. To view more data, slide the scroll bar to the left. Move the scroll bar to the
right to view more current data.
94 SYSCON-PlantStar Help System

The number of plotted values on both graphs is changeable using the Size field. If the size
is set to 100, then 100 SPC samples are plotted. Changing the size does not change the
value of the scroll bar. It only changes the 'depth' of the data selection.
The X-bar mean value for each graph is shown as a solid gray line. The upper and lower
control limits are dashed blue lines. The upper and lower specification lines are shown on the
X-Bar graph as dashed red lines.
Where can you find it?

Choose the History menu on the main your system window.

Choose the SPC History option.
What do you want to know about?
General Functions:
SPC Statistics Concepts
Changing Machines
Changing Jobs
Selecting Process Variables
Displaying Standard SPC Statistics
Exporting Data
Closing the Window
Graph Functions:
Changing the X-axis
Changing Rescaling Options
Viewing Actual Values
Viewing Maximum and Minimum Values

3.4.2 Labor History

The Labor History window displays a table of labor records for a specific job and shift. These
 Shop Floor Monitor 95

records can be adjusted for historical shifts or current shifts. Labor history records include the
following:
· Employee Name
· Labor Category
· Start Date
· Start Time
· End Date
· End Time
· Total Hours
· Down Time
· Total Rejects
· Net Pieces
NOTE: Adjusted totals cannot be negative.
NOTE: If the job selected is a non-family job, the child job selection will display "No Family
Jobs Defined" and the child job selection would be disabled. If the machine selected is running
a family job, the child job selection will be enabled and the user can select from one of the
child jobs running.
NOTE: You must have the proper privileges in order to view/edit Labor History. See
your System Administrator if you do not have this privilege.
Where can you find it?

Click on the History menu.

Choose the Labor History option.
What do you want to know about?

Changing Work Centers

Changing Machines
Changing Jobs
Changing Shifts
Changing Child Jobs
Deleting a Labor Record
Changing Labor Categories
Adjusting Start/End Date
Adjusting Start/End Time
Adjusting Down Time
Adjusting Reject Counts
Adjusting Gross or Net Pieces
Adding an Employee to Labor History
Resizing Columns
Saving your Changes
Undoing your Changes
Closing the Window
96 SYSCON-PlantStar Help System

3.4.3 Material Lot Tracking

The Material Lot Tracking window displays material components and the material lot IDs
that have been entered at a DCM through a bar code reader or a touch screen. You can
select a material lot and view its detail.
Upon entering this window, it is blank. Search keys located in the upper part of the window
help find material lots quickly. If a search is initiated with search keys, all material
components associated with those keys are listed at the bottom of the window. If all fields
are left blank, all material lot records are listed. From this list, you can select a material lot
record and view either its tote box or material lot history. See the Material Lot Detail on-help
section for further information.
Where can you find it?

Click on the History menu.

Choose the Material Lot Tracking option.
What do you want to know about?

Material Lot Tracking Concepts

Searching Material Lots
Clearing Search Fields
Viewing Material Lot Detail
Exporting Data
Sorting Columns
 Shop Floor Monitor 97

Resizing Columns
Closing the Window

3.4.3.1 Material Lot Detail

The Material Lot Detail window displays the net pieces, total rejects, gross pieces, down
time, tote pieces, material components and percents for a selected material lot ID. Each
historical lot record is listed in chronological order, in the Lot ID field, at the top of the window.
Where can you find it?
The Material Lot Detail window can only be opened from the Material Lot Tracking
window.
What do you want to know about?

Selecting/Viewing Job List

Viewing Material Components
Selecting/Viewing Job Details
Selecting/Viewing Tote Details
Selecting a Different Lot ID
Sorting Columns
Resizing Columns
Closing the Window
 98 SYSCON-PlantStar Help System

3.4.4 Pareto/Pie Charts

3.4.4.1 Down_Pareto_Pie

The Down Pareto/Pie window displays down time in terms of hours or minutes. The X-axis
lists the down reasons as previously stated, an ordered histogram of the down time for a
selected shift, job, and child job. There is one vertical bar per down reason. Bar height
represents the down time. Bars are displayed from left to right in descending order, in effect
highlighting the main causes of any down time. The Y-axis represents down time in terms of
hours or minutes. The X-axis lists the down reasons as previously stated.
Where can you find it?

Choose either the Monitor or History menu items on the main system window.
Chose the Pareto/Pie Charts option.
Choose the Down Pareto/Pie option.
What do you want to know about?

Changing Display Groups

Changing Machines
Changing Jobs
Changing Child Jobs
Changing Shifts
Changing Graph Types
Changing Number of Reasons Displayed
 Shop Floor Monitor 99

Scrolling the view

Viewing Next Shift
Viewing Previous Shift
Closing the Window

3.4.4.2 Assist_Pareto_Pie

The Assist Pareto/Pie window displays an ordered histogram of the assist time for the
selected shift, job, and child job. The X-axis lists the assist reasons as defined for a machine.
There is one vertical bar per assist reason. Bar height represents the assist time displayed.
Bars are displayed from left to right in descending order, in effect highlighting the main
causes of any assist time. The Y-axis represents the amount of assist time in hours and
minutes.
The color of the bars reflects the current machine state of the selected machine.
See the Machine State Colors on-help section for further information.
Where can you find it?

Choose either the Monitor or History menu items on the main system window.
Chose the Pareto/Pie Charts option.
Choose the Assist Pareto/Pie option.
What do you want to know about?

Changing Display Groups

Changing Machines
100 SYSCON-PlantStar Help System

Changing Jobs
Changing Child Jobs
Changing Shifts
Changing Graph Types
Changing Number of Reasons Displayed
Scrolling the view
Viewing Next Shift
Viewing Previous Shift
Closing the Window

3.4.4.3 Reject_Pareto_Pie

The Reject Pareto/Pie window displays an ordered histogram of the reject counts for the
selected shift, job, and child job. The X-axis lists the reject reasons as defined for a machine.
There is one vertical bar per reject reason. Bar height represents the number of rejected
parts. Bars are displayed from left to right in descending order, in effect highlighting the main
causes of rejects. The Y-axis represents the number of rejects. The color of the bars reflects
the current machine state of the job running on a selected machine. See the Machine State
Colors on-help section for further information.
The window's scroll bars shift the view of the Pareto chart, allowing you to see all reject
reasons defined for a machine. Click on the scroll bar to view reasons not immediately
visible.
NOTE: If the job selected is a non-family job, the child job selection will display "No Family
Jobs Defined" and the child job selection would be disabled. If the machine selected is
 Shop Floor Monitor 101

running a family job, the child job selection will be enabled and the user can select from one
of the child jobs running.
Where can you find it?

Choose either the Monitor or History menu items on the main system window.
Chose the Pareto/Pie Charts option.
Choose the Reject Pareto/Pie option.
What do you want to know about?

Changing Display Groups

Changing Machines
Changing Jobs
Changing Child Jobs
Changing Shifts
Changing Graph Types
Changing Number of Reasons Displayed
Scrolling the View
Viewing Next Shift
Viewing Previous Shift
Closing the Window

3.4.5 Down Time Editor

The Down Time Editor window displays a table of down time for a specified machine, job,
and shift. There is one row of information in the table per down reason. Incorrect time values
for a job can be corrected in this window.
Adjustments can be made upward or downward for each defined reason. Adjusted
102 SYSCON-PlantStar Help System

totals cannot, though, be negative. There is one row of information in the table for each
down reason. Use the "Adjust +/-" column to make any necessary adjustments.
A machine can also be forced into a down state from the Down Select field on this window.
When a machine enters a forced down state, its associated DCM may or may not continue to
count parts and monitor process variable information. The action taken depends upon how
the down reason which triggered the "force down" is defined in terms of its “force down flag”
and “ignore cycles flag”. These flags are set on the Down Reason Sets window.
Where can you find it?

Click on the History menu.

Choose the Down Time Editor option.
What do you want to know about?

Changing Machines
Changing Jobs
Changing Shifts
Adjusting Times
Forcing a Machine Down
Saving your Changes
Undoing your Changes
Closing the Window

3.4.6 Assist Time Editor

The Assist Time Editor window displays a table of assist time for a specified machine, job,
and shift. There is one row of information in the table per assist reason. Incorrect time values
for a job can be corrected in this window.
 Shop Floor Monitor 103

Adjustments can be made upward or downward for each defined reason. Adjusted
totals cannot, though, be negative. There is one row of information in the table for each
down reason. Use the "Adjust +/-" column to make any necessary adjustments.
Where can you find it?

Click on the History menu.

Choose the Assist Time Editor option.
What do you want to know about?

Changing Machines
Changing Jobs
Changing Shifts
Adjusting Times
Saving your Changes
Undoing your Changes
Closing the Window

3.4.7 Parts Count Editor

Incorrect counts for a shift and job can be adjusted from the Parts Count Editor window.
This window displays two tables. The top table lists reject counts by reject reason for a
specified machine, job, child job, and shift. The bottom table displays gross pieces and net
pieces for the same time period. Adjustments can be made upward or downward for
historical shifts and current shifts.
NOTE: If the job selected is a non-family job, the child job selection will display "No Family
104 SYSCON-PlantStar Help System

Jobs Defined" and the child job selection would be disabled. If the machine selected is
running a family job, the child job selection will be enabled and the user can select from one
of the child jobs running.
Where can you find it?

Choose the History menu on the main your system window.

Choose the Parts Count Editor option.
What do you want to know about?

Changing Machines
Changing Jobs
Changing Child Jobs
Changing Shifts
Adjusting Reject Counts
Adjusting Gross or Net Pieces
Saving your Changes
Undoing your Changes
Closing the Window

3.5 Window Menu

3.5.1 Arrange Icons
To arrange the iconized windows into straight rows and columns, select the Window
menu on the main screen of your system window. Choose the Arrange Icons option.

3.5.2 Arrange Windows

The windows can be arranged in 3 ways:

Cascading:

Vertical Tiles:

Horizontal Tiles:

To choose one of these styles, select the Window menu from the main screen of your
system window. Select one of the options displayed
106 SYSCON-PlantStar Help System

3.6 Help Menu

3.6.1 Help Contents
General content help provides a table of contents for virtually all topics within this application.
The Contents window can be used to jump to topics that explain various windows or how to
get quick access to key reference topics. This help is available by selecting the Contents on
the Help menu item.
Use the scroll bar to the right side of the Help window to view the next page of the Table of
Contents.

3.6.2 Help Index

The Index list is directly accessible from the Index on the Help menu item or from the Index
tab within the on-line help utility. Index terms consist of:
· definitions
· formulas, if applicable
· recommended values, if applicable.
To access an item from the Index list:
· Use the scroll bar on the right hand side to scroll the window to the desired item.
· Point to the term or phase desired.
· Double-click on the highlighted word to open.
-Or-
· Use the keyword field to search for the desired item.
· Once found, double-click on the highlighted word to open.

3.6.3 Help Search

Another method to find a particular topic in Help is to use the Search option. To display the
Search window, either choose Search from the Help menu on the application window or
click the Search tab on the Help topic screen.
Select a topic by:
· Use the keyword field to search for the desired item.
· click on the List Topics button to search on the keyword entered
· A list of related topics then appears on the screen.
· Once found, double-click on the highlighted topic to open.

3.6.4 Help Active Window

Window level help provides information on the display that currently has focus. Information
for each window includes:
· purpose of the window
· specific field descriptions
· window button explanations
 Shop Floor Monitor 107

This type of help is available by selecting and opening a desired window. Once opened,
select the Help-Active Window menu on the application window or press the F1 key.
NOTE: If there are currently no PlantStar windows open, this menu item will not display any
help.

3.6.5 About PlantStar

For up-to-date resource information, the application provides a window with the following
information:
· PlantStar Software Version
· PlantStar Copyright Date
· Microsoft Windows Version
· Amount of free memory
To see this information:
· Select the Help menu on the main menu.
· Choose the About PlantStar menu item.
SYSCON - PlantStar System
User's Guide

Part

IV
 Voice Output 109

4 Voice Output
A PlantStar system configured with the Voice Output Option is able to broadcast messages
relating to currently monitored exception conditions such as:

Down states
Idle states
Fast states
Slow states
Assist states
Production exceptions
Process variable exceptions
Reject Exceptions
These messages can be heard on speakers or public address systems. There are three
primary components to the Voice application:

Configuring Your Voice System

Monitoring Exception Conditions
Monitoring Individual Machine Status
The general procedure for setting up a Voice system is:
· Define Your System Parameters - Decide upon how often announcement messages
should be broadcast. Use the System Parameters window under the Configure
menu to set this schedule.
· Define The Announcement Format - Decide whether each exception announcement
should be preceded by an attention announcement. Use the Attention
Announcement window under the Configure menu to set this schedule.

· Configure The Announcements - Decide on which machines, machine states,

process variable exceptions, assist reasons, and down reasons should be monitored
for exception announcement. Setup of these conditions is done via the Configure
windows.

4.1 File Menu

4.1.1 Exit
To exit the program, choose one of the following methods:
· Select the Exit option under the File menu
· Click your mouse button while it is positioned over the 'x' in the upper right hand
corner of the window.
NOTE: You must have the Exit Panorama privilege to exit the Monitor program.
110 SYSCON-PlantStar Help System

4.2 Monitor Menu

4.2.1 Exception Summary

The Exception Summary window highlights machines that are experiencing performance
problems. These are machines that are in an exception state for the selected display group.
There is one line of information for each machine within a display group. The color of the line
reflects the machine's running state. See the Machine State Colors on-line help section for
further information.
If a machine is in exception, the applicable column information is displayed. For example, if a
machine is in process exception, the Process Variable column displays the variable in
violation. If a machine is in assist state, the assist reason displays in the Assist Reason
column.
NOTE: More than one type of exception can be displayed at one time. The "Machine" and
"Exception Since" columns both display the highest priority machine running state.
Highlighted exception states are:

down state
idle state
off-line state
process exception
production exception
assist state
Where can you find it?

Choose the Monitor menu on the main your system window.

 Voice Output 111

Choose the Exception Summary option.

What do you want to know about?

Changing Display Groups

Changing View Options
Viewing Machine Exceptions
Closing the Window

4.2.2 Machine Exception

The Machine Exception window provides a greater detailed description of a selected

machine's running state than the Exception Summary window. Any running state of the
machine is displayed along with an exception time. If a process variable is in exception, this
window shows whether it is a result of a higher limit or lower limit violation. Also, this window
is color-coded according to the system Machine State Colors.
Where can you find it?

Choose the Monitor menu on the main your system window.

Choose the Machine Exception option.
NOTE: The Machine Exception window can also be accessed from the Exception
Summary window. While on the Exception Summary window, click on a machine's row of
information. Exception information for the selected machine appears.
What do you want to know about?

Changing Display Groups

Changing Machines
112 SYSCON-PlantStar Help System

Closing the Window

4.3 Configure Menu

4.3.1 System Parameters

The System Parameters window lets you set the number of minutes between repeat
announcements of the same exception condition. This time delay can be set for all machines
in the specified work center. If a specific work center is selected and its announcement delay
set, all Voice windows and announcements will refer to only those machines in the selected
work center.
A list of defined work centers is displayed upon the opening of this window. Choose the
desired work center and type in its required Announcement delay.
Where can you find it?

Click on the Configure menu.

Choose the System Parameters option.
What do you want to know about?

Changing Work Centers

Saving your Changes
Undoing your Changes
Closing the Window

4.3.2 Attention Announcement

The Attention Announcement window lets you record and plays attention announcements.
This announcement is broadcast before any other exception announcement and can be
turned on or off as desired from the Play Attention field.
 Voice Output 113

Where can you find it?

Click on the Configure menu.

Choose the Attention Announcement option.
What do you want to know about?

Playing an Announcement
Recording an Announcement
Activating an Attention Announcement
Saving your Changes
Closing the Window

4.3.3 State Announcement

The State Announcement window lets you record and plays announcements for all machine
running conditions except standard. Upon initially opening the window, each condition for
which an announcement can be recorded is listed. Choose the desired machine state and
click on the Record command button.
Where can you find it?

Click on the Configure menu.

Choose the State Announcement option.
What do you want to know about?

Playing an Announcement
Recording an Announcement
Closing the Window
114 SYSCON-PlantStar Help System

4.3.4 Down Announcement

The Down Announcement window lets you record, play and copy announcement
messages for whenever a machine goes into a down state. A separate announcement
can be recorded for each defined down reason within a selected down set.
Note: Down does not mean the machine is no longer cycling. A machine is considered
down under one of the following circumstances:
· The machine is cycling so slowly that the actual cycle time is longer than the down time
threshold specified in the current job.
· The operator has selected a down reason that 'forces' the machine into a down state.

Where can you find it?

Click on the Configure menu.

Choose the Down Announcement option.
What do you want to know about?

Playing an Announcement
Copying an Announcement
Recording an Announcement
Saving your Changes
Undoing your Changes
Closing the Window
 Voice Output 115

4.3.5 Assist Announcement

The Assist Announcement window lets you record, play and copy announcement
messages for whenever a machine goes into an assist state. A separate announcement
can be recorded for each defined assist reason within a selected assist set.
Where can you find it?

Click on the Configure menu.

Choose the Assist Announcement option.
What do you want to know about?

Playing an Announcement
Copying an Announcement
Recording an Announcement
Saving your Changes
Undoing your Changes
Closing the Window
116 SYSCON-PlantStar Help System

4.3.6 Process Announcement

The Process Announcement window lets you record, play and copy announcement
messages for a machine's process variables. A separate announcement can be recorded
for each defined process variable for any existing machine.
Where can you find it?

Click on the Configure menu.

Choose the Process Announcement option.
What do you want to know about?

Playing an Announcement
Copying an Announcement
Recording an Announcement
Saving your Changes
Undoing your Changes
Closing the Window
 Voice Output 117

4.3.7 Machine Announcement

The Machine Announcement window lets you determine which exception states will be
announced on a machine by machine basis. Once selected for announcement, an
exception condition can have its own announcement message recorded and played back.
A list of defined machines is displayed upon the opening of this window. Select the
announcement conditions for a machine by clicking the box to the right of the desired
condition. Click on the Record button to record the appropriate announcement message.
Where can you find it?

Choose the Configure menu.

Choose the Machine Announcement option.
What do you want to know about?

Playing an Announcement
Recording an Announcement
Saving your Changes
Undoing your Changes
Closing the Window

4.4 Options Menu

4.4.1 Silence Mode

All voice announcements can be suspended from the Silence Menu option. When
announcements are suspended, existing voice messages are not deleted. They are saved for
later re-activation. Upon re-activation of all voice announcements, existing messages
immediately sound if an exception condition is occurring. The suspension period stays in
118 SYSCON-PlantStar Help System

effect as long as a check mark appears next to this option.

· To select this mode, choose the Options menu on the main Voice window.
· Click on the Silence menu option. A check mark appears indicating the activation of
announcement suspensions.
· To de-select this option, click on the Silence menu option until no check mark
appears on the left- hand side.

4.4.2 Changing Text Sizes

This option sets the font size for the current PlantStar
application.
Text size choices are:
· Tiny

· Small
· Medium
· Large
· Huge

4.5 Window Menu

4.5.1 Arrange Icons
To arrange the iconized windows into straight rows and columns, select the Window
menu on the main screen of your system window. Choose the Arrange Icons option.

4.5.2 Arrange Windows

The windows can be arranged in 3 ways:

Cascading:

Vertical Tiles:

Horizontal Tiles:

To choose one of these styles, select the Window menu from the main screen of your
system window. Select one of the options displayed.
 Voice Output 119

4.6 Help Menu

4.6.1 Help Contents
General content help provides a table of contents for virtually all topics within this
application. The Contents window can be used to jump to topics that explain various
windows or how to get quick access to key reference topics. This help is available by
selecting the Contents on the Help menu item.
Use the scroll bar to the right side of the Help window to view the next page of the Table of
Contents.

4.6.2 Help Index

The Index list is directly accessible from the Index on the Help menu item or from the Index
tab within the on-line help utility. Index terms consist of:
· definitions
· formulas, if applicable
· recommended values, if applicable.
To access an item from the Index list:
· Use the scroll bar on the right hand side to scroll the window to the desired item.
· Point to the term or phase desired.
· Double-click on the highlighted word to open.
-Or-
· Use the keyword field to search for the desired item.
· Once found, double-click on the highlighted word to open.

4.6.3 Help Search

Another method to find a particular topic in Help is to use the Search option. To display the
Search window, either choose Search from the Help menu on the application window or
click the Search tab on the Help topic screen.
Select a topic by:
· Use the keyword field to search for the desired item.
· Click on the List Topics button to search on the keyword entered
· A list of related topics then appears on the screen.
· Once found, double-click on the highlighted topic to open.

4.6.4 Help Active Window

Window level help provides information on the display that currently has focus. Information
for each window includes:
· purpose of the window
· specific field descriptions
120 SYSCON-PlantStar Help System

· window button explanations

This type of help is available by selecting and opening a desired window. Once opened,
select the Help-Active Window menu on the application window or press the F1 key.
NOTE: If there are currently no PlantStar windows open, this menu item will not display any
help.

4.6.5 About PlantStar

For up-to-date resource information, the application provides a window with the following
information:
· PlantStar Software Version
· PlantStar Copyright Date
· Microsoft Windows Version
· Amount of free memory
To see this information:

· Select the Help menu on the main menu.

· Choose the About PlantStar menu item.
SYSCON - PlantStar System
User's Guide

Part

V
122 SYSCON-PlantStar Help System

5 View and Print

The Custom Reports Print program provides three primary functions:
· Prints custom reports
· Schedules custom reports
· Prints scheduled reports automatically

Prints Custom Reports - Users can print custom reports on-demand. Any criterion that was
defined via the Custom Reports Manager program is used to determine the content of any
report. Both on-line and paper reports can be generated.
Schedules Custom Reports - It is possible to set up a schedule for automatic printing
of custom reports. Listed below are the scheduling options available:
· Reports can be scheduled to print at a specific time
· Reports can be scheduled on a daily basis
· Reports can be scheduled on a weekly basis
· Reports can be scheduled to print at the end of a shift
· Reports can be scheduled to print at the end of each job
· Reports can be printed on any network printer or sent to an HTML file.
Prints Scheduled Reports Automatically – The Custom Reports Print program
automatically prints any custom reports that you scheduled to your default Windows printer.
Other users may schedule different custom reports on their PC. Their reports will not print
out from your PC.
To print scheduled reports, this program actively monitors end-of-shift and end-of-job events
to determine when reports need to be printed. If the Print program is minimized, your custom
reports will automatically print. If the Print program is not running when a scheduled event
occurs, no scheduled reports will be printed. The next time the Print program is opened, you
will receive a message asking to print previously-scheduled reports.

5.1 Custom Reports

5.1.1 View
 View and Print 123

Once a custom report has been designed and defined within PlantStar, the Print Custom
Report window provides the capability of printing those reports on-demand. A list of
defined reports appears upon entry into the window. When one of these custom reports is
printed, any criteria that has been defined for the report is utilized.
In terms of printing capabilities, both on-line and paper reports are available.
Where can you find it?

Choose the Custom Reports menu on the main window.

Choose the Print option.
What do you want to know about?

Selecting a Report
Selecting Criteria for a Report
Viewing the Selected Report
Sending a Report to the Printer
Refreshing the Display

5.1.2 Schedule

The Schedule Custom Reports window lets you schedule custom reports that have
been defined within PlantStar for automatic printing. A variety of scheduling options are
available:
· Weekly Reports
· Daily Reports
· End-of-Shift Reports
· End-of-Job Reports
Custom reports are scheduled on a PC by PC basis. For example, the Custom Reports
Print program automatically prints any custom reports that you schedule to your default
124 SYSCON-PlantStar Help System

Windows printer. Other users may schedule different custom reports on their PC. Their
reports will not print out from your PC.
NOTE: For scheduled reports to print, the Custom Reports Print program must be
minimized. If the Custom Reports Print program is not running when a scheduled event
occurs, no scheduled reports will be printed. The next time the Custom Reports Print
program is opened, you will receive a message asking to print previously-scheduled reports.
Where can you find it?

Click on the Custom Reports menu.

Choose the Schedule option.
What do you want to know about?

Changing Display Groups

Creating a New Report
Changing a Report
Ignore Criteria in a Report
Selecting a Period Interval
Set Report to Display in HTML Format
Assigning a Report File Name
Deleting a Scheduled Report
Saving your Changes

5.1.3 Exit
To exit the program, choose one of the following methods:
· Select the Exit option under the Custom Reports menu
· Click your mouse button while it is positioned over the 'x' in the upper right hand
corner of the window.

5.2 Help Menu

5.2.1 Help Contents
General content help provides a table of contents for virtually all topics within this
application. The Contents window, when on-line, can be used to jump to topics that
explain various windows or how to get quick access to key reference topics. This help is
available by selecting the Contents on the Help menu item.
Use the scroll bar to the right side of the Help window to view the next page of the table of
contents.

5.2.2 Help Index

The Index list is directly accessible from the Index on the Help menu item or from the Index
tab within the on-line help utility. Index terms consist of:
· definitions
· formulas, if applicable
 View and Print 125

· recommended values, if applicable

To access an item from the Index list:
· Use the scroll bar on the right hand side to scroll the window to the desired item.
· Point to the term or phase desired.
· Double-click on the highlighted word to open.
-Or-
· Use the keyword field to search for the desired item.
· Once found, double-click on the highlighted word to open.

5.2.3 Help Search

Another method to find a particular topic in Help is to use the Search option. To display the
Search window, either choose Search from the Help menu on the application window or
click the Search tab on the Help topic screen.
Select a topic by:
· Use the keyword field to search for the desired item.
· Click on the List Topics button to search on the keyword entered
· A list of related topics then appears on the screen.
· Once found, double-click on the highlighted topic to open.

5.2.4 Help Active Window

Window level help provides information on the display that currently has focus. Information
for each window includes:
· purpose of the window
· specific field descriptions
· window button explanations
This type of help is available by selecting and opening a desired window. Once opened,
select the Help-Active Window menu on the application window or press the F1 key.
NOTE: If there are currently no PlantStar windows open, this menu item will not display any
help.

5.2.5 About PlantStar

For up-to-date resource information, the application provides a window with the following
information:
· PlantStar Software Version
· PlantStar Copyright Date
· Microsoft Windows Version
· Amount of free memory
To see this information:
· Select the Help menu on the main menu.
· Choose the About PlantStar menu item.
SYSCON - PlantStar System
User's Guide

Part

VI
128 SYSCON-PlantStar Help System

6 Design Manager
The Custom Reports Manager program transfers custom reports designed in Crystal
Reports into PlantStar. It provides editing capabilities for these reports, deletion
capabilities, and provides for the selection of report search criteria.
Transferring Reports Into PlantStar - The first step in using custom reports within
PlantStar is to design a report within the Crystal Reports program. Once a report has
been designed, it can be transferred into PlantStar. The PlantStar database tables and
fields must be used to create this custom report.
Editing Report Definitions - Custom reports can be edited from the Custom Reports
Manager window. A report's name, description, definitions, and criteria are
changeable.
Selecting Report Criteria - Report criteria can be set up from this window. Report criteria
designate what type of information is included in a report. For example, a job history report
can include all jobs for a certain product or it can be a report on a specific job. Several fields
can be selected as criteria for a report or just one field.
Criteria can also be set up for a report from within the Crystal Reports program. If fields
are also designated as criteria from the Custom Reports Manager program, then the
affected report is based upon BOTH sets of criteria.
 Design Manager 129

6.1 Design Manager

The Custom Reports Manager program transfers custom reports designed in Crystal
Reports into PlantStar. It provides editing capabilities for these reports, deletion
capabilities, and provides for the selection of report search criteria.
Transferring Reports Into PlantStar - The first step in using custom reports within PlantStar is
to design a report within the Crystal Reports program. Once a report has been designed, it
can be transferred into PlantStar. The PlantStar database tables and fields must be used to
create this custom report. Crystal Reports 9.0 or above must be used.
Editing Report Definitions - Custom reports can be edited from the Custom Reports
Manager window. A report's name, description, definitions, and criteria are changeable.
NOTE: Standard PlantStar reports can be edited, but must be saved as a report with a
different name
Selecting Report Criteria - Report criteria can be set up from this window. Report criteria
designate what type of information is included in a report. For example, a job history report
130 SYSCON-PlantStar Help System

can include all jobs for a certain product or it can be a report on a specific job. Several fields
can be selected as criteria for a report or just one field. Criteria can also be set up for a report
from within the Crystal Reports program. If fields are also designated as criteria from the
Custom Reports Manager program, then the affected report is based upon BOTH sets of
criteria.
Where can you find it?
The Custom Reports Manager window is the only window within the Design
Manager application.
What do you want to know about?

Selecting a Report
Transferring a Custom Report into PlantStar
Editing Report Definitions
Setting Report Criteria
Deleting a Custom Report From PlantStar

6.2 Help Menu

6.2.1 About PlantStar
For up-to-date resource information, the application provides a window with the following
information:
· PlantStar Software Version
· PlantStar Copyright Date
· Microsoft Windows Version
· Amount of free memory
To see this information:
· Select the Help menu on the main menu.
· Choose the About PlantStar menu item.

6.2.2 Exit
To exit the program, choose one of the following methods:
· Select the Exit option under the Help menu
· Click your mouse button while it is positioned over the 'x' in the upper right hand
corner of the window.
SYSCON - PlantStar System
User's Guide

Part

VII
132 SYSCON-PlantStar Help System

7 DCM Browser Interface

The browser screens at the DCM are divided into three sections, or frames. The menu frame
is located at the top of the screen and displays the machine, child, and screen which are
currently being viewed. It also supplies easy navigation between machines on the same
DCM, and has the capability of a user definable navigation link that can be accessed by
pressing the SYSCON-PlantStar logo in the upper right corner.
The main frame occupies the central screen area and contains the screen specific data.
This frame, depending on the screen being viewed, can provide summary data, detail data,
and/or data entry capabilities.
Across the bottom of the screen is the lights frame which provides both status information
and navigation. The various buttons, or lights, allow the user to have a quick visual summary
of the status of the currently viewed machine. The colors of the buttons will change
depending on the machine state and follow the color conventions used in all other SYSCON-
PlantStar products.
Both the menu frame and the lights frame are shown for every screen that is being
displayed in the main frame. This allows for a consistent interface regardless of the
current function being utilized.

Menu Frame
 DCM Browser Interface 133

Main Frame

Lights Frame

7.1 Menu Frame

The menu frame is the primary method of navigating between machines on a DCM, and the
children of a particular job. In addition a clock button and the current screen name are
displayed.

What do you want to know about?

Changing machines
Displaying parent or child job information
Changing the language used
Linking to another web page
134 SYSCON-PlantStar Help System

7.1.1 Machine Navigation

These buttons allow you to scroll through the machines on a particular DCM. The
machines available are those that are configured to be on the same DCM and the order
follows the machine index as defined within the shop floor configuration program.

7.1.2 Child Navigation

These buttons allow you to navigate through the children of the currently running job on the
selected machine. The displayed text is the same as the job field as defined when the job was
created.

7.1.3 Menu Clock

The current date and time of the computer being used to browse to the DCM is displayed
here.
This button also allows for the selection of which language is being used to describe the
fields being displayed. Repeated pressing, will cycle through all available languages.

7.1.4 Logo Link

The SYSCON-PlantStar logo in the menu frame is actually an HTML hyperlink. This can be
configured by the system administrator to link any other web page available on the
 DCM Browser Interface 135

company's intranet.
Caution should be used when this link is selected as all three DCM frames will be replaced
with the new page. This may lead to confusion and/or difficulty in returning to the DCM
browser interface.

7.2 Main Frame

The Main Frame for the DCM browser screens occupies the center of the display. While it is
possible to navigate outside of the default frames from setup sheets or through the use of the
logo link, all of the PlantStar data pertaining to a specific DCM will be displayed here.
The Lights Frame that is displayed across the bottom of the screen is the main navigation
tool for moving between the available screens. The following screens can be viewed within
this frame:

Job Summary
Down Select
Assist Select
Reject Update

Process Summary
Process Select
Process Table
Process Graph

SPC Graph
Profile Tiled
Profile Overlay
Profile Cross Plot
Profile Store Graph

SQC Sample

Production Summary
Setup Sheets
Job Update
Labor Login
Material Lot
Machine Logs

7.2.1 Job Summary

The left half of the Job Summary screen displays information for a selected job running on a
machine. A summary of the pieces produced and rejected is provided for the current shift and
the job to date.
136 SYSCON-PlantStar Help System

The Job Summary screen allows you to scroll through the job queue information for the
selected machine which is set up via the Job Scheduling Board in the Shop Floor Monitor
Program. The current job running on the machine can be changed by using the selection
buttons on the right side of the screen.
Images for the current and the next scheduled job products can be displayed in the lower
right area of the screen.

If a tote box is defined for a job, an additional section of information will appear on the Job
Summary screen above the shift and job totals area. The section tracks the job progress in
units based on the tote box size and if required, it allows the operator to mark an incomplete
tote as finished or to reprint a tote label.

7.2.2 Down Select

The Down Select screen allows the operator to select the appropriate reason for why the
selected machine is down. Pressing one of the down reason buttons will highlight that
reason and all down time will be assigned to that reason. If another reason is selected then
any additional down time will be associated with the newly selected reason.
Twenty reasons are listed on a down screen. For installations where the extended down
option has been purchased, the buttons along the top of this screen will allow navigation
to additional down reasons.
 DCM Browser Interface 137

The down select screen displays the accumulated down time for each possible down
reason of the currently running job.
138 SYSCON-PlantStar Help System

7.2.3 Assist Select

The Assist Select screen allows the shop floor staff to "call for help" by pressing the button
for the appropriate assist reason. The call for help is logged in the system and the machine
is put into the assist state which will be reflected in the lights frame. Once selected, time is
accrued until the assist button is pressed again to turn off the assist state.
The screen displays the accumulated assist time for each possible assist reason for the
currently running job.

7.2.4 Reject Update

The Reject Update screen provides a summary of rejects that have been assigned to each
defined reject reason for the current job. It also provides a means for the operator to add or
subtract rejects for a reject reason. For a family job, the parent screen will display an
accounting summary for each child.
Twenty reasons are listed on a reject screen. For installations where the extended reject
option has been purchased, the buttons along the top of this screen will allow navigation to
additional reject reasons.
 DCM Browser Interface 139

Pressing one of the reject reason buttons will highlight that reason and a keypad will be
presented. The amount of rejects to be assigned to that category can then be entered.
Negative numbers can be entered to subtract rejects from a category. In addition to the
actual quantity of rejects, the part weight can be used so that a given weight can be entered
as rejects. This weight will be divided by the part weight so that an actual part count can be
automatically rejected.
140 SYSCON-PlantStar Help System

The Reject Update screen for a family job displays an accounting summary for each child
on the parent screen. The background color of the row in the summary table reflects the
machine state for the child.

This parent screen can be used to reject an entire cycle of parts as shown below.
Using the menu frame to navigate to a child job allows rejects to that specific part
as described above.
 DCM Browser Interface 141

7.2.5 Process Summary

The Process Summary screens display information for a machine's process variables
measured during the last fifty complete machine cycles. The table of values includes the
low and high limits defined for the current job, the last value, the high value and low
value, and the average value for each process variable defined. Up to twenty-five
variables can be displayed per screen and navigation buttons are provided to scroll
between summary screens.
The Process Summary screen provides quick access to the Process Select, Profile, and
SQC Sample screens for a specified machine by using the screen navigation buttons at the
left side.
When a process variable reading is collected, it is compared to the process limits which have
been defined for the job. If a process variable is above the higher limit or below the lower
limit, that process variable is highlighted according to the following default color scheme:
· Red - value is above the higher limit
· Blue - value is below the lower limit
If a process variable is outside of its defined limits for the job, the machine will be
put in the process exception state for that cycle which will be reflected in the lights
frame.

What do you want to know about?

Selecting a process variable to see more detailed information

Displaying profile information
Taking an SQC Sample
142 SYSCON-PlantStar Help System

7.2.5.1 Process Select

The Process Select screen allows for monitoring up to fifty process variables that may be
defined for the currently running job on the selected machine.
It provides a quick visual reference to monitor the process exception state for a machine. If
the last value recorded for a process variable is above the higher limit or below the lower
limit defined for the job, that process variable is highlighted according to the following
default color scheme:
· Red - value is above the higher limit
· Blue - value is below the lower limit
If a process variable exceeds its defined limits for the job, the machine will be put in the
process exception state for that cycle which will be reflected by the color conventions used in
the lights frame.
Pressing a process variable button will display the Process Table screen for the selected
variable.
The Process Select screen also provides quick access to the Profile, and SQC Sample
screens for a specified machine by using the buttons at the top left. Use the Lights Frame to
return to the Process Summary screen.

What do you want to know about?

Selecting a process variable to see the last fifty values

Displaying profile information
 DCM Browser Interface 143

Taking an SQC Sample

7.2.5.2 Process Table

The Process Table screen details the history of a process variable over the last fifty machine
cycles. The name, defined limits, and units of the variable are shown in the table heading. If a
process variable is above the higher limit or below the lower limit defined for the job, that
process variable value is highlighted in the table according to the following default color
scheme:
· Red - value is above the higher limit
· Blue - value is below the lower limit
If the last value of a process variable exceeds its defined limits for the job, the machine will
be put in the process exception state for that cycle which will be reflected in the lights
frame.
There are three screen navigation buttons on the left to navigate among the Process
Screens. The Process Select button will return you to the selection screen. The Graph
button provides the option to display the data in graphical form on the Process Graph
screen. If SPC data is available, a navigation button will be shown to display the SPC graph.

Use the Lights Frame to return to the Process Summary screen.

What do you want to know about?

Displaying the values as a graph

Displaying an SPC graph for the variable information
144 SYSCON-PlantStar Help System

7.2.5.3 Process Graph

The Process Graph screen for a variable can be displayed by pressing the "GRAPH"
button on the Process Table screen. The variable name and the units of measurement are
displayed at the top of the graph. The high and low limits as defined for the job are
indicated on the left side.
The x-axis is the cycle number. The y-axis is the actual process variable value. The graph
can display the last fifty values with the rightmost point being the most recent value. For each
machine cycle update, the new value enters from the right and moves the older values to the
left. An undefined value will be a blank space in the graph.
There are three screen navigation buttons to navigate among the Process Screens. This
screen provides the option to display the data in graphical form on the Process Graph
screen. If SPC data is available, a navigation button will be shown to display the SPC graph
as shown in the screenshot. The Process Select button will return you to the selection
screen.
There are three screen navigation buttons on the left to navigate among the Process
Screens. The Process Select button will return you to the selection screen. The Table
button provides the option to return to the data detail on the Process Table screen. If SPC
data is available, the Navigation button will be shown to display the SPC graph.

Use the Lights Frame to return to the Process Summary screen.

7.2.5.4 Process SPC

The Process SPC screen displays SPC data that is monitored by the DCMs. The standard
SPC statistics are shown at the top of the screen. The top graph is a plot of X-bar values and
the bottom is a plot of the associated range values. The X-axis is the time at which the SPC
 DCM Browser Interface 145

values were recorded.

The Process SPC screen can only be selected from the Process Table screen for a process
variable if SPC data is available.
There are three screen navigation buttons on the left to navigate among the Process
Screens. The Process Select button will return you to the selection screen. The Table button
provides the option to return to the data detail on the Process Table screen. The Graph
button provides the option to display the data in graphical form on the Process Graph
screen. Use the Lights Frame to return to the Process Summary screen.

Alarms are displayed to the right of the graph. The key for the alarms is as follows:
XCL The last X-bar value was not within control limits
RCL The last Range values was not within control limits
INC The last 8 X-bar values were continuously increasing
DEC The last 8 X-bar values were continuously decreasing
ABV The last 8 X-bar values were above the mean
BLW The last 8 X-bar values were below the mean
UTR The last 25 X-bar values show an upward trend
DTR The last 25 X-bar values show a downward trend
RSM Within the last 25 X-bar values, a RUNSUM exceeded 4.
146 SYSCON-PlantStar Help System

7.2.5.5 Profile Tiled

The Profile Tiled screen graphically displays the values of machine's profile data. A profile is
a set of up to 500 readings of a rapidly changing process variable, such as pressure or
position, collected during one machine cycle. Up to four profiles can be monitored and
displayed for a machine.
The Profile Tiled screen is the default profile screen that is displayed when the "PROFILE"
button is selected on either the Process Summary or the Process Select screens.
The area below the graphs provides additional option buttons for displaying profile
information. One or more of the available profile variables can be selected/deselected for
graphing by using the named buttons. In addition, the profile screens provide navigation
buttons to display the four available graph formats:
· the profile tiled graph
· the profile overlay graph
· the profile cross plot graph
· the profile store graph

Use the Lights Frame to return to the Process Summary screen.

7.2.5.6 Profile Overlay

The Profile Overlay screen graphically displays the values of machine's profile data. A
profile is a set of up to 500 readings of a rapidly changing process variable, such as pressure
or position, collected during one machine cycle. The overlay displays up to four profiles for a
machine on one graph.
 DCM Browser Interface 147

The Profile Tiled screen is the default profile screen that is displayed when the "PROFILE"
button is selected on either the Process Summary or the Process Select screens. The
Profile Overlay screen can only be selected from another of the profile graph screens.
The area below the graphs provides additional option buttons for displaying profile
information. One or more of the available profile variables can be selected or deselected for
graphing by using the named buttons. In addition, the profile screens provide navigation
buttons to display the four available graph formats:
· the profile tiled graph
· the profile overlay graph
· the profile cross plot graph
· the profile store graph

Use the Lights Frame to return to the Process Summary screen.

7.2.5.7 Profile Cross

The Profile Cross screen graphically displays the values of machine's profile data. A profile
is a set of up to 500 readings of a rapidly changing process variable, such as pressure or
position, collected during one machine cycle. The cross plot displays two selected profiles for
a machine on one graph. The profiles selected must have the same delay and period defined.
The first variable is the x-axis value and the second variable is the y-axis value in the cross
plot.
If a valid combination of two profile variables has not been selected, the profile store screen
will display the list of combinations from which to choose as shown below.
The Profile Tiled screen is the default profile screen that is displayed when the "PROFILE"
button is selected on either the Process Summary or the Process Select screens. The
Profile Cross screen can only be selected from another of the profile graph screens.
148 SYSCON-PlantStar Help System

The area below the graphs provides additional option buttons for displaying profile
information. One or more of the available profile variables can be selected or deselected for
graphing by using the named buttons. In addition, the profile screens provide navigation
buttons to display the four available graph formats:
· the profile tiled graph
· the profile overlay graph
· the profile cross plot graph
· the profile store graph

Pressure, inject position, and temperature were selected in this example. This is an error
because only two profiles can be selected for the profile cross graph. The valid
combinations are listed on the screen.
 DCM Browser Interface 149

Use the Lights Frame to return to the Process Summary screen.

7.2.5.8 Profile Store

The Profile Store screen graphically displays the values of one machine profile variable
over time. A profile is a set of up to 500 readings of a rapidly changing process variable,
such as pressure or position, collected during one machine cycle. The profile store displays
the profile data from successive machine cycles on one graph.
The Profile Tiled screen is the default profile screen that is displayed when the "PROFILE"
button is selected on either the Process Summary or the Process Select screens. The
Profile Store screen can only be selected from another of the profile graph screens.
The area below the graphs provides additional option buttons for displaying profile
information. One or more of the available profile variables can be selected or deselected for
graphing by using the named buttons. In addition, the profile screens provide navigation
buttons to display the four available graph formats:
· the profile tiled graph
· the profile overlay graph
· the profile cross plot graph
· the profile store graph
150 SYSCON-PlantStar Help System

Use the Lights Frame to return to the Process Summary screen.

7.2.5.9 SQC Sample

The SQC Sample screen allows the operator to sample the next shot and print a sample
label for quality auditing purposes with the "SAMPLE NEXT SHOT" button. The end of cycle
data is written to the machine's log file.
This screen is displayed using the "SQC SAMPLE" button on either the Process
Summary or the Process Select screens.
The screen displays an image of the current job product, job summary data, and the
current shot ID number as well as the shot ID numbers of the samples which have been
taken. The "CLEAR SHOT LIST" button will clear the screen list of sample ID numbers.
 DCM Browser Interface 151

Use the Lights Frame to return to the Process Summary screen.

7.2.6 Production Summary

The Production Summary screen presents a snapshot of the machine's current state in
terms of machine performance and progress toward completion of the current job. The
background color of the line reflects the machine's state.
In addition, the Production Summary screen has navigation buttons to access and update
further levels of production information. The Setup Sheet button is used to display the Job
Setup information. The Update button allows updating of the actual multiplier, reject multiplier,
and box count. The Labor button accesses the optional Labor Tracking feature which allows
employees to log in and out of specific machines and labor categories. The Material button
accesses the optional Material Lot Tracking feature. The Logs button displays the detail of
the event log.
152 SYSCON-PlantStar Help System

What do you want to know about?

Displaying information on the setup sheets.

Updating the reject multiplier, actual multiplier, or box count
Logging into a machine
Displaying the employees logged in for a machine
Logging out of a machine
Changing your labor category on a machine
Displaying the material components for a job
Changing a material component or lot ID number for a job
Displaying the event log for a job

7.2.6.1 Job Setup

The Job Setup screen allows for the display of job setup instructions for the current job or
any job in the job queue for a machine.
On browser based DCMs the setup sheet can contain HTML code and will be displayed as
such. This allows the insertion of hyperlinks and other html objects in the setup sheet.
 DCM Browser Interface 153

Use the Lights Frame to return to the Production Summary screen.

7.2.6.2 Job Update

The Job Update screen displays the standard multiplier for a job which is a product
parameter that defines the maximum number of pieces produced per machine cycle for a
job.
The actual multiplier, reject multiplier, and box count may be updated from this screen. To
update a value, first press the update button to the left of the desired field. The row will be
highlighted and the value that is typed on the keypad will be used to update the selected
row.
154 SYSCON-PlantStar Help System

Use the Lights Frame to return to the Production Summary screen.

7.2.6.3 Labor Login

If the Labor Tracking feature is enabled for your system and configured for a machine, the
Labor Login screen can collect employee data to help in the tracking of operator/staff
requirements and the costs of jobs being run on the shop floor.
The Labor Login screen allows an employee to login or logout of a specific machine. The
screen lists all employees currently logged into a machine, their labor category, and their
login time. The employee is prompted to enter a valid employee id with the keypad.
Employee's identification numbers and valid labor categories are defined in the Shop Floor
Configuration program. If the employee id is not valid, the user is presented with an "Invalid
Employee" message.
 DCM Browser Interface 155

When a valid employee id is entered with the keypad, a second screen is presented. The
name of the selected employee is shown in bold in the center of the screen. The keypad can
be used to change the selected employee.
The top of the screen displays up to 30 labor categories that are valid for the employee. The
employee must choose a labor category and press the "log in" button to log in to the
machine. The bottom of the screen lists the currently logged in employees for the selected
machine.

The Labor Login screen also allows an employee to logout of a machine or to change their
labor category on the selected machine. When the employee ID for an employee currently
logged into the machine is entered, the second screen which is presented will highlight the
selected employee's row in the employee list on the lower half of the screen. The logout
button is used to logout the selected employee and return to the Labor Login screen.
The valid labor categories for the employee are presented at the top of the screen. To
change labor categories, click on any valid category on the top of the screen and press the
"log in" button. The employee will be logged out of their current labor category for the
machine and logged in for their new category.
156 SYSCON-PlantStar Help System

Use the Lights Frame to return to the Production Summary screen.

7.2.6.4 Material Lot

If the Material Lot Tracking feature is enabled for your system, the Material Lot screen
provides an auditing feature to trace material lot usage. A material lot can be traced to a
specific tote box. For each tote box or material lot change at the DCM, an event is
recorded to form a lot history.
The Material Lot screen displays a list of the material components and material Lot IDs for
the current job. The Lot ID can be vendor or user-defined and will create an audit trail
between the lots of raw material fed into the machine and the finished products produced.
Several material changes can be specified to take effect as a group.
If a different raw material lot needs to be used on a running job, the SELECT button to the left
of the material name can be used to access a typewriter screen to enter a new material
name, Lot ID, and delay timer. The delay timer is used to specify the amount of time in
minutes that should elapse before the raw material change is to take effect on the job.
 DCM Browser Interface 157

To make your required changes, click the button below the field that you wish to update.
The button for the selected field will be highlighted. Type in the new value and press enter.
The value will be shown in the "Next Material Component", "Next Lot ID", or "Delay"
column as specified. If a delay is not specified, the default delay timer value is set to zero.
After all the required changes are entered, click "RETURN" to go back to the Material Lot
List screen.

Your changes will be recorded in the "Next Material Component", "Next Lot ID", and
158 SYSCON-PlantStar Help System

"Delay" columns on the material list.

At this time, additional materials can be selected from the list to specify changes that will take
effect as a group.
The timer will begin counting down when the RUN button is pressed on the material list
screen. The change goes into effect when the timer value counts down to zero. The PAUSE
button can be used to temporarily stop the timer count down. The CANCEL button will
discard any pending changes. When the time expires, the current materials are replaced
with the new materials and the event will be recorded in the audit trail.
Use the Lights Frame to return to the Production Summary screen.

7.2.6.5 Machine Logs

The Machine Log screen displays a list of the most recent events relating to a selected
machine. These events are recorded at the DCM.
All recorded events will be displayed by default or the events displayed can be filtered by
using one of the event type buttons on the left side of the screen. The selected filter button
will be highlighted. Event types include
· Job Related Events - start/end of a job or a job change;
· Shift Related Events - start of a new shift or a shift idle period;
· Down Events - start and end of down time periods;
· Assist Events - start and end of assist time periods;
· Process Alarm Events - time of a process exception, the actual "exception" value,
and the limit it violated. Process exceptions are only logged, though, if the machine
is not in a down state. If a process exception begins while a machine is down, the
exception events are not logged for the machine.
 DCM Browser Interface 159

· Material Events - material changes on the selected machine

· Labor Events - login and logout of users on the selected machine

Use the Lights Frame to return to the Production Summary screen.

7.2.7 Journals
The PlantStar Process Journal program is a web-based program designed to provide the
shop floor personnel with a method to record changes made to a process being monitored
by the PlantStar system.

An overview of the Process Journal program and instructions for how to view and
create Process Journal tickets can be found in Application Notes 2007-03 and 2007-
04.

7.3 Lights Frame

The Lights Frame, at-a-glance, gives the user the current machine state of the selected
machine. The colors of the buttons will change depending on the machine state and follow
the color conventions used in all SYSCON-PlantStar products.
This frame also serves as the primary navigation method for changing the screen that is
displayed within the main frame.
SYSCON - PlantStar System
User's Guide

Part
VIII
 System Administration 161

8 System Administration
8.1 Configuring the Host
This section outlines the installation for first-time setup of the host computer and
describes the installation results. For QuickShot systems, host configuration changes
require attachment of a monitor and keyboard, not supplied with the system.
Hardware Overview
The host computer and support equipment is, in virtually all cases, directly purchased from
SYSCON-PlantStar. The standard hardware package includes
· Server with external modem
· Uninterruptible power supply (UPS)
· Keyboard
Optional equipment, such as additional disk drives, printers, Modems and CDRW
drives can be purchased depending upon site configuration.
On QuickShot Systems, the host and DCM are both contained in one NEMA box.
Disk Space
The system database stores historical production and SPC information. How much it can
store on disk is dependent upon available disk space. Typically a year or more can be stored
on the supplied disks. The speed at which disk space is used is dependent upon the number
of machines defined and the number of monitored process variables. The host automatically
monitors its free space and alerts the administrator, via console messages, when space is
getting low.
Printers
Printers for generating paper copies of reports and screen captures can be connected to
the host computer directly or by Ethernet. Production reports are printed via client
workstations using their default or user-specified printer.

8.1.1 Software Configuration

Software Configuration
This section describes the steps necessary for first-time configuration of the host
computer. Another Chapter, Administering the Host Computer, provides information for
general maintenance on an on-going basis.
There are two utilities that set up the host computer – configure.f2k and netconfig. The
configure.f2k utility is used to define the host computer's time zone, your company name,
host name, and authorization key. It is also used to start and stop information routing
processes that run on the host. The netconfig utility is used to define and change the host's
Ethernet/internet and Slip addresses.

Configure.f2k Utility
162 SYSCON-PlantStar Help System

1. Log into the host computer as root. The initial password is pstar.
2. Check to make sure that the shop floor processes are running. Two processes
automatically startup upon booting. Type in psg sfd and then psg pcd.
3. The following should appear. The highlighted entries indicate that the Panorama
processes are running.
psg sfd

(A) 00:00:00 sh -c (sfd -s 60; CODE=$?7; DIFF…

(B) 00:00:00 sfd -s 60

psg sfd

(A) 00:00:00 sh -c (pcd ;CODE=$?7; DIFF=`dc >…

(B) 00:00:00 pcd

NOTE: More lines than shown above may appear.

4. At the shell prompt, type in configure.f2k and press the <ENTER> key. This command
starts up a utility to facilitate setting up your system. The following menu appears:

--Focus2000 Configuration--
Select Configuration Option

1. Set Time zone

2. Set System Time
3. Set Authorization Key
4. Set Company Name
5. Set Host name
6. Enable / disable startup
7. Start MySQL / Panorama
8. Stop MySQL / Panorama
9. Configure Email Server
10. Configure CD Burner
0. Exit
< OK > <Cancel>

5. Menu items 1 and 4 must be done for a first time software configuration. Each menu
item asks a series of questions. Be careful when answering these questions. The
configure.f2k program does not always have verification prompts
6. To set the time zone, type in 1, tab to <ok>, and press <ENTER>. The following
displays on the screen.
 System Administration 163

The MySQL RDBMS and Panorama will now be stopped.

After the time zone is set MySQL and PlantStar will be restarted.
< Yes > < No >

7. The first question is a warning message. Tab to <yes> and press the <ENTER> key
to continue. After Panorama and MySQL are stopped, the following will appear.
--HARDWARE CLOCK SET TO UTC--
Is the hardware clock set to Coordinated Universal Time
(UTC/GMT)? If it is, select YES here. If the hardware clock
is set to the current local time (this is how most PCs are
set up), then say NO here. If you are not sure what this is,
you should answer NO here.

NO Hardware clock is set to local time

YES Hardware clock is set to UTC
< OK > <Cancel>

8. Type n (or y), tab to <ok>, and press the <ENTER> key to continue. The time zone
options will appear.

--TIMEZONE CONFIGURATION--
Please select one of the following time
zones for your machine:
US/Alaska
US/Aleutian
US/Arizona
US/Central
US/East-Indiana
US/Eastern
US/Hawaii
US/Indiana-Starke
US/Michigan
US/Mountain
US/Pacific
US/Samoa
Africa/Abidjan…
< OK > <Cancel>

9. Scroll to select the desired time zone, tab to <ok>, and press <ENTER>. Panorama
will restart and the configuration menu will return.
10. The second option on the configuration menu is to set the system time. Select 2,
or scroll to the entry, tab to <ok>, and press <ENTER>. A warning prompt will
appear.
164 SYSCON-PlantStar Help System

Panorama will now be stopped.

After the time is set Panorama will be restarted.

< Yes > < No >

11. Respond with "yes", again, with tab to <yes> and press the <ENTER> key. After
Panorama is halted, a "Set Date" panel will be presented.

--Set Date--
Move between boxes with the Tab key.
Use the arrow keys to change values.
?
Month Year
March 2008

Sun Mon Tue Wed Thu Fri Sa

t
2 3 4 5 6 7 81
9 10 11 12 13 14 15
16 17 18 19 20 21 22
23 24 25 26 27 28 29
30 31
v(+)

< OK > <Cancel>

12. Tab to the Month, Year, and Day fields and use the scroll keys to select the
appropriate values. Then tab to <ok> and press <ENTER>. The "Set system Time"
panel will appear.
--Set System Time--
Move between boxes with the Tab key.
Use the arrow keys to change values.

10 : 55 : 55

< OK > <Cancel>

13. Move between the hours, minutes, and seconds, and then use arrow keys to scroll to
the desired values. Note the 24 hour clock vs. a.m. and p.m. When ready, select <ok>
and <ENTER>, as before. The time and date will be reset, Panorama will be
restarted, and the configuration menu will return.
14. Setting the authorization key, item 3, will be done by SYSCON-PlantStar personnel.
15. Select item 4 as previously-described to set the company name. This task does not
 System Administration 165

reboot the computer. A screen similar to the following appears.

--Company Name--
Your company name is currently:
?
SYSCON International, Inc.
?
Select Yes to change the name or No to abort.
< Yes > < No >

16. Select <Yes> and press the <ENTER> key to change your company name. Edit your
company name in the subsequent panel.

--Company Name Update--

Please enter your new company name (up to 50
characters)
My Company Name

< OK > <Cancel>

17. After updating your company name, select <ok> and <ENTER>. The system responds
with:

Company name update completed.

< OK >

18. Select <ok> and return to the configuration menu. Once finished with running all four
menu items, exit the configure.f2k program by selection option 0 (zero) and <ENTER>
19. Verify that the network environment is working. On a previously-configured
workstation, PING to the host computer.
Typical Installation Results
A successful host computer installation performs the following operations:
· Sets up the host computer hardware: console terminal, modem, and tape drive
· Sets the computer's time zone
· Sets the computer's company name
· Sets the computer's Ethernet/internet address
· Enables workstations to ping to the host computer
On the host computer, all system files are located in the directory, /focus2000. This
directory has four sub-directories. A brief description of each follows:
166 SYSCON-PlantStar Help System

Directory Purpose
DBextended Stores auxillary data files
installed Stores binary executable files and environment scripts
log Stores log files for all processes;
tmp Used for sorting and other miscellaneous tasks

8.2 Administering the Host

Administering the Host Computer
System monitoring of the host computer may need to be done periodically. Several LINUX
commands are described below to help in this monitoring activity. Your system provides
additional commands for viewing the status of the shop floor routing processes, identifying
current system users, and viewing your authorization string.
System Monitoring Commands
cat <filename>
Displays contents of a file. This command is useful for looking at the contents of log files, etc.
If a file is large, the tail command may be more efficient. Combine the cat command with the
more command to view files page by page:
cat sfd.log | more
Note: you must be in the /focus2000/log directory in order for this command to find the
sfd.log file.
df -l
Displays the amounts of free disk space and the percentage used. One line of information
appears for each defined file system. This command is useful for determining when to archive
system job information. It is recommended that one-third of the available space always
remain free.
Sample Output:
Filesystem 1K-blocks Used Available Use% Mounted on
/dev/md1 1003932 535244 468688 54% /
/dev/md3 132267060 9596352 122670708 8% /var
/dev/md4 2007932 82876 1925056 5% /tmp
/dev/md5 10008072 5805064 4203008 59% /home
/dev/md6 9992008 5094440 4897568 51% /usr

f2kdown <Level> <Time>

This utility will signal an orderly shutdown or startup to all active
workstations. Usage: f2kdown [Level] [Time]
Level - Shutdown level -1 =shutdown, 0=startup
Time - Minutes to wait before shutdown, 0 to 99
f2kulog -l
Displays a list of users currently logged into your system. This command can also be used
to delete any user processes that no longer respond from the workstation.
 System Administration 167

Sample Output:
LOG LOGIN USER INET ADDRESS PCC PID
SEQ TIME NAME (station)
10047 06/16/1994 08:46:42 pstar 128.1.11 .2(engtest2) 16075
Several other options are available for this command:
-d SEQ Deletes the F2K user login where LOG_SEQ = SEQ
-d all Deletes all existing F2K user logins.
-k SEQ Deletes the F2K user login where LOG_SEQ = SEQ and kills the associated
f2kpcc process. This option is used when the workstation has become
unresponsive.
ls
Displays a list of files for a directory in alphabetic order. If the -l option is used with the ls
command the mode, number of links, owner, group, size (in bytes), and time of last
modification for each file displays. If the file is a special file, the size field contains the major
and minor device numbers. If the file is a symbolic link, the path name of the linked-to file is
printed preceded by a ->. The attributes of the symbolic link are displayed.
more
Paginates displayed information; can be used with almost any Linux command.
For example:
set | more = displays current environment variables page by page.
cat sfd.log | more = displays the sfd.log file page by page for ease of reading.
Use the space bar to scroll to the next page of information;
Use the <ENTER> key to scroll one line;
Press the Q key to stop viewing the information in question.
ps -ef
Displays active processes in terms of time started, process IDs, and other general
information. List has headings for each column of information provided.
Sample Output:
USER PID TTY STAT TIME COMMAND
root 29501 tty3 Ss+ 0:00 -bash REMOTEHOST=…
root 1647 tty6 Ss+ 0:00 /sbin/agetty 38400 tty6…
read_auth
Displays the host computer's current authorization string as well as all authorized system
features. A Yes or No appears after each available feature.
168 SYSCON-PlantStar Help System

Example Output:

Authorization Utility for Panorama, Version 4.30

Authorization String: PIBPHFCE IBKFFLBH GHEKGOLM QHEHFIQH DIKIKEBE

********** Authorized Features ***********

1(10)Max Users | 2(Y)PVAR | 3(N)Camac XTA | 4(Y)Maco 8000
5(N)Moog | 6 (N) GageTalk | 7 (N)Mitutoyo | 8(N)Mettler
9(Y)Engel |10(N)Precisa |11(Y)Camac 486,VSX |12(N)Camac VLC
13(Y)Roboshot,ACT |14(N)CRT-C |15(Y)Pathfinder |16(N)Accudata
17(N)BetaMUX |18(N)HPM CMD |19(N)Unilog 9000B |20(Y)Toyo
21(N) NetStal |22(Y)L Type TC |23(N)Extended SPC |24(Y)Husky
25(N)JSW uPac |26(Y)Mat Lot Track |27(Y)Multiple Mat |28(Y)Profile
29(N)RKC F900 |30(Y)Toshiba |31(Y)Tote Label |32(Y)Voice
33(N)Maco 4000 |34(Y)Setup Sheets |35(N)Square D |36(N)A-B PLC5/E
37(N)A&D Scale |38(N)TI-545 PLC |39(Y)Ext Down/Rej |40(N)Kawaguchi
41(N)Hekuma |42(Y)Delta |43(Y)Panorama |44(N)Portrait
45(Y)Family Mold |46(N)KuDA |47(N)AC-9000 |48(Y)Design Mangr
49(Y)Labor Track |50(N)French |51(Y)German |52(Y)Spanish
53(Y)Dutch |54(N)Chinese |55(N)Language 6 |56(N)Language 7
57(N)Language 8 |58(N)Language 9 |59(N)Language 10 |60(N)Language 11
61(N)Language 12 |62(N)Language 13 |63(N)Language 14 |64(N)Language 15
65(N)Language 16 |82 (200)Max Machines
Use -x option to print additional
features. bash$ read_auth -x

Authorization Utility for Panorama, Version 4.30

Authorization String: PIBPHFCE IBKFFLBH GHEKGOLM QHEHFIQH DIKIKEBE

***********Extra Features**********
66(Y)Sartorius |67(Y)Asset Manage |68(Y)Nissei |69(N)Ext. MatLot
70(Y)OPC_plc |71(Y)SPI_plc |72(Y)Labor Auth |73(Y)Tech Connect
74(N)Cycle Log |75(N)Rate Based |76(Y)Arburg |77(Y)Ohaus
78(Y)Indusoft Dryer|79(Y)Sequencing |80 (N)Extreem |81 (Y)Maco 6000
83(N)AB DF1 |84(Y)Branson |85(N)Peet Bros

set
Displays current environment variables.
sfdctrl -stats
Reports the current status of the shop floor routing process.
Sample Output:
Panorama shop floor daemon control program, version 4.30
Requesting status from sfd.
localhost:sfd is online and active.
Debug level logging is disabled.
Trace level logging is disabled.
Shop floor daemon statistics. Accumulation interval = 60 minutes.
Overall stats:
Avg service time = 0.000, Max = 0.000, Count = 1
Avg idle time = 1739.000, Max = 2.000
Datagram stats:
 System Administration 169

Received = 1, Unknown type = 0, Bad size = 0

End-of-cycle stats:
Service SF-comm DB-update
Count 0
Avg time 0.000 0.000 0.000
Max time 0.000 0.000 0.000
Shop floor update stats:
Avg service time = 0.000, Max =0.000, Count = 0

su - <user name>
Changes a user's privileges and authorizations to those of the specified user. If no user
name is provided, the current user's privileges will be changed to those of the Root
user id.
tail <number of lines> <filename>
Displays the end of a file. This command is useful when a file is large like the log file for the
shop floor routing process.
An example valid command is:
tail -40 sfd.log displays the last 40 lines of the sfd.log file
tail -f sfd.log displays the end of the sfd.log to the terminal
monitor and continues to display new output until <Delete>
is typed.
Startup and Shutdown Procedures
Your system is designed to run continuously. It is extremely rare that the host computer will
need to be powered down or rebooted. It is also rare that any process will need to be
manually stopped or started. Step-by-step instructions on startup and shutdown procedures
are included, though, in the case of known power outages and extreme error conditions. It is
recommended that you contact SYSCON-Intl Customer Support before attempting to
manually start and stop processes.
Starting System Processes
The shop floor message and routing processes (shop floor daemon) are configured to
automatically start up upon booting the host computer. Use the ps command to verify that
they are running.
If the shop floor processes have been stopped and need to be re-started, use the
configure.f2k utility. This utility starts up all system processes without the need for
rebooting the host computer.
1. At the system prompt, type in configure.f2k and press the <ENTER> key.
2. The following screen appears.

--Focus2000 Configuration—
Select Configuration Option
1 Set Time zone
2 Set System Time
3 Set Authorization Key
4 Set Company Name
5 Set Host name
170 SYSCON-PlantStar Help System

6 Enable / disable startup

7 Start Mysql / Panorama
8 Stop MySQL / Panorama
9 Configure Email Server
10 Configure CD Burner
0 Exit

< OK > <Cancel>

3. To start up system processes, select menu item 7. This menu item does not reboot the
host computer.
4. This process takes a few minutes. When complete the Configuration menu returns.
5. Type in 0 (zero) to exit configure.f2k.
6. Wait about 5 minutes for all system processes to start.

Stopping System Processes

If an error situation is occurring that necessitates stopping all system processes, use the
configure.f2k utility.
1. At the system prompt, type in configure.f2k.
2. The following screen appears.

--Focus2000 Configuration—
Select Configuration Option
1 Set Time zone
2 Set System Time
3 Set Authorization Key
4 Set Company Name
5 Set Host name
6 Enable / disable startup
7 Start MySQL / Panorama
8 Stop MySQL / Panorama
9 Configure Email Server
10 Configure CD Burner
0 Exit

< OK > <Cancel>

3. To stop all system processes, select menu item 8. This menu item does not
reboot the host computer.
4. Upon completion, the Configuration menu returns.
5. Type in 0 (zero) to exit configure.f2k.

Rebooting The Host Computer

If an error situation occurs that necessitates rebooting the host computer, follow these
instructions.
 System Administration 171

1. At the system prompt, type in shutdown –r now. Note that this command is case-
sensitive.
2. The system shuts down all active processes and then reboots. At times the process
appears to pause. This is normal behavior.
3. All system processes are automatically started upon boot up. They do not have to
be manually started.
4. Log back in.
5. Wait about 5 minutes for all system applications to start.
6. If desired, check the shop floor processes to ensure that they are running. Type in
ps -ef:

PID TTY STAT TIME COMMAND

29501 pts/1 Ss+ 0:00 -bash REMOTEHOST=…
1647 tty6 Ss+ 0:00 /sbin/agetty 38400 tty6…

!!!Caution !!!
Do not press the RESET button on the host computer to reboot. This action can result
in serious complications.
Powering Down The Host Computer
There are times when the host computer needs to be powered down -- either for power
outages or maintenance. If any of these situations arise, follow these instructions:
1. At the system prompt, type in shutdown –h now. Note that this command is case-
sensitive.
2. A message appears stating the shutdown program has begun. At times the process
appears to pause. This is normal behavior.
3. Once shutdown has been invoked, it must be allowed to run to completion.

!!!Caution !!!
Do not just turn the power switch off. This action can result in serious complications.

8.3 Archiving Data

Archiving Data
Your system collects and stores large amounts of historical information. After a period of
time, the host computer's disk space becomes full. To free up disk space, your system
provides an archiving utility. This utility, archive.f2k, saves completed job information to a
file, CD or CDRW and then removes it from the database. The file can be FTP’d to a
backup file system. On the QuickShot System the file must be ftp'd to another computer;
CD or CDRW backup is not provided. It is recommended that you contact PlantStar
Customer Support before archiving. This topic is covered in Application Note 2004-06.
Archiving should be done before the host computer's disk space is used up. Checking
the host computer's disk space is done via the df command. The amount of disk
space displayed, in combination with plant guidelines, determines the timing of the
archive process. Note that the archive.f2k utility does not save all Portrait
information. For a complete back up of your system, refer to the next section on
Backing Up the System.
172 SYSCON-PlantStar Help System

NOTE: We recommend archiving no more than three months worth of data at a

time.

Once job information is stored on a file, CD or CDRW, it can be restored for system
users. The unarchive.f2k utility provides this function.

To obtain a list of completed jobs available for archiving before a specific date:
1. Log onto the host computer.
2. At the system prompt, type in archive.f2k –l –e YYMMDD and press the <ENTER> key.
3. A listing similar to the following should appear:

f2karc -l -e 060101
Panorama History Archive V4.30

preparing job list by DATE

.
preparing shift list
.
preparing material list
.
The list of jobs finished before 2006-01-01 23:59:59:

1. job=Idle, family _seq=-150381, family _count 1

1 ss records, 0 spc records, 0 ls records,
1 jts records, 1 mls records, 0 ts records

2. job=, family _seq=0, family_count 0

0 ss records, 0 spc records, 0 ls records,
0 jts records, 0 mls records, 11 ts records

To archive and remove jobs completed before a specific cutoff date:

1. Log onto the host computer.
2. Select the media you wish to use and put it into the host. The archive utility will
check CD or CDRW for usability automatically.
3. Decide on a cutoff date for completed jobs. The archive process generally takes at
least 30 minutes to run for an average number of jobs. The more SPC information
that is collected per machine, the longer the archiving process takes.
4. At the system prompt, type in archive.f2k -e YYMMDD -r -y –m <media> where
YYMMDD is a desired cutoff date and <media> is the media you are archiving to. The -
r option removes all archived jobs from the database after writing them to the media.
The -y option will not prompt for individual confirmation of each job to be archived. If
you wish to individually confirm each job, do not add the -y option.
5. A message prompting for media appears. Press the <ENTER> key.
6. The archiving process begins.

Several other options are available for the archive command. All options and their
 System Administration 173

descriptions are provided below:

archive.f2k [-cdlnqrtyz] [+f] -m media [-e YYMMDD] [-j JOB_NAME] [-A num_months]
-A NUM_MONTHS Automatic archive jobs finishing before NUM_MONTHS.
-c Counts jobs and records only.
-d Enables debug level message log.
-e YYMMDD Cut-off date (in YYMMDD format), archive
only those jobs that finished before the given cut-off
date.
-j JOB NAME Archive those jobs that match the given job name.
-l Lists jobs only, no archive
-m <media> Write Archive to media type <media>. (No
Default) Valid values are: file, cdr, cdrw, and
ftp. Files are originally written to
/focus2000/tmp/archive
cdr, cdrw, options remove files after the disk is verified
ftp removes files after ftp is verified.
file leaves files in directory until manually
removed. Copies of files are kept in
/focus2000/tmp labeled as f2karc.dat and
archive.dat until manually removed or
overwritten by next archive.
-n Prevents archiving. This option is intended for use with
the -r option to allow the permanent removal of
unwanted job histories.
-q Run all queries, but don't archive.
-r Remove the jobs from the database after archived.
-t Enables trace level message log.
-y Don't prompt for confirmation for individual jobs when archived and
removed.
-z <file> Specify <file> path/name to use with media file type. File
automatically has .dat extension added.
All data files are automatically zipped (.gz added)
The archive.dat file is copied as archive-<file>
Note: the default file (f2karc.dat and archive.dat) remain
In the /focus2000/tmp directory until removed or overwritten.
NOTE: Either the -j or -e option must be used, not both.
To obtain a list of archived jobs on CD or CDRW:
1. Select the archived media and put it into the host.
2. Log onto the host computer.
3. At the system prompt, type in unarchive.f2k –l –z and press the <ENTER> key.
4. A listing similar to the following appears:
174 SYSCON-PlantStar Help System

Options: f2kunarc program -z -l "" ""

mount: block device /dev/cdrom is write-protected, mounting read-only
found opt file: f2karc-060101.dat.gz
looking for archive-060101 .dat

Historical Job Data of Panorama 0.

Date of Archive: 2008-04-14 10:53:01

The list of jobs found in the archive:

1. job=Idle, family_seq=-1 50381, family_count 1
1 ss records, 0 spc records, 0 ls records,
1 jts records, 1 mls records, 0 ts records

2. job=, family_seq=0, family_count 0

0 ss records, 0 spc records, 0 ls records,
0 jts records, 0 mls records, 0 ts records

8.4 Backing Up the System

Backing Up The System
SYSCON-PlantStar provides automatic back up capabilities of all system information. The
timing and frequency of backups is configurable. When determining a backup schedule, keep
in mind the following:

The length of time between backups determines the amount of risk you are willing to
take on the potential loss of data. If, for some reason, the system database becomes
corrupted, backups are used to restore all information. The database is restored to the
point in time when the backup was done. SYSCON-PlantStar recommends at least a
weekly backup schedule.
The system application is available during the backup process. Users are able to log
in. shop floor information is still collected during this down time.
The CD or CDRW disc must be large enough to store the system database. The
backup utility does not write to multiple CDs. If multiple CDs are necessary, contact
SYSCON Customer Service.
The backup process can take up to an hour for large databases.
PlantStar's backup utility incorporates database maintenance and clean up
commands which affect the performance of system applications.
Backup schedules are implemented by SYSCON-PlantStar personnel upon request.
When backup needs are ascertained, contact SYSCON-PlantStar Customer Service.
Once the backup schedule is set up, it is the System Administrator's responsibility to
maintain the backup schedule:
1. Select a media and place it in the drive at the designated backup schedule time.
You can put the media in ahead of time. Once the backup is complete, change
media on the morning after the scheduled backup and leave it in until the next
scheduled time.
 System Administration 175

2. To check the backup logs, type in cd /focus2000/log to change directories.

3. Review the backup.log file. Type in cat backup.log | more. Any errors that
occur during the backup process are written to this file.

Note: backup.f2k MUST be run with specific command line switches. You should review
your current settings before attempting to backup independent of a scheduled backup. It is
always wise to contact Customer Support prior to issuing a backup.f2k command.
For informational purposes only, the command line argument explanation follows:
Backup script for Panorama 4.30 started Tue Apr 15 14:36:52 CDT 2003
Usage: /focus2000/installed/bin/backup.f2k [-ik] [-s <media>] [-w <device>] [-d <tmp_dir>] [-t
<type> | - [cmou] ]
Option descriptions:
-d <dir> Use directory <dir> for temp space. Default is F2K_DIR/tmp/backup
for one-disk systems, and /Database/backup for two-disk systems.
-s <media> Write backup to media type <media>.Valid values are hd, cdr, and
cdrw. The default is cdr.
-t <bckup_type> Perform <bckup_type> type backup. Valid values are
checkpoint, online, maintenance, unload.
-c Perform checkpoint backup.
-m Perform maintenance backup.
-o Perform online backup.
-u Perform unload backup.
-i Use semaphore to synchronize access to tape device.
-k Remove old checkpoint files from disk (online backups only.)
-w <dev> Specify backup device location. Defaults are /dev/nrct0 for tape;
/dev/rcd0:5,0 for CDR and CDRW; and the current directory for hard
drive.
Running backup.f2k with no arguments will perform a checkpoint backup to CDR.
4. The following is a sample backup log file with no errors:
System shutdown.
System snapshot daemon control program
Sending shutdown request to sfd.
Waiting for confirmation from
sfd. Shutdown confirmed.
PC daemon control program, version 2.0
Sending shutdown request to f2kpcd.
Waiting for confirmation from f2kpcd.
Shutdown confirmed.
Terminating qaspcd; pid = 10725
System shutdown complete.
.
176 SYSCON-PlantStar Help System

.
beginning checkpoint to tape /dev/rmt0. 1 of 1 locations
Sun May 8 00:10:25 1994 CPP: Starting checkpoint of location: focus2000 to tape:
path = '/dev/rmt0. 1',
file = 'c0003001.ckp'.
mount CDR and press return
tar: /dev/rmt0. 1
a ./focus2000/install/up2.scr 61 blocks
a ./focus2000/install/up3.scr 60 blocks
a ./focus2000/install/up4.scr 40 blocks
a ./focus2000/bin/f2krep 61 blocks
.
.
.
f2kdbmod - Compress table structures in database focus2000
rows)
Continue
* * * Executing ...
rows)
Continue
* * * Executing
.
.
.
System startup complete.
Backups can be run on-demand:
1. Select a media and place it in the drive.
2. Log in as root to the host computer.
3. At the system prompt, type in backup.f2k, (options). The backup utility writes all
necessary files to the media, or runs some database maintenance programs.
4. All status and output information appears on the screen for this utility.

8.5 Host Log Files

Host Log Files
Host computer log files are located in the /focus2000/log directory.
Log File Name Contents
backup.log Log file containing status messages from the last Portrait backup
eoj.log Log file containing status messages from the last time end-of-job reports were
generated
eos.log Log file containing status messages from the last time end-of-shift
reports were generated
f2karc.log Log file containing status messages from the last Portrait archive task
f2kunarc.log Log file containing status messages from the last Portrait unarchive task
f2kpcd.log Log file containing status messages about the PC connection to the host
 System Administration 177

computer
sfd.log Log file containing status messages about the shop floor message and routing
process

8.6 Software Upgrades

Software Upgrades
Special maintenance updates for the host computer are done via the update.f2k utility.
During an update, users do not have access to system applications.
If an update is received, follow these instructions:
1. Log onto the host computer as root.
2. Ensure that all system users are off the system.
3. Go to the following directory:

cd /focus2000/installed/install
4. At the system prompt, type in update.f2k.
5. The update utility checks user privileges, shuts down all system processes, backs
up production data, and then installs the update. At certain points, the procedure
asks whether to proceed or abort the update process. Answer y to continue, n to
stop.
Sample Output of update.f2k utility
System update script.
***** WARNING *****
This script is intended for updating the system host software from a PlantStar
supplied distribution media.
Shutting down system services.
***** WARNING *****
This update script must have EXCLUSIVE access to the system database. Failure to
comply with this requirement may cause the update to fail and/or the system database to
be corrupted.
This script will now pause until it has exclusive access to the system database. If you are
unable to close all open sessions, press <CTRL-C> to abort this script.
Proceeding with update.
Please insert the media labeled "Final Backup Before Update" which came with the
update kit. Proceed with final backup -> y
Compressing the database...
Checkpointing database to media...
Please remove the media. Turn the write protect indicator to SAFE.
Store the media in a safe place.
Proceed with final backup -> y
178 SYSCON-PlantStar Help System

Please insert the media labeled "Host Distribution” which came with the update kit.
Proceed with update -> y
Pausing for any manual adjustments before proceeding with the version specific
portion of this update.
Press <Enter> to proceed, <Ctrl>-C to abort ->
5. Once the distribution media is read, the update procedure prompts for continuation.
6. When finished, the system prompt appears.

If an update requires on-site support, advance notification is provided.

8.7 Product Standards Import

Product Standards can be imported from other systems or databases via a transfer of
records and fields in ASCII format. The layout of the data can be configured to meet the
customer's needs. The application used on the system host to accomplish this task has
several parameters as shown below:
# primp
Focus-2000 product standards import program, version 4.10
Usage: primp PS_ASCII_FILE [-a] [-d] [-f] [-n N _MAX] [-s FMT_SEQ]
-a Update all machines for a matching product if a particular machine is not specified.
-d Enable debug level logging.
-f Use default product standard to update missing fields if there is no matching product
standard.
-n N_MAX Import only first N_MAX product standards from ASCII
product standards file into database. If -n option is not used,
all product standards in the file will be imported.
-s FMT_SEQ Sequence number of the file/field format used for
converting product standards file into database. If -s option is
not used, the first format in the database will be used.
Additionally, this import can be used on a recurring basis for those companies that make
engineering changes regularly to Product Standards. Our Customer Support staff will
create the initial upload for you, as well as configure a recurring upload if needed.
 System Administration 179

8.8 Work Orders Import

Some customers wish to integrate their scheduling efforts with other systems. This is made
possible by the import of new Work Orders from another system. Our system host utility
allows customers the flexibility to import a list of jobs to be scheduled, or if desired, an
entirely configured "master schedule". Our Customer Support staff will configure the import
capability with your data file. It can be run on command or on a recurring basis.
# woimp
Usage: woimp WO_ASCI I_FI LE [-a][-C][-d][-f][-n N_MAX][-p S_PORT][-s FMT_SEQ]
-a Import-ADD mode. Bring in only non-existing orders.
-C Clear-and-replace mode. This option will clear all current job queues and then place
those imported work orders that have machine name and queue position specified into
job queues accordingly.
-d Enable debug level logging
-f Use default job standard if there is no matching job standard.
-h Do not check history for duplicate work orders.
-n N_MAX Import only first N_MAX work orders from ASCII work order
file into database. If -n option is not used, all work orders in the file
will be imported.
-o Only look for duplicates in the work order list
-p S_PORT Service port of shop floor daemon for datagram. The default is "f2k-sfd".
-r Remove mode. This option will remove current work orders before import begins.
-s FMT_SEQ Sequence number of the file/field format used for converting work
order file into database. If -s option is not used, the first format in the database
will be used.
-u Stop and replace the current running job. This option will stop and replace the current
running job on the DCM for an imported work order with its queue position set to zero.

8.9 Production and/or Process Data Export

Your system collects various types of valuable information that could be used by other
systems. One of the utilities we provide for this purpose is the Product/Process Data Export
Utility. Our Customer Support staff will, with your assistance, select the desired fields of data
that can be used in other company information systems. This export can be configured to run
on a recurring basis or on demand, and can also be configured to transfer the created data
files to the appropriate server that will use the data.
# f2kexp
Panorama Production/SPC/Labor/Material Lot export program, version 4.31
Usage: f2kexp [-e] [-d] [-r] [-j JOB_NAME] [-J JOB_SEQ] [-p [PROD_FILE]]
[-s EOS_SEQ] [-f FMT_SEQ] [-x [SPC_FILE]]
180 SYSCON-PlantStar Help System

-e Exclude idle jobs from job and shift production exports. Idle
jobs are defined as those having zero pieces required.
-d Enable debug mode.
-r Right justify all number fields, left justify all text
This option is used primarily for any system that
requires a fixed decimal point (such as an AS/400).
-j JOB_NAME Export production and/or spc data for the
job with the given JOB_NAME. This option cannot be
used with the -J or -s option.
-J JOB_SEQ Export production and/or spc data for the
job with the given JOB_SEQ. This option cannot be
used with the -j or -s option
-p PROD_FILE Export production data for a job (with -j
option) or a shift (with -s option) to the ASCII file
PROD_FILE. If PROD_FILE is not specified, default
name prod.exp is used.
-l LABOR_FILE Export labor data for a shift with -l options to
ASCII file LABOR_FILE. If LABOR_FILE is not specified,
default name labor.exp is used.
-s EOS_SEQ Export production and/or spc data for the
shift with given EOS_SEQ. This option cannot be used
with the -j or -J option
-f FMT_SEQ Sequence number of the file/field format
used for writing data to the work order file. The -f option
must be used.
-x SPC_FILE Export SPC data for a job (with -j option) or
a shift (with -s option) to the ASCII file SPC_FILE. If
SPC_FILE is not specified, default name spc.exp is used.
Exactly one of the -j, -s, or -J options must be used.
At least one of the -p, -x or -l options must be used.
The format sequence number must be specified (via the -f option.)

8.10 Job Schedule Data Export

Some customers prefer to use our Job Schedule Board to create the final actual machine
loading of their shop floor, but need to send that information to other information systems.
Our Job Queue Export Utility will generate a data file that can be used (imported) by those
other systems. As with other utilities we provide, it is flexible, can be run on demand, and can
be run on a recurring basis
# f2kjqexp
Panorama Job/Work Order program, version 4.10
Usage: f2kjqexp [-d] [-r] [-e EVENT_TYPE] [-f FMT_SEQ] [-o OUT_FILE] [-m MACH_SEQ] [-w]
 System Administration 181

-d Enable debug mode.

-r Right justify all number fields, left justify all text
This option is used primarily for any system that
requires a fixed decimal point (such as an AS/400).
-e EVENT_TYPE Export data for only the specified event.
This flag is only valid for a machine log export template.
-f FMT_SEQ Sequence number of the file/field
format used for writing data to the export file. The -f
option must be used.
-j Export current and queued job data.
-o OUT_FILE Export data to the ASCII file OUT_FILE. If
OUT_FILE is not specified, default name data.exp is used.
-m MACH_SEQ Export data for only the specified machine
sequence number.
-w Export work order data.

8.11 Material Lot Data Export

Customers that have purchased the Material Lot Tracking option almost always have the
need to export the data collected by their system to another information system that is
tracking inventory quantities, ISO Lot information or both. Our utility is flexible and can be
configured to run recurrently or on demand as the customer's need dictates.
# f2kmatexp
Panorama Material Lot export program, version 4.10
Usage: f2kmatexp [-d] [-r] [-J JOB_SEQ] [-m [PROD_FILE]]
[-s EOS_SEQ] [-f FMT_SEQ] [-C] [-L]
-d Enable debug mode.
-r Right justify all number fields, left justify all text. This option is
used primarily for any system that requires a fixed decimal point
(such as an AS/400).
-j JOB_NAME Export production and/or SPC data for the job with
the given JOB_NAME. This option cannot be used with the -J or -s
option.
-J JOB_SEQ Export material history data for the job with the
given JOB_SEQ. This option cannot be used with the -j or -s
option
-m MATERIAL_FILE Export material data for a shift with -m
option to ASCII file MATERIAL_FILE. If MATERIAL_FILE is not
specified, default name material.exp is used.
-s EOS_SEQ Export material data for the shift with given
EOS_SEQ. This option cannot be used with the -j or -J option
-f FMT_SEQ Sequence number of the file/field format used for
182 SYSCON-PlantStar Help System

writing data to the work order file. The -f option must be used.
-C Summary by material component.
-L Summary by material lot id.
Exactly one of the -s, and -J options must be used.
The format sequence number must be specified (via the -f option.)
Only one of the -C and -L options may be used.
SYSCON - PlantStar System
User's Guide

Part

IX
184 SYSCON-PlantStar Help System

9 Knowledge Base
9.1 Application Notes
Application Notes
The following list of Application Notes is available to all customers via FAX or email.
Simply review the list and call Customer Support and request the document by the App
Note Number.
App Note Topic
91-004 PLC Serial Interface Handbook
92-001 SACK Code Listing/Explanations
92-002 High Speed Data Acquisition / Inj. Molding
92-004 Sensor Selection: Injection Molding Machines
92-005 Non-Normal Data Analysis in QA/S
92-008 Paralleling Existing Sensors
92-009 Configuring a CP3-32, CP3-32S, CP3-64
92-018 Printer Setups to Allow Labels to Work.
93-005 Net Parts Counting
93-006 Calculating Tonnage
93-007 Siemens/Pathfinder Up/Download Instructions
96-004 Checking Statistics at a Communications Processor
96-006 Power Conditioning
96-011 Identifying M-CIM hardware (CPU revision, memory)
96-015 Material Lot Tracking description.
97-010 HP Network Printer Setup for Portrait
97-012 Material Lot Tracking at DCM
98-006 PlantStar-Hekuma Communications Link
98-007 TI-545 PLC
98-008 PlantStar-Nissei Interface
98-009 Toshiba InjectVisor S10/V10
98-010 Toshiba InjectVisor S10/V10v Parameter List for PlantStar Process Variables
99-005 Adding a Permanent Route on Host (SCO and AIX)
99-007 Using crontab Feature
99-009 How to Troubleshoot the Custom Reports Ingres/Net Client
99-010 Disaster Recovery: Identifying a Failed Hard Disk or Partition
99-011 Disaster Recovery: Failed Second Hard Disk
99-015 New Boolean Equation Type JEQ_CYC2 in Panorama v2.40
99-016 CPU7.0 Board Information and Ethernet DCM16 Info. (DIP switches, etc.)
99-018 Changing the System Host Name When "configure.f2k" is not Available
99-021 Configure HP Network Printers Updated.
99-026 Implementing and Troubleshooting Import-Export Templates and Scripts
99-027 Checkpoint Backup Restoration Procedures
99-029 PowerChute Password Instructions and Procedures.
2001-001 Installing Lexmark Printer Drivers for SCO UNIX.
2001-002 Running Multiple Logins for Shop Floor Monitor.
© 2008 ... SYSCON International, Inc.
 Knowledge Base 185

2001-004 Installing Engel Serial Interface on RTLDCM's

2001-005 Linking the RTLDCM Browser Interface to Support Documents
2002-002 Creating Browser Links from Setup Sheets
2002-003 CIM/RTL Setup and Operation for Production
2002-004 Configuring IP Address on Linux Web-Pad
2002-005 Tips for Crystal Report Conversion for Family Molding
2002-006 Command Line Options for Multiple Vnode Printing
2002-007 Procedure to Change an Ethernet el7 to an rs485 el7
2002-008 Resetting APC Smart-UPS after Battery Change
2002-009 Nissei Interface
2002-010 RTL-Boot Disks
2002.11 Customer Host Upgrade Instructions X.10
2003.1 Database Transfer Host to Host
2004.1 Installation of Windows 2003 Server on a Host
2004.2 Toshiba Serial Cable Diagram
2004.3 Configuring the PlantStar Server as a Gateway
2004.4 Setting Up WINXP for dial-up slip
2004.5 Using f2karc
2004.6 Using archive.f2k
2004.7 PlantStar OEE Definitions
2004.8 Compaq Workstation Linux Slackware Install
2005.1 Excel Spreadsheet Problems and PlantStar
2005.2 Reiser Image Installation Guide
2005.3 Pstar_setup Instruction Guide
2005.4
2005.5 PlantStar Software Patch Installation
2005.6 View & Print User Privileges
2005.7 Touch 8 Set-Up Instructions
2006.3 Process Journals User Manual
2006.4
2006.5 Machine Removal Instructions
2006.6 PM Asset Import from External Source
2006.7 Using Excel or Access with PlantStar
2006-08 Using Microsoft Excel or Access with PlantStar
2006-09 Linux Serial and USB Device Management Using usbconf
2006-10 RTL Screen Saver Setup
2007-01 DNS Mail Server Setup
2007-02 Apache Web Server Daemon Change
2007-03 Process Journal User Manual
2007-04 Process Journal Administrator's Manual
2007-05 Understanding and Developing Digital Equations
2007-06 Passing Parameters in a Link
2007-07 Creating Browser Links from Setup Sheets (Replaces 2002-01)
2007-08 Configuring Remote System Logging
2008-01 Scheduled MySQL Backup
2008-02 Cincinnati Milacron Mosaic Control Instructions to Change Sequencer IP
Address
2008-03 Linux Server Build Instructions
2008-04 OPC Client Application User's Guide
2008-05 APC UPS Configuration in Linux
2008-06 Ingres to MySQL Database Conversion
2008-07 Script & Directory Changes for Version 4.30
186 SYSCON-PlantStar Help System

9.2 Arranging Windows and Icons

9.2.1 Arange Icons
To arrange the iconized windows into straight rows and columns, select the
Window menu on the main screen of you your system window.
Choose the Arrange Icons option.

9.2.2 Arrange Windows

The windows can be arranged in 3 ways:

Cascading:

Vertical Tiles:

Horizontal Tiles:

To choose one of these styles, select the Window menu from the main screen of your
system window. Select one of the options displayed.
 Knowledge Base 187

9.3 Changing View Options

The View button opens the View Options window. This window filters the list of machines
that appear on a Monitor window. The filtering is done by machine state or a selected
machine list. Click on one of the circles to the left of the desired machine state. The Monitor
window immediately changes its list of machines to those that are currently in the selected
machine state.
Where can you find it?
The View Options window is accessible from the Material Usage, Production
Summary, Exception Summary, and Machine Performance windows.
What do you want to know about?

Selecting a Machine State

Selecting Specific Machines
Selecting All Machines in a Display Group
Clearing Machines
Closing the Window

9.4 Colors
This image represents the possible machine states and their associated colors.
188 SYSCON-PlantStar Help System

9.5 Creating Work Orders

Work Orders are essentially jobs that have been defined but not yet scheduled. In order to
schedule jobs, you must first create a work order. A work order consists of a set of job
parameters. These parameters define the job. They include such things as the number of
pieces required and the standard rate at which the pieces will be produced.
A work order may be created manually by entering the parameters or by loading in a product
standard. Work Orders can be created from the Work Orders or Job Schedule Board
windows.
From the Work Orders window:
· Click on the New button.
· Select a machine from the machine field.
· Move the cursor to the Value column for each desired parameter. Directly type in
parameter values. If default information is displayed, edit it as desired by typing over it.
· Click on the Apply button to save the new work order after all relevant job parameters
have been entered. Once a work order is saved for a machine, an asterisk appears next
to the machine in the machine field. This asterisk signifies that a work order exists for
the specific machine and product combination.
From the Job Schedule window:

· Click on the button. The Edit Job Parameters window appears which looks similar
to the Work Orders window.
· Move the cursor to the Value column for each desired parameter. Directly type in
parameter values. If default information is displayed, edit it as desired by typing over it.

· Click on the Commit button on the Job Schedule window to save the changes to
the Job Schedule Board. If this step is not done, the changes will not be permanent or
sent down to the shop floor.

9.6 FAQ - Frequently Asked Questions

Following are the most common questions asked about your system. Scan this list
before you call Customer Service. Each question is followed by the answer.
 Knowledge Base 189

Question 1:
What do I do when a message appears stating that system resources are too low to open a
window?
Answer:
System resource limitations restrict the number of windows which can be open at one time. If
you are running your system and several other programs, close one or more of the other
programs. If you are only running your system and receive this message, close some of
your open windows. To see how much free resources are available, select the About... menu
item under the Help menu within your system.
Question 2:
Why did your system stop updating the Real-Time windows within Monitor?
Answer:
If window information is not being updated, make sure all host computer programs are
running. Specifically, the System Administrator should check and ensure that the shop floor
routing process is running. Use the sfdctrl -stats command on the host computer to obtain
the current status of the shop floor routing process.
Question 3:
Automatic reports are not printing. Why?
Answer:
If automatically scheduled reports are not running
· Open the Schedule Reports window under the REPORTS menu within the Monitor
program. Ensure that the reports are correctly set up for the scheduled time. Make sure
that there is a shift schedule for the current year. (At year end, shift schedules do not
roll over.)
· Check the printer to ensure it is ready and on-line.
· Use another program to try to print something to the printer.

Question 4:
Why does your system report that a machine is down (appears blue) when the machine
is actually running.
Answer:
· The down threshold may be set too low. Open the Edit Current Job window in the
Monitor program and make sure that the down threshold setting is larger than the
current cycle time of the machine.
· The machine's DCM may not be receiving a contact closure from the machine. Check
the wiring from the machine's relay to the DCM. Check the relay inside the machine
cabinet. It should open and close each time the machine cycles. Make sure that all
ribbon cables are seated securely at both ends.
Question 5:
Why would all machines show as off-line (appear white in the Monitor windows)?
Answer
· Make sure that there is power to the DCM.
· Check all wiring. Using a volt meter, measure the RS-232 voltages inside the DCM. Go to
the COMM 1 section of the terminal board and measure the voltage across RXD and
190 SYSCON-PlantStar Help System

GND. The voltage should be between -8.0 VDC and -11.0 VDC. If this voltage is not
present, the wiring is faulty.
Question 6:
How can I find out the version number from a system distribution tape?
Answer
The system version number is documented within the install.f2k and update2.sh installation
files.

· Untar the first tar set on the distribution tape into a temporary (for example, tmp)
directory.
· Two files -- update2.sh and install.f2k -- now exist after the untar procedure.
· View either file. Look for the F2K_VERSION variable within either file. This variable
displays the version number for the distribution tape.

9.7 Getting A Screen Capture

Windows within your system can be printed using the standard Print Screen Key function
and any windows application that will accept a Windows Clipboard Paste. This utility
provides an easy way to capture and print either an active window or the entire screen. The
screen picture can be resized and pasted into any Windows program which handles
graphics such as Microsoft Word or Paint Brush.

9.8 JIT - Product Standard Matching

JIT scheduling is an authorized feature that allows customers to switch product standards by
selecting from a drop-down list of products on the work order edit screen. For instance, the
customer knows he needs to make "Cooties", but his ERP system does not know which of
six tools will be used. Each tool defines a unique product standard. Work order import
requires the import of a unique "Cooties" standard. Once this is completed, the user can go
to the Job Edit screen and select from a drop-down list of unique tools (in this example)
and over-write the work order with selected information from the selected product standard
associated with that tool.
The implementation of this feature requires a custom import template to be written.
Please contact Customer Support for information regarding this template.

9.9 Job Schedule Board Overview

In order to collect process variables and production data for a machine, a job must be
assigned on that machine. The process of scheduling or queuing jobs is handled through the
Job Schedule window.
The Job Schedule window consists of a Gantt style scheduling board. Calendar time is
shown on the horizontal axis. Machines within a selected display group are shown on the
vertical axis. Each row represents a machine's job queue and each rectangular block is a
scheduled job. The first rectangular block for each machine is its current job. The block
length indicates the expected run time for the job. Block labels are selectable. They can be
either job or product names.
 Knowledge Base 191

A job is scheduled by selecting a work order and placing it in the job queue of a given
machine. By default, jobs are scheduled sequentially from left to right. There are two
scheduling methods available within Panorama:
· Schedule jobs by earliest start date (default)
· Schedule jobs by due date
The default method on the Job Schedule window is for jobs to run immediately following the
completion of previously-queued jobs. The estimated completion time of a job becomes the
starting time for the next queued job. Under this method, jobs that are expected to be
completed on time are shown in green. A red rectangular block indicates that a job will not
complete by its estimated completion date. The default method is active unless the second
scheduling method has been activated and/or saved during a previous session.
The second method is to schedule jobs by due date. This method places a selected job (or
jobs) on the job board at the latest possible time which allows it to be completed by its due
date. Specifically, a job's required by date is used as the starting point. The length of time to
run a job is then used to walk backwards through the shift schedule to estimate the start date.
Using this method, gaps may occur between a job's starting time and a previous job's ending
time. These "gaps" are represented on the job board by gray blocks and indicate slack time
where new jobs can be scheduled. Under this method, jobs that are expected to be
completed on time are shown in green. If this method causes a subsequent job to become
late, the late job's rectangular block is colored orange.
The marker, located along the top of the job board area, indicates which jobs are
scheduled according to their due dates. All jobs to the left of this marker are scheduled
according to the earliest possible start -- a job starts immediately upon completion of the
previous job (method one). All jobs to the right of this marker are displayed on the job board
according to their due dates (method two). (For more detailed explanations refer to the field

help provided on the icon.)

NOTE: You must have the proper privileges in order to schedule jobs. See your System
Administrator if you do not have the Scheduling privilege.

9.10 Job Scheduling Concepts

Once the shop floor is defined, its work schedule can be created. There are numerous
steps for creating the shop floor work schedule. The first step in understanding how to
schedule jobs centers around the Work Center. Work centers define how jobs are
scheduled and when they run.
The following sections discuss some basic relationships about scheduling jobs. These
relationships are presented here to facilitate the use of the SCHEDULE windows. Once
understood, job scheduling within your system is straightforward.
Shifts
A machine follows one shift schedule -- the one belonging to its work center. It is important to
design your work centers with this in mind. Each work center has a set of annual shift
schedules. Annual shift schedules are divided into 52 weeks. Weeks start on Monday and
end on Sunday.
192 SYSCON-PlantStar Help System

Schedules for each week of the year can be set from one of twelve weekly schedules. Each
weekly schedule defines the day-to-day shift changes for up to six different day shifts. Two
idle periods per day are available for times when the machines should not be in operation.
During an idle period, the machine's DCM ignores all inputs. Only idle time is accumulated. If
no shift schedule is assigned to a machine, the machine is considered to be up 24 hours a
day.
These shift schedules are important because they are used by your system to create
historical production records. The production records are the raw data for the monitoring
windows. A new historical production record is created for each machine at each shift or
job change.
Jobs
A job is the basic unit which defines production monitoring on a machine. Every monitored
machine in the system must have a job assigned to it. Scheduling a job is a two step
process. Every job within your system starts as a work order, which is step one. A work
order is a job which has not yet been scheduled on a machine. It consists of parameters
which define how to monitor a job's performance and progress. These parameters are based
upon the type of product produced and the machines on which the product will run. They, in
essence, describe the job and set the standard for monitoring it. They define the line
between the normal operating mode and various exception states for a machine. All
monitoring is based upon these values. Examples of job parameters are job name, product,
material, tool, standard cycle, pieces required, required date, and process limits. Care
should be taken when defining job parameters. For instance, if the Standard Cycle
parameter is set to 30 seconds and the Cycle Tolerance is set to 10 percent, a machine
would be considered slow if its cycle time was currently 33 seconds. This same machine
would be considered down if the down time threshold parameter was set to less than 33
seconds.
Job parameters also determine the expected run time of a job. The pieces required,
standard setup and the standard rate factor are used when computing the completion date
of a job. If 10,000 pieces are required and the standard rate is 50 pieces/hour, then the
runtime of a job would be 200 hours. Add this to the standard setup time and you have the
expected runtime of a job. The Schedule Now and Schedule Factory parameters also
affect the calculated completion date. These fields determine if the shift schedule should be
followed when computing the completion date.
Once a work order is created, it can be scheduled as a job -- the second step in job
scheduling. Each machine has a currently-running job and a queue of jobs waiting to run.
The scheduling person must know which jobs can be run on which machines. The main
objective is to arrange the job queues so that as many jobs as possible complete on or
before their required completion date.
Once started, a job cannot be removed or stopped. It can only be replaced by another job. If a
current job is not complete when it is replaced with a new job, it can be suspended. A new
work order is created. The Pieces Required parameter on this work order is set to equal the
pieces remaining to complete the job. The comment parameter will indicate that this work
order was created from a suspended job. The work order can then be scheduled on a new or
the same machine at a future date.
A job is considered completed when the pieces required for a job is equal to the net pieces
produced. When a job is completed, it may be set to an idle state if there is no new job in the
 Knowledge Base 193

machine's queue. This "job idle state" is exactly the same as a shift idle period for a single
machine. The machine's DCM ignores all inputs from the machine. To put a job in the idle
state, set the job parameters "Schedule Now" and "Schedule Factory" both to No.
Additional Considerations:
Estimated completion dates for a job are only as accurate as the job's parameters and shift
schedule. The parameters Standard Rate and Standard Setup Time: are especially
important for accurate estimates.
To facilitate the creation of a work order, a Product Standard can be created. Product
Standards are templates which contain the same parameters as a work order. A library of
standards can be created and maintained within your system. When a work order needs to
be created, a Product Standard can be loaded in and used as a base for the work order.
Pieces Required and Required Completion Date are the most common parameters which
are set when using a standard to define a new job.
A maintenance (non-production) job can be created within your system. This is
accomplished by setting the job parameters Pieces Required and Standard Rate both
equal to zero. The Standard Setup parameter can then be used to define the duration of the
maintenance job.
194 SYSCON-PlantStar Help System

9.11 Loading a Product Standard onto a Job

Any job can be updated by loading (copying) a product standard from the Load Product
Standard window.
Where can you find it?
· The Load Product Standard window can be accessed from the Current/Queue Job,
Work Orders, and Job Schedule Board windows.
· Click on the Load Std button.
· The Select Product Standard window appears. Select a product standard. Once
selected, the Work Order window reappears with the job parameters of the desired
standard.
 Knowledge Base 195

9.12 Logging into your PlantStar system

The login window provides security for all programs within your system. Only users
that have permission to access the application are allowed. Only ONE Monitor
session is allowed per workstation.
To access:
· Install the application into your Windows software.
· If the Monitor icon is highlighted, then double-click on the icon. If it is not
highlighted, move the mouse pointer to the icon and then double-click on it.
· The main login window appears which asks for a user name and password. Both of
these can be obtained from the System Administrator.
· Use the <TAB> key to go from field to field. After your name and password are
entered, click on the Login button or press the <ENTER> key.

NOTE: If your password does not seem to work, first try to re-enter your password. If it still
does not work, contact your System Administrator.

9.13 Material Lot Tracking Concepts

Every monitored machine has a job assigned to it. The job has a defined material
formula. This formula can consist of up to four raw materials. Once a job is running on a
machine, its associated DCM enables the entering of Material Lot IDs for each of the raw
materials.
Lot IDs can be vendor or user-defined. Lot IDs create an audit trail between the lots of raw
material fed into a machine and the tote boxes of finished products which come out of the
machine. If a different raw material lot needs to be used on a running job, the new Lot ID and
material name can be entered at the DCM.
196 SYSCON-PlantStar Help System

A delay timer is available for specifying the amount of time to elapse before a new material
lot is used on the current job. When the time expires, the current material lot is replaced
with the new material lot. The current material lot then becomes part of the historical audit
trail.
Material Lot Tracking is an auditing feature that traces material lot usage. A material lot
can be traced to a specific tote box. Each time a tote box becomes full, an operator presses
the tote change button on a DCM, or a material lot changes for a job, the event is recorded.
These events form a lot history.

9.14 O.E.E.
OEE is a tool to measure the performance of individual equipment or an entire process.
OEE can be used to measure losses caused by poor quality, equipment problems or non-
optimal run rates. The calculation for OEE is:
%OEE = (% availability)*(% productivity)*(% quality)
This equation can be applied to a single machine or an entire process. It should be tracked
over time to see the impact of changes in equipment, training, and maintenance,
purchased materials and management direction.
OEE will help identify the areas requiring improvement, the potential revenue from an
improvement and serve as a benchmark against competition. One of many ways of
expressing OEE is (Operating Time/Total Time)*(Std Cycle/Std Mult)
Typical items measured by OEE will be actual downtime vs. planned, slower production
rates than standard, defects, and minor but important problems. The Emerson Company
offers the following guidelines for OEE. Other references can be found on the web by
searching on OEE.
Quartile
Process Worst 3rd 2nd Top
Continuous <78%
Type 78-84% 85-91% >91%
Batch <72% 72-80% 8 1-90% >90%
Chem., <85% 85-90% 91-95% >95%
Power
Paper <83% 83-86% 87-94% >94%

The elements of OEE are Availability, Productivity and Quality.

Availability takes into account Down Time or stoppages, time the machine is not running as
scheduled.
% Availability is defined as Actual Production time/Planned production time, or Operating
Time/ planned production time, or the percentage the equipment is available for
production. It can be affected by changes in process variables, preventive maintenance,
and machine failure detection.

Avail =
Uptime
(Uptime Downtime) .
+

PlantStar defines availability as

Idle time is not a part of this calculation. I.e. A machine is not available when idle for
 Knowledge Base 197

whatever reason. Idle time can be scheduled or non-scheduled.

Productivity or Performance takes into account Speed Loss.
% Productivity is defined as Actual Production/Optimum Capacity or (Minutes/part)/(Total
parts/Operating time), or Ideal cycle Time/(operating time/Total parts), or (Total
parts/Operating time)/Ideal run rate, or parts per time to produce. Material availability,
operator training, equipment breakdowns and machine speeds affect it. If production was
planned for a machine and it is down, the productivity clock is still running.
PlantStar defines productivity as (gross parts produced/up time)*(std
cycle/std mult). Or (gross parts/up time)*((seconds/cycle)/pieces/cycle).
Productivity is a unit less quantity, a number. Expanding just a little:
Gross Parts Gross Parts Time to make a part
Productivity = ---------------- = ---------------------- X --------------------------
Scheduled Pieces Time to make a part Scheduled Pieces

Gross Parts Time to make a part

Productivity = -------------------------- X -----------------------------------
Time to make a part Std Mult x Num of Cycles

Gross Parts Time to make a part

Productivity = X
(up time)/Std Cycle Std Mult x Num of Cycles

Gross Parts (Time to make a part x Std Cycle)

Productivity = -------------------- X -----------------------------------------
up time (Std Mult x Num of Cycles)

where Std rate = Std Mult/Std Cycle

Gross Parts 1
Productivity = ---------------- X ---------
up time std rate

Quality takes into account bad parts or wastage.

% Quality is defined as (Product produced – (rejects))/Product produced, or Good parts/total
parts. It is affected by changes in process variables, material quality, and equipment
performance.
PlantStar defines Quality as (net pieces/gross pieces).
The total calculation can be expressed as:
(up time/(up time + down time))(net parts produced/(up time + down time))(std cycle/std mult)
For Example:
Shift Time = 8 hrs
Breaks = 30 minutes
Lunch = 1 hr
Down time = 35 minutes
198 SYSCON-PlantStar Help System

Ideal Run Rate = 10 seconds

Gross parts = 2200
Rejects = 37
Availability = Operating time/Planned production time = (480–30-60-35)/(480-30-60) = 0.91
Availability = Up Time/(Up Time + down time) = 355/390 = 0.91
Productivity = Gross Parts/Scheduled Parts = 2200/(60*390)/10 = 2200/2340 = 0.94
Productivity = Gross Parts/operating time/run rate = 2200/390*60/10 = 0.94
Quality = Good Parts/(good parts + rejects)= 2163/2200 = 0.98
OEE = Availability * Productivity * Quality = 0.91 * 0.94 * 0.98 = 0.838

9.15 OSI Model

Networks are a series of computers and devices tied together by the Open System
Interconnect (OSI) model. The OSI model provides a way of describing the way a computer
connects a running program to the network. Within a computer there are many layers of
things going on both at the hardware and software level. There is the CPU connected to
several buses, in turn connected to memory, drives, ports etc. There is a software operation
system, software modules running the connected devices, and one or more application
programs. As a user we see all this as a computer not as all its parts. This is called looking at
the computer as a whole as a level of abstraction. The OSI model provides a level of
abstraction to view the connection between a network and the running program.
There are seven layers in the OSI model:
1. Application
2. Presentation
3. Session
4. Transport
5. Network
6. Data Link
7. Physical
The Application layer provides services to the running program. It handles such matters as
screen size and fonts. The Presentation layer converts the information flow to a network
standard. Different computers define character sets, escape characters etc. in a different
way. The Presentation layer converts these to a network standard. The Session layer
handles the bookkeeping required. It knows to whom it is talking and can re-establish
communication if contact is lost or part of a file transfer must be repeated. The Transport
layer handles the end to end communication. It must cut up a message into packets that
match the ability of the network to handle. If a file transfer was done in one packet of a million
bytes and one present of the packet was lost on each transfer, the file would never complete.
If the file was sent as one thousand packets of one thousands bytes each, only a small
percent would have to be re-transmitted to cover the lost packet. The Network layer handles
the routing. It keeps track of the route over which a packet must travel. The Data Link layer
provides error control, re-assemblies packets of data that may have been scrambled in
transmission and puts packets back in order. It does the handshaking between connections.
It requests a re-transmission of a lost packet and throws out duplicate packets that might
arrive. The media access control or MAC is located in the Data Link layer and contains the
device address. The Physical layer provides the connection to the network. It deals in ones
 Knowledge Base 199

and zeros and the time between them.

A Domain is a feature that allows the Internet to map from a language description (English
usually) to an Internet address. For example mordred.cs.purdue.edu is the English name for
a computer at Purdue. Its domain is purdue.edu. It is in the computer science department
and its name is mordred.
The domain for PlantStar is Syscon-intl.com. The domain most of you will be working on will
be mycompany.com All Internet addresses are actually what are known as a dotted quad.
This is four numbers between 0 and 255 each separated by a period or dot. An example is
192.17.10.11 which is the address of a Syscon computer. When you type a name into your
computer, it goes up the chain of servers on the net until it finds one that knows the correct
dotted quad address equivalent to the name you typed. That address is returned to your box
and the connection is then made. The new address is saved in a routing table in your
computer so the next time that name is typed in, your computer will already know where to
find the requested address. As an FYI, the world is running out of numbers and the dotted
quad will change to a dotted sextet sometime soon. This will provide a unique number for
every square meter on earth
A PlantStar host has two network cards. One handles communication with the DCMs and
the other handles communication with the PCs.
Local Area Networks:
This section will discuss local area network (LAN) as used by the PlantStar System. A LAN
is a network where multiple devices (stations) use the same media access technology and
exist within the same broadcast domain. That is, each device can send and receive
information without the need for routing. PlantStar is usually set up as a single LAN and all
devices see the traffic at the data link layer. If a message is not for a given computer it stops
at the data link layer. If a large area or more than one building is covered then a router or a
bridge can be used for connecting devices. If a bridge is used to connect devices within a
LAN it is known as an Extended LAN. A router can be used to connect multiple LANs at the
network layer. Each LAN would have its own broadcast domain and the router would be
used when a device in one domain talked to a device in another domain. The collection is
known as a wide area network (WAN).
A computer can broadcast to ALL devices in its domain by sending the first three numbers in
its dotted quad and making the last number 255. As an example at Syscon, the address
would be 172.17.10.255. A broadcast is used by a host to ask all the computers in its
domain to tell it their addresses.
200 SYSCON-PlantStar Help System

There are a number of types of networks and the standards that define them. PlantStar is
an Ethernet network defined by IEEE standard 802.3. Each DCM has a unique address,
which can be assigned during setup. This standard allows all stations to try to talk at any
time. Collisions are detected and stations back off a variable amount of time and try again.
This technique is known as CSMA/CD, which stands for Carrier Sense Multiple
Access/Collision Detection. In a PlantStar only network (no other devices on the local net)
Collisions are not a problem. PlantStar is a talker/listener system. The host goes from
station to station and requests information. It listens for a response and then goes to the
next station. There are never two units trying to talk at the same time.
Workstations may have a fixed address or have one assigned to them when they power up
using Dynamic Host Communication Protocol (DHCP). Which approach is used in your
shop is based on a decision made by your IT person.
Ethernet comes in several speeds. Older networks run at 1 0Mbyes/sec half duplex (talk in
only one direction at once). Today's standard is 100 Mbytes/sec full duplex. One Gbyte/sec
is available and plans are underway for a 10 Gbyte/sec system. Other LAN types are Token
Ring and FDDI (Fiber Distributed Data Interface. A special bridge can be used to connect a
Token Ring or a FDDI ring to a standard Ethernet but that technology is outside this
discussion.
PlantStar uses the Transmission Control Protocol/Internet Protocol (TCP/IP) (standard) to
talk to devices on the network. Many other protocols exist and are often used on wide area
networks and the Web. Again these other protocols will not be covered during this class.
Network Topology:
PlantStar uses a distributed star topology. In a small system the host computer is connected
to each of the DCMs with a network cable. As the system gets larger, routers and bridges are
used to reduce the length of cable runs and to isolate sections of the network. It is possible to
connect individual DCMs and the PlantStar host to a plant bus as it passes the devices.
However, PlantStar prefers to run a local bus for the PlantStar system and join the PlantStar
system and the plant bus together at the host using two network cards in the host to separate
the networks. This provides a high degree of isolation between systems and makes
maintenance and troubleshooting much easier. If all devices are on one plant network, an on-
site technician may be required to keep the systems up and running.
Networks can be hard wired or wireless. Wireless is usually cheaper today but comes with
its own set of problems. The specification is numbered 802.11 and comes in several flavors,
 Knowledge Base 201

b and g being the ones that are interesting for a PlantStar system. The b version talks at up
to 11mbytes/sec and the g version up to 54 mbytes/sec. Both offer 11 channels to talk on
but these channels overlap so that there are really only three usable in a plant 1, 6, and 11.
Each DCM will need a bridge and depending on the distance up to eight bridges might talk
to one access point. Cable is usually run from the access point to the host. One combination
would be to run a group of machines say eight on channel 1 to the first access point, the
second eight machines to the second access point on channel 6 and the third set of eight
machines to another access point on channel 11. Repeat until done.
Another approach might be to alternate channels 1 and 11 throughout the shop and use
channel 6 to bring the signals back to the host. A key to making this work is that each
access point can be told what addresses it can and can not talk to, which prevents two
access points trying to talk to the same machine and causing problems with the host.
Cabling:
Computers can be connected with copper wire, fiber optic cable, coaxial cable or even
wirelessly. Copper wire is the media used in almost all installations today. UTP5e is the
designation. It describes Unshielded Twisted Pair cable and the capacitance between wires.
A shielded version (STP5e) is also available but used only in very noisy installations. Some
UTP3 is in place in older systems, it will support a 10Mbytes/sec Ethernet connection up to
100 meters. UTP5e will support 100Mbytes/sec. Because of increased usage, there is little
difference in cost and all new installations should be run with 5e. The connector used with
this cable is known as RJ45, an eight-wire connector that started life in the telephone
industry. In your house it may be a different story. If you have cable, it will be run with coax.
Coax cable can support broadband while UTP is always baseband. Baseband is when the
ones and zeros appear directly on the cable as a plus and minus voltages. The cable pair
can support only one bit of information at a time. With broadband, the data is used to
modulate a frequency carrier and thousands of signals, each at a different frequency can co-
exist on the wire. This technique is expensive and used on the Internet backbone where a
large amount of data is carried. The frequencies can extend to the range of light and fiber
optic cable can be used.
Bridges, Hubs, Switches, Routers, Gateways:
Bridges are used to connect two or more subnets or LAN with the same domain. A standard
bridge contains just the data link and physical layers of the OSI. They can determine if a
data packet needs to be passed from one LAN to another by checking the destination
address in the packet. A translation bridge is capable of translating data packets from one
type of network to another. This also reduces total traffic on the extended LAN.
A hub typically connects 8, 16 or 24 devices. A hub can be used to reduce the amount of
wiring required in a plant. A hub can concentrate a number of devices in one area into one
line connecting to the rest of the plant. Smarter hubs can be accessed over the network to
check their operation and change some parameters.
Another step up is a switch. A bridge provides a “one to one” connection, a hub provides a
“one to many” connection, a switch provides a “many to many” connection. A switch can be
used to connect multiple networks without the use of a backbone or to reduce the traffic on a
backbone. A backbone is the highest level the signal must traverse to get to and from its
goal. In a plant the backbone would be the wire connecting accounting, the shop floor, the
front office, etc. In a multi-plant operation, it would be the wiring connecting the plants. On
202 SYSCON-PlantStar Help System

the Internet it is the grid connecting major cities all over the world.
A router works with more than just the data and physical layers. Adding network and
transport layers allows routers to handle traffic between different types of networks.
A gateway is a smart router. It stands at the entry to a domain and looks at all traffic into
and out of a domain. It can be set to reject a single internet address (Whitehouse.com),
addresses that are mostly personal (JUNO.net), a list from the anti-porn league, or what
have you. The reject list is maintained by the IT group.

Virtual Private Networks (VPN):

A VPN is a way to connect a remote device to a network with a reasonable level of security.
Just adding a modem to a system allows the remote device the same access that any other
device on the LAN to which it is connected. If the modem is connected to a LAN segment that
is in turn connected to the main LAN, it may be possible for a remote connection to access
sensitive information. If the modem is connected through a level three switch, the switch can
be told to match software and hardware address from the remote device. This will restrict
unauthorized users from getting into the system; furthermore, if the switch and modem are
properly located, the external device will only be allowed to access the LAN to which the
modem is connected. If the PlantStar system is set up as a separate LAN, then the switch
can be set up so the PlantStar system can be contacted by Syscon for service but Syscon
would be blocked from access to anything else.

9.16 Process and Production Monitoring

There are two primary types of monitoring windows within your system -- process and
production. Production information is available for a specific machine or a group of machines.
Process information is available for a specific machine. Both types of windows are accessible
through the MONITOR menu.

How a job is set up directly relates to the monitoring information available. The job
parameter Schedule Now, for example, determines whether to monitor a job without
reference to its machine's defined shift schedule. If this job parameter is set to "yes", the
machine is monitored and job data is generated regardless of any idle periods in the shift.
If this parameter is set to "no", the state of the Schedule Factory parameter determines
when the machine is monitored.
The Schedule Factory job parameter indicates whether to use the factory shift schedule for
the job. If this parameter is "yes", the job follows the defined shift schedule. If this parameter
is set to "no", the job is considered to be idle and the associated machine is not monitored. If
the Schedule Now parameter is "yes", this parameter is ignored.
Thus, these two job parameters affect how and when a job is monitored. How a machine
is defined also affects the monitoring component of your system. Process variables and
profile variables, if defined, have numerous windows devoted to reporting their behavior.
The following sections discuss some other job parameters and basic concepts that
influence how information is monitored and presented within your system. A few of the
more important types are discussed individually.
 Knowledge Base 203

Production Monitoring
For production monitoring, there are two fundamental pieces of data -- pieces and time.
Virtually all monitoring information involves or uses these two pieces of data to report on the
progress and performance of a job.
Pieces
The first fundamental production monitoring quantity is pieces. Gross pieces are
accumulated by counting closures of the primary contact. The standard multiplier is a
parameter entered in the job's work order. It defines the maximum number of pieces
produced per machine cycle for a job. The actual multiplier reports the number of pieces
currently produced per machine cycle.
Reject pieces
Reject pieces are counted within your system to keep track of the number of good pieces.
Rejects can be entered in one of three ways:
· by an operator at a keypad or EL/TS DCM,
· by a user at a work station,
· by automated equipment using contact inputs to the DCM.
Rejected pieces are used in the calculation of net pieces. The number of rejected pieces is
subtracted from gross pieces to obtain net pieces.
Net parts counting is an alternate method of monitoring good parts. Using this method,
finished boxes of good parts are counted instead of counting rejected parts. Any difference
between the good parts counted and the gross pieces produced by the machine is
automatically accumulated in the machine's designated reject reason. (The designated
reason is defined from the Force Scrap flag on the Down Reason Sets window.) The
number of good parts to be counted each time the net parts input contact is closed is tracked
by the job parameter, net parts multiplier.
Time
The second fundamental production monitoring quantity is time. Production time is divided
up into up time, down time and idle time. Down time is accumulated based upon cycle
time exceeding the down time threshold. Pieces, possibly good pieces, can be produced
while down time is accumulating. This depends upon how the down threshold and
standard cycle time parameters are defined for a job. Down time quantities may be
adjusted by a user at a work station.
Assist time is accumulated in parallel with production time. No assist time accumulates
while a job is idle. Operators may call for assistance at any time by selecting one of the
available assist reasons. This does not affect the production monitoring of the machine.
Process Monitoring
Process Variables
If defined for a machine, up to 50 process variables can be monitored. Most process
variables are collected once per machine cycle. These types of process variables are used
to monitor characteristics which are repeated with every machine cycle. Examples are
204 SYSCON-PlantStar Help System

pressure, temperature or time duration process variables.

Some process variables are collected only when new readings are provided by the
operator. These types of process variables are used to monitor something which is
sampled at irregular intervals. Examples are measurements of sampled parts such as
weight or dimensions.
Whenever a reading is collected, it is compared to the process limits which have been
defined for a job. If the reading is out of bounds, a process violation is flagged. This
violation is displayed on the monitoring windows as a process exception.
Profiles
Up to 4 profiles can be monitored for each machine. Their behavior can be graphically
displayed on any work station or at the relevant EL/TS DCM. A profile is a set of up to 500
readings of a single process input channel collected during one machine cycle. The input
channel can be sampled as fast as once every 10 mS. Limits may be set for the minimum
and maximum values (similar to process limits) to flag a process violation. Again, any
violations are displayed on the monitoring windows.
Various values can be collected from a profile. These values can be read as process
variables (called pseudo variables) for further tracking and limit checking.
SPC Data
DCMs calculate and monitor a variety of SPC parameters. X-bar and Range graphs display
SPC alarms for defined process variables. On an EL/TS, the alarms are displayed to the
right of the graph. The key for the alarms is as follows:
XCL The last X-bar value was not within control limits
RCL The last Range values was not within control limits
INC The last 8 X-bar values were continuously increasing
DEC The last 8 X-bar values were continuously decreasing
ABV The last 8 X-bar values were above the mean
BLW The last 8 X-bar values were below the mean
UTR The last 25 X-bar values show an upward trend
DTR The last 25 X-bar values show a downward trend
RSM Within the last 25 X-bar values, a RUNSUM exceeded 4.
If any of these parameters fall outside of accepted norms, an SPC violation is flagged on an
EL/TS DCM. SPC subgroups can be collected for each process variable on a job-by-job
basis. Monitor X-bar and Range charts are then provided in the monitoring windows for all
current jobs. Historical X-Bar/Range charts can be displayed for completed jobs. Undefined
and down cycle process readings are never included in SPC subgroups. SPC data can be
transferred to the Extended SPC database for more advanced analysis.
 Knowledge Base 205

9.17 Saving Jobs as a Product Standard

Any job can be saved as a product standard from the Save as Product Standard window.
Where can you find it?
· The Load Product Standard window can be accessed from the Current/Queue Job,
Work Orders, and Job Schedule Board windows.
· Select an existing job or work order from the list on the left-hand side of the window
· Click on the Save Std button.
· The Save as Product Standard window appears.
· To save a job as a new standard, click on the New button.
· To update an existing standard, click on the Update button. (See the Save As
Product Standard window on-line help topic for further information.) The Update
button replaces the existing job standard's parameters with the job parameters from
the previous window.
· Once changes are complete, the Save As Product Standard window immediately
returns you to the previous window.
206 SYSCON-PlantStar Help System

9.18 Setting up your System

The general operating procedure for setting up your system is:
· Define your Shop Floor Characteristics - Describe your machines, process
variables, DCMs, profiles, reason sets and all other relevant information from the
Shopfloor Configuration program.
· Schedule Jobs To Run - Schedule jobs from the Monitor program. There are four
basic steps to scheduling jobs -- creating shift schedules, creating product standards,
creating work orders, and assigning work orders to machines to run as jobs.
1. Creating shift schedules is done from the Shift Schedule window. Shift schedules
are created for a work center. Each work center has multiple schedules -- one for
each year desired. Each week within a year may have a different work schedule.
2. Creating product standards is optional. Product Standards facilitate the creation of
work orders (step three).
3. Work orders are not optional. You must create work orders to schedule jobs. Work
Orders can be created from the Job Schedule Board or the Work Orders windows
4. Assigning work orders to machines to run as jobs through the Job Schedule Board
window.
· Monitor the Shop Floor - After machines have been defined, summary, production
process and material lot tracking information can be monitored using a variety of
windows within the Monitor program.
· Print and/or View Reports - Your system offers several types of reports. You can
decide what reports should be printed automatically at the end of a shift or end of a
job. You can also select certain reports for immediate printing.
· Generate Quality Assurance Information (optional) - X-bar and Range graphs are
available for a machine's process history within the Monitor program. There is also a
statistical process control package which interfaces with your system for further SPC
analysis.
There are a number of optional capabilities available within your system that you may or may
not have purchased. These options can be added to your system at any time. All of the
options require not only additional software licensing, but some may require additional
hardware be purchased.

9.19 Shift Scheduling

Shift schedules define the start and end times for work shifts, idle times for holidays or
weekends, and any other events when jobs should not be running or have special needs.
Shift schedules are not required but they do provide the flexibility to control part of the job
process. If shift schedules are not created, all jobs run all the time.
Shift schedules are created for a work center. Each work center has multiple schedules --
one for each year desired. Each year schedule may have up to 12 different weekly work
schedules. There must, therefore, be at least one work center defined before access to
the Shift Schedule window is possible. The Scheduling privilege is also needed in order
to access this window.
The Shift Schedule window is used to create, assign, delete and change work center
 Knowledge Base 207

schedules. If no schedules have been defined, the window appears blank. To create a work
center schedule, use the NEW button.
What do you want to know about?

Selecting a Work Center Schedule

Creating a Work Center Schedule
Changing a Work Center Schedule
Creating a Weekly Schedule
Assigning a Weekly Schedule to an Annual Schedule
Deleting a Work Center Schedule

Selecting a Work Center Schedule

· Once on the Shift Schedule window, position the cursor on the arrow to the right of the
WC field.
· Choose the new work center by sliding the pointer down the selection list to the
appropriate work center and click.
· Upon selection, a new list of year schedules assigned to the selected work center
appears in the Year field.
· The Calendar and Weekly Schedules list reflects the annual schedule for the visible
work center and year.
Every work center schedule has multiple annual schedules. To select a specific year's
schedule and its work schedule assignments:
· Once on the Shift Schedule window, position the cursor on the arrow to the right of the
Year field.
· Choose the new year by sliding the pointer down the selection list to the appropriate line
and click.
· Upon selection, the Calendar and Weekly Schedules List reflects the work schedule
assignments for the visible work center and year.
An annual schedule may have up to 12 weekly schedules defined and associated with it. A
'none' weekly schedule always appears at the top of the Weekly Schedules List. It is used
for clearing out or 'unassigning' a weekly schedule previously assigned to a yearly schedule.
Creating a Work Center Schedule
A work center schedule is created from the Shift Schedule window. A work center schedule
consists of one or more annual schedules and one or more weekly work schedules.

· Go to the Shift Schedule window.

· If there is no work center schedule for the current year, click on the NEW button to
create a current year work center schedule. Each time the NEW button is selected, it
checks to see what the latest, existing year schedule for the selected work center is.
The NEW button increments the year by one each time it is pressed.
· Move the cursor to the Weekly Schedules List field. If a work center schedule existed
for a previous year, the Weekly Schedules List contains the previous year's weekly
schedules. Define any new weekly schedules for the new year or change any existing
weekly schedules.
208 SYSCON-PlantStar Help System

· Assign weekly schedules to all or some of the week blocks on the Calendar.
· Click on the Save button when all weekly schedules are assigned to the new year
schedule.
· A new work center schedule is created.
Changing a Work Center Schedule
Many different types of changes can be made to a work center schedule from the Shift
Schedule window. Possible changes are:
· Assign a different weekly schedule to a specific week on the Calendar;
· Change a start, idle, or end idle time in a weekly schedule;
· Un-assign a weekly schedule for a specific week on the Calendar;
· Change the name of a weekly schedule.
To make a change:
· Go to the Shift Schedule window.
· Move the cursor to the WC field. Choose the work center desired.
· Move the cursor to the Year field. Choose the year schedule desire.
· The weekly schedules associated with the selected yearly schedule appear in the
Weekly Schedules List.
· Make any necessary changes by referring to the appropriate on-line help section listed
below:
A. Assign a different weekly schedule to a specific week Calendar week; Refer to the
Assigning Weekly Schedules For A Year help topic.
B. Change a start, idle, or end idle time in a weekly schedule; Refer to the
Creating Weekly Schedules help topic.
C. Un-assign a work schedule for a specific week block on the Calendar; Refer to
the Assigning Weekly Schedules To The Calendar Board help topic.
D. Change the name of a weekly schedule; to change a schedule name, simply
type over the existing schedule name in the Weekly Schedules List field.
· Click on the Save button.
· The work center schedule is updated.
Creating a Weekly Schedule
· Go to the Shift Schedule window.
· Move the cursor to the WC field. Choose the work center desired.
· Move the cursor to the Year field. Choose the annual schedule desired. Any defined
weekly schedules for the selected work center and year appear in the Weekly
Schedules List, located in the upper left corner.
· Move the cursor to the Weekly Schedules List field.
· If you want to edit an existing work schedule, click on it. The Work Schedule Chart,
located below the Schedules list displays running and idle periods for the selected
weekly schedule.
· To change a shift time, move the cursor to the appropriate field, click, and type over
any existing time.
· If you want to create a new work schedule, click on a row in the Weekly Schedules
List that is 'unused'. Click again to set the insertion point. Enter a new name over
the unused title. Use the <DELETE> key to erase any unwanted characters.
· Move the cursor to the shift name fields. These names default to 1, 2, 3, 4, 5, 6,
 Knowledge Base 209

Idle, and End Idle. You can change the shift names, which can be up to 4
characters long.
· Move the cursor to the desired time fields on the Weekly Schedule Chart and click.
Type in new times.
· Click on the Save button.
NOTE: A change made to a weekly schedule affects all weeks using the same
schedule in that calendar year.
Assigning a Weekly Schedule to an Annual Schedule
The Shift Schedule window lets you assign one weekly schedule to each week within
an annual schedule. An annual schedule can have a mixture of different weekly
schedules or no weekly schedule. Assignments are done using the Calendar Board
and a 'drag and drop' method.
To assign weekly schedules to an annual schedule:
1. Go to the Shift Schedule window.
2. Choose a work center with the WC field.
3. Choose a year with the Year field.
4. Move the cursor to the Weekly Schedules List field. Click on the desired weekly
schedule. Holding down the mouse button, drag the rectangle that appears to the
desired week block on the Calendar. If you want to un-assign' a work schedule from a
specific week, click on the NONE option in the Weekly Schedules List (always
located at the top of the Weekly Schedule List). Holding down the mouse button, drag
the rectangle that appears to the desired week block on the Calendar.
5. Release the mouse button. The week block color changes to match the color of the
weekly schedule in the Weekly Schedules List.
6. Repeat steps 4 and 5 as many times as needed.
7. Click on the Save button.
Deleting a Work Center Schedule
Existing shift schedules may be deleted from the Shift Schedule window. Deleting a yearly
schedule deletes not only the selected year schedule but all the year's weekly schedules
as well.
To delete a work center schedule:
· Go to the Shift Schedule window.
· Move the cursor to the WC field. Choose the work center desired.
· Move the cursor to the Year field. Choose the year schedule targeted for deletion.
· The weekly schedules associated with the selected year schedule appear.
· Click on the Delete button.
· The work center schedule is deleted.

9.20 Shop Floor Configuration

There are numerous steps to setting up and defining a shop floor. Each step entails providing
specific information. The information on one element of the shop floor directly relates and is
associated with a second element. communication processor information, for example, needs
210 SYSCON-PlantStar Help System

boot set information. Machine definitions need communications processor and Data
Collection Module (DCM) information. Changes to some shop floor definitions force a re-
initialization of a DCM. This, in turn, affects the currently running job.
The following sections discuss some basic relationships between specific shop floor
components. These relationships are presented here to facilitate the entering of
information.

What do you want to know about?

User Defined Labels

Reason Sets
Work Centers
Display Groups
Labor Categories
Communications
Processors DCMs
Machines
Process Variables

9.21 SPC Statistics Concepts

Standard SPC statistics can be viewed on the Process Trend/SPC and SPC History
windows. Standard SPC statistics are defined as:

X-Bar Upper Control Limit

X-Bar Lower Control Limit
Range Upper Control Limit
Range Lower Control Limit
X-Bar Mean
Range Mean
Upper Specification
Lower Specification

These values can be viewed by pressing the icon. To close the popup window,
click on this icon again.
What do you want to know about?

SPC Graph Area

Graph Area
Viewing Actual Values on a Graph
Viewing Maximum and Minimum Graph Values
Size Field
Changing The X-Axis
Graph Scaling Options
Manually Scaling Graphs
Autoscaling Graphs
Auto Scale Every Cycle
Cycle
 Knowledge Base 211

Cycle Value
SPC Graph Area
The window displays a line chart of the SPC values collected for a specific process variable.
It includes two graphs. The top graph is a plot of X-bar values and the bottom is a plot of the
associated range values. The X-axis is the time at which the SPC values were recorded.
The number of values graphed may be a subset of the total collected.
To view the maximum value for a graph, click anywhere on the far right-hand side of the
window, outside of the graph borders but within the top and bottom lines of the desired
graph. To view the minimum value of a graph, click anywhere on the far left-hand side of
the graph, outside of the graph borders. To view actual values, click in the middle of the
graph area.
Graph Area
The graph area displays a plot of the most recent process variable values. Clicking
anywhere within the graph area displays a new window with exact x, y coordinate values.
A vertical line marker also appears -- designating the data point selected.
To view the maximum value for a graph, click anywhere on the far right-hand side of the
window, outside of the graph borders but within the top and bottom lines of the desired
graph. To view the minimum value of a graph, click anywhere on the far left-hand side of
the graph, outside of the graph borders. To view actual values, click in the middle of the
graph area.
Viewing Actual Values on a Graph
There are two ways to view the exact values of the last 'n' cycles on a graphical window:
· Click anywhere within the borders of the graph. A vertical line marker appears --
designating the data point selected. A new window also appears displaying the
exact x, y coordinates. The data point selected by the mouse placement is
highlighted on the new window.
- Or -
· Click on the icon for a table format of a Trend graph.
· For each machine cycle update, the new value appears in the Cycle 1 Value cell,
moving older values down sequentially.
Viewing Maximum and Minimum Graph Values
To view the maximum value on any graph window:
· Click anywhere on the far right-hand side of the window, outside of the graph borders
but within the top and bottom lines of the desired graph.
To view the minimum value:
· Click anywhere on the far left-hand side of the window, outside of the graph borders,
but within the top and bottom lines of the desired graph.
212 SYSCON-PlantStar Help System

Size Field
Changes the number of plotted values on the graph.
Changing The X-Axis
The x-axis may be changed from the Size field. The Size field represents the displayable
history size for the process history graph or the SPC History size for the X-Bar and Range
chart.
To change the x-axis:
· Click on the Size field.
· Move the cursor down the selection list to the desired x-axis range.
· Release the mouse button.
Graph Scaling Options
There are three primary scaling options:
· Manual Scale - This option allows you to manually enter the maximum and minimum
values for the Y-axis. The Manual Scales window appears when this button is pressed.
1. Click on the icon.
2. Type in the values you wish to change.
3. To make the changes effective, select the OK button.
4. To cancel any changes made, select the Cancel button.
· Auto scale Once - This option automatically scales the graph when the button is
pressed. The maximum and minimum values for the Y-axis are calculated using the
selected data, the high limit, and the low limit. Once these values are calculated, they are
retained until this button is clicked again or another scale option is chosen.
· Auto scale every machine cycle - Each window update forces a rescale when the
button is chosen. The graph is always scaled according to the displayed data. The
maximum and minimum values for the Y-axis are calculated using the selected data, the
high limit, and the low limit.
Manually Scaling Graphs
Allows you to manually enter the maximum and minimum values for the Y-axis. A new
window appears when this button is pressed.
Auto Scaling Graphs

Automatically scales the graph when the above button is pressed. The maximum and
minimum values for the Y-axis are calculated using the selected data, the high limit and the
low limit. Once these values are calculated, they are retained until this button is clicked again
or another scale option is chosen.
Auto Scale Every Cycle
Forces a rescale when chosen. The graph is always scaled according to the displayed data.
The maximum and minimum values for the Y-axis are calculated using the selected data, the
high limit, and the low limit.
 Knowledge Base 213

Cycle
The actual machine cycle number.
Cycle Value
The actual machine cycle value.

9.22 System Architecture

All of the systems we supply run on your existing Local Area Network. We may employ a
subnet to optimize performance, or include wireless components for mobility, or we may
even link multiple plants together in a Wide Area Network. In any of these cases, we employ
system components that come together as in the following examples of system architecture:

9.23 Understanding Machine States

All monitoring windows display the state of a machine by color. On machine-specific
windows, the background color of the window represents the machine state. Monitoring
windows which list multiple machines display the machine state from each machine name's
214 SYSCON-PlantStar Help System

background color. On DCMs, the colored lights represent the machine states.
A machine's state is determined by a set of exception flags. Each flag indicates one possible
exception condition. The following table lists each machine state and its associated color. The
highest priority state determines the color displayed. The states are listed below in order of
priority, with the highest of importance listed first.

A machine can be in one or more states at a time. It can have a process or production
exception and be in the assist state. Process and production exception states can also co-
exist on the same machine at the same time. The following list provides a general overview of
machine states and their relationships to each other.
· The off-line state is mutually exclusive from all other machine states.
· If a machine is idle, all other states, except off-line, are excluded.
· If a machine is down, it can still be in assist or have a process and/or production
exception.
· A machine can be fast, slow, standard, or down.
Other combinations not specifically mentioned above are possible.
There are many ways that machines can enter or exit a certain state. Selection of an assist
reason by an operator at a DCM triggers the respective state for the selected machine.
Process exceptions occur when a process variable measurement is outside of an assigned
limit, either high or low. A machine can go in or out of a process exception state with each
new cycle value.
Production exceptions occur when a machine's pieces to go is negative (too many pieces
have been made) or when its job-to-date percent rejects is greater than its reject threshold
for the current job. Once these two relationships are no longer true, a machine exits the
production exception state.
There are two ways a machine can enter an idle state. A machine becomes idle if it is
following a shift schedule that has an idle period defined. For the duration of the idle period,
the machine is classified as idle. The second way a machine can become idle is by
suspending its job. To suspend a job, set the job parameters Schedule Now and Schedule
Factory both to No. The idle state stays in effect until these job parameters are changed.
The down state is entered when the average cycle time exceeds the down threshold. The
 Knowledge Base 215

down state ends when the average cycle time is once again less than the down threshold.
The down state can also be entered if the operator selects a down reason which is
configured to force a machine down.
The fast, slow, and standard machine states are basic indicators of machine performance.
For each machine cycle, the cycle tolerance is monitored. The tolerance is the percent
deviation of a job from its normal standard cycle time. An average cycle is computed and a
comparison is made using the cycle tolerance and standard cycle values. If the average
cycle is greater than the resultant value, the machine is considered to be running slow. If the
average cycle is less than the resultant value, the machine is considered fast.
Moving Average Cycle
The moving average cycle is compared to the standard cycle to determine the fast state/slow
state of a machine.
The machine is slow if:
(Average Cycle) > (Standard Cycle) + ((Cycle Tolerance) * (Standard Cycle) /1 00)
The machine is fast if:
(Average Cycle) < (Standard Cycle) - ((Cycle Tolerance) * (Standard Cycle) /1 00)
The "Your System" Icon
When your system is iconized, the icon displays on the bottom of the workstation
monitor. The top three circles signal exception states for any machine listed on an open
window. For example, if you open the Machine Performance window and then iconize your
system, the icon blinks if one of the machines displayed on the window goes into exception.
Exceptions displayed from the icon are down, assist, production exception, and process
exception.
216 SYSCON-PlantStar Help System

9.24 User Preferences

The User Preference window enables you to customize the PlantStar environment in
terms of:
· Font Size -- Changing Text Sizes sets the font size for all PlantStar
windows. ·

· Job Primary Label -- The label to use for all jobs displayed on the Job Schedule
Board window can be selected. The job label field lists all jobs on the Gantt chart
by job name. The product label shows all jobs by product name.
· Default When Moving a Job - You can select what will happen by default when
moving work orders or jobs from one machine to another on the Job Schedule
window.
· Screen Load Behavior - This option enables the quick loading of screens. When
the quick load option is enabled, a screen is loaded without retrieving the data
for the selection criteria. Data is loaded after the window is opened and selection
 Knowledge Base 217

is made.
· Search Criteria - The search method used on the Job Schedule Board window
can be selected. There are three search methods: left, embedded, and exact. Left
matching searches for records that start with a specified text. Embedded
matching finds all occurrences of a text wherever it is located. Exact matching
finds exact matches only. (Specific examples are provided under each method's
field help topics.)
· Show labor hours displays the total number of man hours required for each shift.
· Language - This allows the users to select their language preference.
These preferences are saved from session to session and will not change until the next
modification.
Where can you find it?
· Choose the File menu on the Monitor window.
· Choose the User Preference option.
What do you want to know about?

Changing Preferences
Saving Your Changes
Undoing Your Changes
Closing the Window

9.25 Using PlantStar Help

9.25.1 About PlantStar
For up-to-date resource information, the application provides a window with the following
information:
· PlantStar Software Version
· PlantStar Copyright Date
· Microsoft Windows Version
· Amount of free memory
To see this information:
· Select the Help menu on the main menu.
· Choose the About PlantStar menu item.

9.25.2 Help Active Window

Window level help provides information on the display that currently has focus.
Information for each window includes:

· purpose of the window

· specific field descriptions
· window button explanations
This type of help is available by selecting and opening a desired window. Once opened,
select the Help-Active Window menu on the application window or press the F1 key.
218 SYSCON-PlantStar Help System

NOTE: If there are currently no PlantStar windows open, this menu item will not display any
help.
9.25.3 Help Contents
General content help provides a table of contents for virtually all topics within this
application. The Contents window can be used to jump to topics that explain various
windows or how to get quick access to key reference topics. This help is available by
selecting the Contents on the Help menu item.
Use the scroll bar to the right side of the Help window to view the next page of the Table of
Contents.
9.25.4 Help Index
The Index list is directly accessible from the Index on the Help menu item or from the Index
tab within the on-line help utility. Index terms consist of:

· definitions
· formulas, if applicable
· recommended values, if applicable.

To access an item from the Index list:

· Use the scroll bar on the right hand side to scroll the window to the desired item.
· Point to the term or phase desired.
· Double-click on the highlighted word to open.

-Or-

· Use the keyword field to search for the desired item.

· Once found, double-click on the highlighted word to open.
9.25.5 Help Search
Another method to find a particular topic in Help is to use the Search option. To display the
Search window, either choose Search from the Help menu on the application window or
click the Search tab on the Help topic screen.

Select a topic by:

· Use the keyword field to search for the desired item.
· Click on the List Topics button to search on the keyword entered
· A list of related topics then appears on the screen.
· Once found, double-click on the highlighted topic to open.
SYSCON - PlantStar System
User's Guide

Part

X
220 SYSCON-PlantStar Help System

10 Functions
10.1 Activating an attention announcement
The Play Attention field on the Attention Announcement window determines whether an
attention message is played before any other exception message.

To activate an attention message:

· Click on the box to the left of the Play Attention field.

· An "x" appears. This "x" signifies that an attention message will be broadcast
before any other message is played.
· To cancel the playing of the attention message, click on the box to the left of the Play
Attention field until the "x" disappears (usually once).
· Click on the Update button.
10.2 Adding a DCM
· Click on the New button.
· Type in the new DCM name.
· After entering your information, click on the Update button to temporarily store your
changes and to allow other windows access to the new DCM.
· To send the new DCM definitions to the shop floor, select the Save Session command
under the File menu.

A window's Delete button deletes information from PlantStar's database. Depending upon the
window, a reason set, boot set, work center, display group, communications processor,
machine or DCM will be deleted.
10.3 Adding a labor category
· Click on the Labor Categories tab located at the top of the window.
· Scroll the list until you find an empty record. Up to 30 labor categories can be added.
· Type in the new labor category name.
10.4 Adding an employee
· Click on the Employees tab located at the top of the window.
· Click on the New button.
· Type in the new employee name.
10.5 Adding an employee to labor history
If an employee is not logged in during the shift they work, they may need to be added to the
labor history at a later time. To add an employee record to history, click the Add button at
the bottom of the screen. Once clicked, you will be presented a login dialog.

© 2008 ... SYSCON International, Inc.

 Functions 221

From this dialog you would enter a valid employee id. Employees are defined in the Labor
Setup window, which is in the Shop Floor Configuration program. If the employee id is
invalid, you will be presented with a pop up message "Invalid Employee". Once a valid
employee id is entered, you will be prompted for a labor category you wish to log into.

From this dialog you can select a labor category from the drop down list. The drop down list
consists only of the categories that have been assigned to the employee id entered.
Employee-Labor Category definitions are defined in the Shop Floor Configuration program.
Once a labor category has been selected, the login record will be added to the shifts labor
history.
NOTE: Labor history records cannot be added to the current shift. Employees can be
added to the current shift by logging in at the DCM or from the Labor Status window.
10.6 Adding child jobs
Up to 12 child jobs can be assigned to either a work order or a product standard.

To assign a child job to an existing product standard,

· Select the "Add Child" button at the bottom of the screen.
· This will add a child job to the product standard using the parent information as a base.

To assign a child job to an existing work order:

· Use the mouse and right click over the work order list or the child parameter grid.
· Select "Add Child" from the pop up menu.
- or -
· Use the mouse and select "Edit" from the main PlantStar window.
· Select "Add Child" from the menu.
NOTE: Child Jobs cannot be added or removed from current jobs or queued jobs. In other
words, the number of child jobs assigned to a job cannot be changed once the job has been
scheduled.
10.7 Adding machines to a display group
222 SYSCON-PlantStar Help System

The Add button enables you to include new machines into an existing display group.

· Select a machine from the Available Machines list by clicking on the desired machine in
the list.
· To select several machines next to each other, keep the mouse button pressed down
and move the mouse up or down. Then let go.
· To select several machines that are not next to each other in the list, press the
CTRL button, in combination with the mouse button, over each desired machine.
· Click on the Add button.
· Click on the Update button.
· Select the Save Session command under the File menu.
10.8 Adding machines to an REU list
The Add button enables you to include new machines and make them accessible from an
REU.

· Select a machine from the Available Machines list by clicking on it. To select several
machines next to each other, keep the mouse button pressed down and move the
mouse up or down. Then let go. To select several machines that are not next to each
other in the list, press the CTRL button, in combination with the mouse button, over
each desired machine.
· Click on the Add button.
· Click on the Update button.
· Click on the Save Session button under the File menu to transfer the new machines
for the REU to the shop floor.
10.9 Adding users
The New button on the User Accounts window clears the window and enables you to type
in a new user's information. To add a user:

· Go to the User Accounts window

· Click on the New button. Type in the new user name. The name may contain
letters and/or numbers and be up to 20 characters in length.
· Set up the user's password by clicking on the Password button.
· Set the user privileges by clicking on the appropriate check boxes next to each privilege.
· Click on the Save button to add the new user to the system.
· If a user already exists with that name, a warning message will be displayed. Type in a
different user name and select the Save button again.
· To permanently save the new user, click on the Save Session command under the File
menu.
 Functions 223

10.10 Adding/editing multiple materials

If you have the multiple materials feature, a pop up window appears when clicking the
material button on the job editor screen.
To add one material, enter the name in the material field. To add multiple materials:
· Enter the material formula in the material field.
· Click or tab out of the material field. Another window appears.
· Enter the name of a material component. Up to four components can be entered.
· Enter a component percent for each material listed.
· Click or tab out of the component fields to close the window.
10.11 Adjusting gross or net pieces
Incorrect piece counts can be adjusted. Adjustments can be made upward or
downward. To adjust gross pieces or net pieces:
· Move the cursor and select the reject cell to update
· Type in the adjustment value.
10.12 Adjusting reject counts
Incorrect reject counts can be adjusted. Adjustments can be made upward or
downward. To adjust reject counts:
· Move the cursor and select the reject cell to update
· Type in the new reject value.
10.13 Adjusting start/end date
· Move the cursor and select the cell to update
· Type in the new date value. Format is Day/Month/Year (dd/mm/yy).
10.14 Adjusting start/end time
· Move the cursor and select the cell to update
· Type in the new time value. Format is Hours: Minutes (hh:mm).
10.15 Adjusting times
Incorrect time values can be adjusted. Adjustments can be made upward or downward
for each defined reason.

To adjust times:

· Move the cursor and select the cell to update

· Type in the new time. Format is Minutes:Seconds (mm:ss).
· If you wish to subtract time you can press the plus button on the screen.
· To change to positive values click the minus button on the screen.
· Using the plus and minus keys on the keyboard functions in the same manner.
224 SYSCON-PlantStar Help System

10.16 Anchoring selected job

Anchoring job in the Job Schedule Board allows you to move the selected job anywhere
within its position of the job queue. This gives you the ability to schedule the job at a more
precise date and time than the other job scheduling methods.

First, you must first choose one of the two scheduling methods:

· Schedule jobs by earliest start date (default)

· Schedule jobs by due date
The default method on the Job Schedule window is the first method; which will schedule the
next job to run immediately following the completion of previously-queued jobs.

To anchor a selected job:

· Choose one of the two scheduling methods desribed above. This determines the
anchor point of the selected job.
· Click on the Anchor button. This will display an anchor icon on the selected bar.
· If the job schedule by earliest start date is selected, the icon will appear on the left
side of the selected job. If the job schedule by due date is selected, the icon will
appear on the right side of the selected job.
· Once anchored, you can move the selected job anywhere within its position of the job
queue. This allows you to specify the exact time a job will run.
· Click on the Commit button.

NOTE: If the job is anchored at its earliest start date, the anchor on the bar will appear red
in color. If scheduled at any other time, the bar anchor will appear blue.
10.17 Assigning a report file name
· Move the cursor down the report list to the desired choice
· Type in the directory name and file name of the file you wish to export the report.
10.18 Assigning an employee to a labor category
Labor cateogories are user-definable categories which one or more can be assigned to an
employee. When an employee attempts to login, they are presented with a list which consist
only of the labor categories to which they have been assigned. Employee-Labor Category
definitions are also defined in the Labor Setup window.
To assign an employee to a labor category:
· Select the employee record to update.
· Select the column that corresponds to the labor category you wish to assign.
· Using the mouse or cursor, check the check box in the labor category column.
10.19 Assigning child jobs
To assign child jobs, there must be existing unassigned child jobs to assign to a child job.
Unassigned child jobs would appear in the "Available Child Jobs" list, which is directly under
the work order list.
To assign a child job to an existing child job:
· Use the mouse and right click over the work order list or the child parameter grid.
 Functions 225

· Select "Load Child" from the pop up menu. You will be presented with a list of available
child jobs.
· From this screen, you can search or scroll through the list of child jobs.
· Once a child has been selected, click the "OK" to load the child job onto the child job
selected.
· Alternatively, you can use the default product standard by clicking the "Default" button
and selecting "OK".
NOTE: You can only assign child jobs to existing child jobs. See Adding Child Jobs for further
details.
10.20 Assigning weekly schedules
The Shift Schedule window lets you assign one weekly schedule to each week within
an annual schedule. An annual schedule can have a mixture of different weekly
schedules or no weekly schedule. Assignments are done using the Calendar Board
and a 'drag and drop' method.

To assign weekly schedules to an annual schedule:

1. Choose a work center with the Work Center field.

2. Choose a year with the Year field.
3. Move the cursor to the Weekly Schedules List field. Click on the desired weekly
schedule. Holding down the mouse button, drag the rectangle that appears to the
desired week block on the Calendar. If you want to 'unassign' a work schedule from a
specific week, click on the None option in the Weekly Schedules List (always located
at the top of the Weekly Schedule list). Holding down the mouse button, drag the
rectangle that appears to the desired week block on the Calendar.
4. Release the mouse button. The week block color changes to match the color of
the weekly schedule in the Weekly Schedules List.
5. Repeat steps 4 and 5 as many times as needed.
6. Click on the Save button.
10.21 Changing a comm processor's name
· Type over the existing Comm Processor's name.
· Click on the Update button.
· Select the Save Session command under the File menu to immediately transfer any
changes to the shop floor.
10.22 Changing a machine's name
· Type over the existing machine name.
· Click on the Update button.
· To send your changes to the shop floor, select the Save Session command under the
File menu.
10.23 Changing a report
There may be times when a scheduled report needs to be changed. Shift changes, period
changes, day of the week and even the type of report can be changed. To make changes:

· Move the cursor down the report list to the desired choice
· Click on the arrow to the right of the report field.
· Choose the report you want by sliding the pointer down the selection list to the
226 SYSCON-PlantStar Help System

appropriate line
10.24 Changing an existing work center's name
To change a work center's name

· Type over the existing work center name.

· Click on the Update button.
· Select the Save Session command under the File menu.
10.25 Changing child jobs
To change the Child Job that you are viewing:

· Position the mouse pointer over the arrow to the right of the Child Job field and click.
· Choose the new Child Job you want by sliding the pointer down the selection list to
the appropriate line. Click again.
10.26 Changing com port settings

The com ports tab allows the user to set the serial port communications.
To change the Com Ports settings, click on the Com Ports tab located in the middle of the
screen.

These are used to pass messages to and from printers, barcode scanners, and machine
specific PLCs. In order to use these devices the correct communication protocols for the
device need to be specified here.
10.27 Changing contact input settings
 Functions 227

The Contact Inputs tab allows the user to set up simulated contact inputs.
To change the Contact Inputs settings, click on the Contact Inputs tab located in the
middle of the screen.
This is useful for diagnostic purposes. The first input is always Cycle Time. The open and
close ticks are defined as being 10 milliseconds per tick, so to have the contact open for 5
seconds the setting should be 500. In order for the DCM to operate correctly these must be
reset to zero when testing is completed.
10.28 Changing display groups
To change the display group that you are viewing:

· Position the mouse pointer over the arrow to the right of the Display Group field and
click.
· Choose the new display group you want by sliding the pointer down the
selection list to the appropriate line. Click again.
10.29 Changing down, assist and reject data
This privilege gives users the ability to update historical down, assist, reject, gross or
net pieces information. These updates are done via three windows within the Monitor
program:

· Down Time Editor

· Assist Time Editor
· Parts Count Editor
228 SYSCON-PlantStar Help System

10.30 Changing end date

· Move the cursor to the end date field
· Type in the date value. Format is Day/Month/Year (dd/mm/yy).
10.31 Changing forecast start date
The start date displayed is the date Labor Forecasting will start calculating manning
factors for the scheduled jobs. To change the start date:

· Move the cursor to the start date field

· Type in the date value. Format is Day/Month/Year (dd/mm/yy).

- or -

· Position the mouse pointer over the arrow to the right of the Start Date field. A pop up
calendar will display the current date selected.
· Choose a start date by navigating the calendar to the selected date. To select the
current date, select the "Today" button at the bottom of the pop up calendar.
NOTE: Dates prior to the current date cannot be selected. Labor Forecast was designed to
forecast man-hour needs for jobs currently running and scheduled to run in the future.
10.32 Changing forecast views
There are two different views to Labor Forecasting:

· Grid View - The Grid View displays a table of labor manning factors for a specific
shift and labor category.

· Graph View - The Graph View displays an ordered histogram of the manning factors for
a labor category. There is one vertical bar per shift. Bar height represents the man
hour needs for the given shift. Bars are displayed from left to right in order of shift
occurrence.
To select one of the views, select from the Grid View or Graph View tabs, at the top of the
screen.
 Functions 229

10.33 Changing general DCM settings

The general tab allows the user to set the appropriate physical settings for the DCM.
To change the General settings:
· Click on the General tab located in the middle of the screen.

These include Base Model type, Display Type, Memory, Job History Size, etc. If a setting is
grayed out the option is currently unavailable either because of setup limitations or the option
has not been authorized. The memory required field is used as a guide line to let the user
know approximatley how much memory the current setup will require. These figures are
estimates only, and problems may occur if the memory required is greater then the memory
installed on the DCM. This is only an issue with older DCMs such as the CPU5 and the CPU7
where memory is very limited.
10.34 Changing graph types
To change the type of graph you are viewing:

· Position the mouse pointer over the Graph field.

· Choose the new graph type, by sliding the pointer down the selection list to the
appropriate line.
10.35 Changing jobs
To change the Job that you are viewing:

· Position the mouse pointer over the arrow to the right of the Job field and click.
· Choose the new Job you want by sliding the pointer down the selection list to the
appropriate line. Click again.
10.36 Changing labor categories
· Move the cursor and select the labor category cell to update
· Position the mouse pointer over the arrow to the right of the labor category field and
click.
· Choose the new labor category you want by sliding the pointer down the
selection list to the appropriate line.
230 SYSCON-PlantStar Help System

NOTE: The Labor Forecast screen allows the selection of "All" labor categories. To view
All labor categories, select the item "All", which is the first item in the labor category list.
10.37 Changing machines
To change the machine that you are viewing:

· Position the mouse pointer over the arrow to the right of the Machine field and click.
· Choose the new machine you want by sliding the pointer down the selection list to
the appropriate line.
10.38 Changing material components
To change the material components that you are viewing:
· Position the mouse pointer over the arrow to the right of the material name field and
click.
· Choose the new material components you want by sliding the pointer down the
selection list to the appropriate line. Click again.
10.39 Changing number of plotted values
The combo box indicates the number of plotted values on the graph:
To change the number of plotted values that you are viewing:
· Position the mouse pointer over the arrow to the right of the field and click.
· Choose the new number you want by sliding the pointer down the selection list to
the appropriate line.
10.40 Changing number of reasons displayed
The combo box indicates the number of reasons displayed in the Pareto chart.
To change the number of reasons that you are viewing:

· Position the mouse pointer over the arrow to the right of the field and click.
· Choose the new number you want by sliding the pointer down the selection list to
the appropriate line.
10.41 Changing number of shifts
The number of shift records PlantStar should attempt to retrieve for the given selection
criteria.
To change the number of shifts to display:
· Position the cursor in the "Num of Shifts" field.
· Enter the number of shifts to display.
NOTE: If the shift count exceeds the number of actual shift records, PlantStar will only return
the actual shift records found.
NOTE: The Labor Forecasting window allows entries of 1-100. Job Summary window allows
entries of 1-350
10.42 Changing passwords
To change your password:
 Functions 231

· Choose the User menu on the main Shop Floor Configuration window.
· Choose the User Accounts window.
· Click on the Password button on the User Account window.
· A new window appears with 2 fields: a password field and a verification field.
· Type in your new password and its verification.
· Click on the OK button.
· Click on the Save button on the User Account window.
· To permanently save all user changes, click on the Save Session command under the
File menu.
10.43 Changing preferences
· Select a font size -- tiny, small, medium or large.
· Select a Job Schedule Board window label.
· Select the default job movement method for the Job Schedule window.
· Select screen load behavior.
· Select the search method to be used on the Job Schedule Board window for work
orders and on the Job Schedule Search window.
· Select the language preference.
10.44 Changing process graph modes
The graph mode button plots a graph of the n most recent values of a variable on a machine.

· To change the graph mode, click the graph mode button

10.45 Changing process variables name
You can change a process variable or profile name at any time.
· Select the process variable or profile desired from the variable index field. Click on the
arrow to the right of this field. Move your cursor down the list to the appropriate variable
and click again.
· Type in a new name for the variable in the variable name field. (Directly type over
the existing name.)
· Click on the Update button.
· Select the Save Session button under the File menu to transfer this information to the
shop floor.
10.46 Changing profile graph modes
Profiles can be viewed by themselves, overlaid on top of other profiles, or crossplotted
with other profiles. If more than one profile is selected, the default viewing mode is to
overlay the profiles.
To overlay two or more profiles:

1. Select the desired profiles by clicking on the colored box to the left of each profile. An 'x'
appears in the box. As each profile is selected, its line graph is drawn on top of the
previously selected profile. To de-select a profile, click on the colored box to the left of
the profile name again. The 'x' disappears.
2. Or if you have the CROSSPLOT mode turned on, then click on the button to
display all selected profiles in overlay mode.
To crossplot two or more profiles:
232 SYSCON-PlantStar Help System

1. Select the desired profiles by clicking on the colored box to the left of each profile. An 'x'
appears in the box. As each profile is selected, its line graph is drawn on top of the
previously selected profile. To de-select a profile, click on the colored box to the left of
the profile name again. The 'x' disappears.
2. Click on the button to crossplot the profiles.

10.47 Changing profile variables name

You can change a process variable or profile name at any time.
· Select the process variable or profile desired from the variable index field. Click on the
arrow to the right of this field. Move your cursor down the list to the appropriate variable
and click again.
· Type in a new name for the variable in the variable name field. (Directly type over
the existing name.)
· Click on the Update button.
· Select the Save Session button under the File menu to transfer this information to the
shop floor.
10.48 Changing rescaling options
There are three primary scaling options:

1. Manual Scale - This option allows you to manually enter the maximum and minimum
values for the Y-axis. The Manual Scales window appears when this button is pressed.
· Click on the icon.
· Type in the values you wish to change.
· To make the changes effective, select the OK button.
· To cancel any changes made, select the Cancel button.
2. Auto scale Once - This option automatically scales the graph when the button is
pressed.
The maximum and minimum values for the Y-axis are calculated using the selected
data, the higher limit, and the lower limit. Once these values are calculated, they are
retained until this button is clicked again or another scale option is chosen.
3. Auto scale every machine cycle - Each window update forces a rescale when the button
is chosen. The graph is always scaled according to the displayed data. The maximum and
minimum values for the Y-axis are calculated using the selected data, the higher limit, and
the lower limit.
 Functions 233

10.49 Changing RIO settings

The RIO tab is only available after an RIO has been defined in the com ports tab.
To change the RIO settings:
· Click on the RIO tab located in the middle of the screen.

This tab allows the configuration of the Remote I/O unit. In order for a machine to be able to
collect data from the RIO the check box next to the machine number must be selected. Once
selected, the machine will retrieve all process variables and profile data including cycle time
from the RIO unit. The other boxes allow the user to specify whether 1 RIO is connected to all
machines or each machine has its own RIO, if the analog card in the RIO is isolated, or
whether the shuttle type boot set should be downloaded to the RIO.
10.50 Changing shifts
To change the shifts that you are viewing:

· Position the mouse pointer over the arrow to the right of the shifts field and click.
· Choose the new shifts you want by sliding the pointer down the selection list to the
appropriate line.
NOTE: If the All shifts menu option is available, selecting the item "All", will update the
display with all available shifts.
10.51 Changing start date
· Move the cursor to the start date field
· Type in the date value. Format is Day/Month/Year (dd/mm/yy).
10.52 Changing the x-axis
The X-axis may be changed from the Size field. The Size field represents the displayable
history size for the process history graph or the SPC History size for the X-Bar and Range
chart.

To change the X-axis:

234 SYSCON-PlantStar Help System

· Click on the Size field.

· Move the cursor down the selection list to the desired x-axis range.
· Release the mouse button.
10.53 Changing tools
To change the tool:

· Position the mouse pointer over the arrow to the left of the Tool field.
· Click and slide the pointer down the selection list to the appropriate line.
10.54 Changing user-defined labels
To change user-defined field label

· Select the field title to change from the parameter name field.
· Type in the new label for the field in the current name field.
10.55 Changing work centers
To change the work center that you are viewing:

· Position the mouse pointer over the arrow to the right of the work center field and click.
· Choose the new work center you want by sliding the pointer down the selection list to
the appropriate line.
10.56 Clearing machines
The Clear All button clears the existing machine selection.
10.57 Clearing process history information
The Clear button deletes all current process history information for the displayed job and
machine. This button is enabled for both the graph and table modes. In order to use it, the
Change SPC and PVAR History Data privilege on the User Accounts window must be
granted.

10.58 Clearing search fields

The Clear All button blanks out all searching key fields and any material components found.
10.59 Clipping the graph
The Process Trend/SPC and Profile windows feature a 'clip' option for the graph. Clipping
redraws the graph, displaying only the positive or zero values. The clipping feature stays into
effect until canceled.

To clip the graph:

1. Click on the button.
2. Once selected, this button appears 'depressed' into the background of the window.
3. To cancel this feature, click on the icon again. It should appear not selected.
10.60 Closing the window-Close
To close the current window, choose one of the following methods:

· Select the Close button.

- or -
 Functions 235

· Click your mouse button while it is positioned over the 'x' in the upper right hand
corner of the window.
10.61 Closing the window-OK-Cancel
To close the current window, choose one of the following methods:

· Select the OK button at the bottom of the window.

- or -
· Select the Cancel button at the bottom of the window.
- or -
· Click your mouse button while it is positioned over the 'x' in the upper right hand corner
of the window.

NOTE: If the Cancel button is selected, all changes will be disregarded and you will not be
prompted to save your changes.

After saving, any necessary adjustments will be sent to the DCM and other PlantStar clients.
10.62 Coldstart a DCM
Many changes made to the DCM setup require a restart of the DCM for the changes to take
effect. If this check box is grayed out, it means that when you save your changes from the
Save Session command under the file menu, the DCM will reboot and your changes will be
implemented. You may also wish to manually check this box to force the DCM to coldstart.
10.63 Committing a schedule

The Commit button on the Job Schedule Board window sends the schedule to the shop
floor.
Click on this button to transfer job queues to a DCM.
10.64 Copying a product standard
An existing product standard can be copied and then edited to create a new standard.

· Select a standard to copy.

· Click on the New button. The screen will still display the previous standards information.
· Make any necessary changes.
· Click on the Apply button. A new product standard has been created using the previous
standard as a template.
236 SYSCON-PlantStar Help System

10.65 Copying an announcement

Announcements or voice files can be copied from:

· one assist reason set to another

· one down reason set to another
· one assist reason to another
· one down reason to another
· one process variable to another
· one machine's process variables to another
To copy:

· Select the Process Announcement, Assist Announcement or the Down Announcement

window from the Configure menu.
· Select the process variable, assist reason, or down reason, which is to be the
destination for the copy.
· Click on the Copy command button. The Select File To Copy window appears.
· Select the down set, assist set, or machine from which to copy.
· Click on the down reason, assist reason or process variable to copy.
· Click on the OK button. The voice file associated with the item from the previous step
is copied to the originally-selected reason or process variable.
10.66 Creating a comm processor
The New button allows the user to add a new communications processor:

· Click on the New button.

· Type in the new Communications Processor's name.
· After entering your information, click on the Update button to temporarily store your
changes.
· Select the Save Session command under the File menu to transfer the new
changes to the shop floor.
10.67 Creating display groups
The New button enables you to define a new display group.

· Click on the New button.

· Select a work center from the work center field. A list of available machines appears in
the Available Machines field.
· Type in the new display group's name and any comments you may have.
· Select the desired machines from the Available Machines list for inclusion in the
group. Highlight a machine or group of machines.
· Click on the Add Button.
· Click on the Update button.
· Select the Save Session command from the File menu.
 Functions 237

10.68 Creating machines

The New button allows the user to add a new machine:

· Click on the New button.

· Type in the new machine's name.
· After entering your information, click on the Update button to temporarily store your
changes. Other windows, such as the Display Group window, will now have access to
the new machine.
· Select the Save Session command under the File menu to transfer the new
machine to the shop floor.
10.69 Creating new standards
To create a new standard based upon the job or work order on the previous window, click
on the New button.

Once the update is complete, the Save As Product Standard window immediately returns
you to the previous window.
10.70 Creating process variables
For each machine, PlantStar lets you define 0, 20, or up to 50 process variables
depending on the options purchased.

To create a new process variable:

· Choose the Shop Floor menu on the main Shop Floor Configuration window.
· Choose the Machine Setup option.
· Select a machine on the window.
· Click on the process option button, located on the left hand side of the window. A
list of defined process variables displays.
· Click on the arrow to the right of the variable index field. Select a process variable
index that has an empty process variable name field. If none are empty, you cannot
add a new process variable.
· If one is empty, type in your new name for the process variable in the variable name
field. Select a source type and complete all source type information.
· Click on the Update button to save your information.
· Select the Save Session command under the File menu to send the process
variable to the shop floor.
10.71 Creating product standards
· Click on the New button.
· Select a machine from the machine field.
· Move the cursor to the Value column for each desired parameter. Directly type in
parameter values. If default information is displayed, edit it as desired by typing over it.
10.72 Creating profile variables
PlantStar lets you define up to 4 profile variables if the profile option has been
purchased. To create a new profile:
· Choose the Shop Floor menu on the main Shop Floor Configuration window.
· Choose the Machine Setup option.
238 SYSCON-PlantStar Help System

· Select a machine on the window.

· Click on the Edit profile option button, located on the left hand side of the window. A
list of defined profiles displays.
· Move the cursor to the variable index field. Click on the arrow to the right of the field
and slide your cursor down the list. Select a variable index that has an empty variable
name field. If none are empty, you cannot add a new profile variable.
· If one is empty, type in your new name for the profile and then fill out any other relevant
information.
· Click on the Update button to save your information and then on the Save Session
command under the File menu.
10.73 Creating reason sets
The New button allows the user to add a new reason set or boot set:

· Click on the New button.

· Type in the new set's name and any comments you may have.
· Enter the list of reason names for the reason set by clicking on a row in the reason
table. Type over the text in the Reason List if you want to change the default names
displayed.
· If editing boot sets, click on the boot file column to select or de-select a boot file.
· After entering your information, click on the Update button to temporarily store your
changes.
· Click on the Save Session button under the File menu to immediately download your
changes to the shop floor.
10.74 Creating REUs
The New button enables you to define a new REU. As of version 4.10 this feature is
no longer supported.

· Click on the New button.

· Type in the new REU's name, its address, communications processor, boot set, and
location.
· Highlight the machines which are accessible on the REU from the Available Machines
list. To select several machines next to each other, keep the mouse button pressed
down and move the mouse up or down. Then let go. To select several machines that
are not next to each other in the list, press the CTRL button, in combination with the
mouse button, over each desired machine.
· Click on the Add Button.
· Enable the REU, if desired.
· Click on the Update button.
· Click on the Save Session command under the File menu to transfer REU
information to the shop floor.
10.75 Creating unassigned child jobs
Unassigned child jobs can be created to be added to work orders at a later time.

To create an unassigned child job:

· Select a work order from the work order list.
· Use the mouse and right click over the job selected in the work order list. A pop up
menu will appear directly over were you clicked the mouse.
 Functions 239

· Select "New Child" from the pop up menu. This will create an unassigned child job
based off of the work order selected.
10.76 Creating weekly schedules
An annual schedule may have up to 12 weekly shift schedules defined and associated with it.
A 'none' weekly schedule always appears at the top of the Weekly Schedules List. It is used
for clearing out or 'un-assigning' a weekly schedule previously assigned to a yearly schedule.

To create a weekly schedule:

· Go to the Shift Schedule window.
· Move the cursor to the Work Center field. Choose the work center desired.
· Move the cursor to the Year field. Choose the annual schedule desired. Any defined
weekly schedules for the selected work center and year appear in the Weekly
Schedules list, located in the upper left corner.
· Move the cursor to the Weekly Schedules list.
· If you want to edit an existing work schedule, click on it. The Work Schedule Chart
located below the Schedules list displays running and idle periods for the selected
weekly schedule.
· To change a shift time, move the cursor to the appropriate field, click, and type over
any existing time.
· If you want to create a new work schedule, click on a row in the Weekly Schedules
list that is 'unused'. Click again to set the insertion point. Enter a new name over the
unused title. Use the DELETE key to erase any unwanted characters.
· Move the cursor to the shift name fields. These names default to 1,2,3,4,5,6, Idle,
and End Idle. You can change the shift names, which can be up to 4 characters
long.
· Move the cursor to the desired time fields on the Weekly Schedule Chart and click.
Type in new times.
· Click on the Save button.
10.77 Creating work center schedules
Work center schedules are created from the Shift Schedule window. A work center schedule
consists of one or more annual schedules and one or more weekly work schedules.

· Go to the Shift Schedule window.

· If there is no work center schedule for the current year, click on the New button to
create a current year work center schedule. Each time the New button is selected, it
checks to see what the latest, existing year schedule for the selected work center is.
The New button increments the year by one each time it is pressed.
· Move the cursor to the Weekly Schedules List field. If a work center schedule existed
for a previous year, the Weekly Schedules list contains the previous year's weekly
schedules. Define any new weekly schedules for the new year or change any existing
weekly schedules.
· Assign weekly schedules to all or some of the week blocks on the Calendar.
· Click on the Save button when all weekly schedules are assigned to the new year
schedule.
· A new work center schedule is created.
10.78 Creating work centers
240 SYSCON-PlantStar Help System

To create a work center:

· Click on the New button.

· Type in the new work center's name and any comments you wish.
· After entering your information, click on the Update button to temporarily store your
changes.
· Click on the Save Session command under the File menu.
10.79 Creating work orders
Work Orders are essentially jobs that have been defined but not yet scheduled. In order to
schedule jobs, you must first create a work order. A work order consists of a set of job
parameters. These parameters define the job. They include such things as the number of
pieces required and the standard rate at which the pieces will be produced.
A work order may be created manually by entering the parameters or by loading in a product
standard. Work Orders can be created from the Work Orders or Job Schedule Board
windows.

From the Work Orders window:

· Click on the New button.

· Select a machine from the machine field.
· Move the cursor to the Value column for each desired parameter. Directly type in
parameter values. If default information is displayed, edit it as desired by typing over it.
· Click on the Apply button to save the new work order after all relevant job parameters
have been entered. Once a work order is saved for a machine, an asterisk appears
next to the machine in the machine field. This asterisk signifies that a work order
exists for the specific machine and product combination.
From the Job Schedule window:

· Click on the button. The Edit Job Parameters window appears which looks
similar to the Work Orders window.
· Move the cursor to the Value column for each desired parameter. Directly type in
parameter values. If default information is displayed, edit it as desired by typing over it.

· Click on the Commit button on the Job Schedule window to save the
changes to the Job Schedule Board. If this step is not done, the changes will not be
permanent or sent down to the shop floor.
10.80 Customizing the work order list
For ease of use, the work order list can be partially customized in two ways:

· The work order list can be restricted to show only certain work orders.
· The type of work order information displayed is selectable.
Selecting the Type of Information Displayed:

The work order list has two columns. The first column displays the work order name, or
product name depending on the user preferences selected. The second column displays any
of the following based upon your selection:
 Functions 241

· Job Name
· Product name
· Tool name
· Material formula
· Required by date
· Free text 1,2,3 or4
· Comment
To select what to display in the second column, click on the list box to the right of the work
order list. Highlight your selection by clicking with the mouse.

Customizing the Work Order List:

The work order list can be filtered, providing a way to limit what is displayed. For example, if
only work orders for a specific product are desired, a filtering mechanism enables you to
specify which product.

To list specific work orders:

· Click on the list box to the right of the work order list.
· Move your cursor down the selection list to the desired filter item. Click again.
· Move your cursor down to the text field located directly below the list box.
· Type in the desired search criteria. Press the ENTER key.

NOTE: How the search is performed depends upon the searching method defined on the User
Preference window. Searching methods can be left matching, embedded matching, exact
matching, and case sensitive. If left matching has been designated on the User Preference
window, then entering the word 'poly' (if material formula was chosen as the search criteria)
would find work orders that use 'polypropylene' and 'polyurethane'. If embedded matching is
designated, then entering the word '285' would find work orders using 'polyurethane 285 Black'
and 'Acrylic V285-100 Clear'. Exact matching means that searching for 'polypropylene' would
only find work orders that are using 'polypropylene'.
10.81 Deleting a comm processor
A window's Delete button deletes information from PlantStar's database. Depending upon the
window, a reason set, boot set, work center, display group, communications processor,
machine or DCM will be deleted.

To delete:

· Select the reason set, boot set, or work center, etc. you wish to delete.
· Click on the Delete button.
· Click on the Save Session button under the File menu to immediately transfer your
changes to the shop floor.
10.82 Deleting a custom report from PlantStar
To delete a report:

· Click on the arrow to the left of the Report field. Select a report by moving the cursor
down the list to the desired item and click. The report's description and filename
242 SYSCON-PlantStar Help System

appears.
· Click on the Delete button.
10.83 Deleting a DCM
· Select the DCM. you wish to delete.
· Click on the Delete button.
· Click on the Save Session button under the File menu to immediately transfer your
changes to the shop floor.
10.84 Deleting a labor category
· Click on the "Labor Categories" tab located at the top of the window.
· Select the Labor Category you wish to delete.
· Clear out the Labor Category name. Only Labor Categories with names will
appear in Labor Category list.
10.85 Deleting a labor record
Employee records can be permanently removed from labor history.

To delete an employee’s labor record:

· Select the employee record to delete.
· Using the mouse or cursor, check the delete check box on the left side of the employee
record

NOTE: Once saved, the employee labor record will no longer exist in the Plantstar system.
NOTE: The employee record will not be deleted until you save your changes. The Delete
Employee Record check box only flags the employee record for deletion.
10.86 Deleting a scheduled report
· Select a scheduled report. Scheduled reports are listed on the right-hand side of the
window.
· To select one for deletion, move the cursor over to the list and click on the desired
report.
· Upon clicking, the selected report is highlighted.
· Click on the Delete button.
 Functions 243

10.87 Deleting an employee

· Click on the "Employees" tab located at the top of the window.
· Select the Employee you wish to delete.
· Click on the Delete button.
10.88 Deleting display groups
The Delete button deletes a display group.
To delete a group:

· Select the group you wish to delete from the work center and display group field. For
example, select a work center from the work center list. Next, select a display group
from the display group list.
· Click on the Delete button.
· Select the Save Session command under the File menu.
10.89 Deleting jobs from the schedule board
Queued jobs can be deleted from a machine's job queue and work orders can be deleted
from the work order list.

To delete a job:
· Position the cursor over the job you wish to delete. Click on the job to highlight it.

· Click on the Delete button.

· Click on the Commit button.

NOTE: A current job cannot be deleted, it can only be replaced.

10.90 Deleting machines
To delete a machine:

· Go to the Machine Setup window.

· Select the machine to delete by clicking on the arrow to the right of the Machine field.
Move your cursor to the appropriate machine and click again.
· Click on the Delete button.
· To send your changes to the shop floor, select the Save Session command under the
File menu.
NOTE: Once a machine has been deleted, the same machine can never exist again. If a new
machine is created with the same name, it is not considered the same machine. Because of
this rule within PlantStar, a machine with historical job records should be deleted only if it is to
be permanently removed from the system. If its future is uncertain, the machine should not be
deleted. It should be disabled so that it can be reactivated later.
244 SYSCON-PlantStar Help System

10.91 Deleting process variables

To delete a process variable:

· Choose the Shop Floor menu on the main Shop Floor Configuration window.
· Choose the Machine Setup option.
· Select a machine on the window.
· Click on the edit process option button, located on the left hand side of the window. A
list of defined process variables displays.
· Select the process variable index and name that you want to delete.
· Blank out the process variable name field.
· Move your cursor to the Source field and select the 'None' usage option for the process
variable.
· Click on the Update button.
· Select the Save Session command under the File menu.
10.92 Deleting profile variables
To delete an existing profile:

· Choose the Shop Floor menu on the main Shop Floor Configuration window.
· Choose the Machine Setup option.
· Select a machine on the window.
· Click on the edit profile option button, located on the left hand side of the window. A
list of defined profiles displays.
· Select the profile that you want to delete by moving your cursor to the variable index
field. Click on the arrow to the right of this field and slide your cursor down the list to the
desired index. Click again.
· Blank out the variable name field.
· Move your cursor to the Source field and select the 'None' usage option for the profile.
· Click on the Update button.
· Select the Save Session command from the File menu to transfer the deletion to the
shop floor.
10.93 Deleting reason sets
A window's Delete button deletes information from PlantStar's database. Depending upon the
window, a reason set, boot set, work center, display group, communications processor,
machine or DCM will be deleted.

To delete:

· Select the reason sets you wish to delete.

· Click on the Delete button.
· Click on the Save Session button under the File menu to immediately transfer your
changes to the shop floor.
 Functions 245

10.94 Deleting REUs

The Delete button deletes an REU.

· Select the REU you wish to delete.

· Click on the Delete button.
· Click on the Update button.
· Click on the Save Session button under the File menu.
10.95 Deleting schedules
Existing shift schedules may be deleted from the Shift Schedule window. Deleting a yearly
schedule deletes not only the selected year schedule but all the year's weekly schedules as
well.

To delete a work center schedule:

· Go to the Shift Schedule window.

· Move the cursor to the Work Center field. Choose the work center desired.
· Move the cursor to the Year field. Choose the year schedule targeted for deletion.
· The weekly schedules associated with the selected year schedule appear.
· Click on the Delete button.
· The work center schedule is deleted.
10.96 Deleting unassigned child jobs
Unassigned child jobs can be removed permanently from the system.
To delete an unassigned child job:

· Select an unassigned child job from the child list.

· Use the mouse and right click over the child list.
· Select "Delete Child" from the pop up menu. This will remove the child job from the child
list.
10.97 Deleting users
The Delete button on the User Accounts window deletes an existing user. To delete a user:

· Select the user from the User Name list box.

· Click on the Delete button.
· To permanently delete the user, click on the Save Session command under the File
menu.
10.98 Deleting work centers
A window's Delete button deletes information from PlantStar's database. Depending upon the
window, a reason set, boot set, work center, display group, communications processor,
machine or DCM will be deleted.
To delete:

· Select the work center you wish to delete.

· Click on the Delete button.
246 SYSCON-PlantStar Help System

· Click on the Save Session button under the File menu to immediately transfer your
changes to the shop floor.
10.99 Deleting work orders and product standards
· Select a work order or product standard to delete from the list, on the left hand side.
· Click on the Delete button.

· After answering "Yes" to the confirmation message, the work order or product standard
will be deleted.
10.100 Discarding a schedule
The Discard button on the Job Schedule Board restores the job schedule back to the last
time you committed (saved). Click on this button to restore all information.
10.101 Displaying standard spc statistics
Standard SPC Statistics can be viewed by pressing the icon, on the Process
Trend/SPC and SPC History windows.

To close the pop up window, click on this icon again. The Standard SPC
statistics are:
· X-Bar Upper Control Limit
· X-Bar Lower Control Limit
· Range Upper Control Limit
· Range Lower Control Limit
· X-Bar Mean
· Range Mean
· Upper Specification
· Lower Specification
 Functions 247

10.102 Editing child parameters

· Use the tab key or mouse to select the child job to edit.
· Move the cursor to the desired job parameter.
· Type in a new value in the Value column for the job parameter.
NOTE: Child Jobs cannot be added or removed from a current job or queued job. They can
only be added when the job is a work order. In other words, once scheduled, the number of
child jobs assigned to a job cannot be changed.
10.103 Editing employee records

The Employees tab lets you add, change or delete Employees for a given work center.
Defining an Employee is necessary before that employee can be logged in or out.

Where can you find it?

Choose the Labor menu on the main Shop Configuration window.

Choose the Labor Setup option.
Choose the Employees tab
248 SYSCON-PlantStar Help System

What do you want to know about?

Adding an Employee
Updating an Employee
Assigning an Employee to a Labor Category
Deleting an Employee
10.104 Editing jobs from the schedule board
· Highlight the job by selecting it on the Job Schedule Board.
· Double-click on the yellow box surrounding the desired queued job. The Edit Job
Parameters window appears.

or –

· Click on the Edit Button on the tool bar.

· Move the cursor to the desired job parameter. Type in a new value in the Value
column for the parameter.
· Click on the Apply button. You will be returned to the Job Schedule Board window.

· Click on the Commit Button on the tool bar to save the changes to the Job
Schedule Board. If this step is not done, the changes will not be permanent or sent
down to the shop floor.
10.105 Editing labor categories

The Labor Category window lets you add, change or delete Labor Categories for a given work
center. Defining Labor Categories is optional although this parameter offers you a way to
group labor requirements for Labor Forecasting.
Where can you find it?

Choose the Labor menu on the main Shop Configuration window.

Choose the Labor Setup option.
Choose the Labor Categories tab

What do you want to know about?

 Functions 249

Adding a Labor Category

Updating a Labor Category
Deleting a Labor Category

10.106 Editing labor manning factors

One primary reason for setting labor manning factors is to track and schedule labor for a job or
shift. In order to track labor, you need to enter labor manning factors for the job. Editing of
these parameters is, however, optional.
To edit labor manning factors:
· Click on the Labor tab located in the top of the window.
· A list of labor categories and their corresponding forecast types appears.
· Type in a new manning factor in the appropriate column.
250 SYSCON-PlantStar Help System

10.107 Editing machine parameters

· Move the cursor to the machine parameters grid, which is under the child job
parameters.
· Type in a new value in the Value column for the machine parameter.
10.108 Editing parent parameters

· Move the cursor to the job parameter grid, which is under the job parameters label.
· Type in a new value in the Value column for the parameter.
NOTE: SPC Subgroup Size cannot be changed for current jobs.
 Functions 251

10.109 Editing process and profile limits

One primary reason for setting variable parameters is to track process variable exceptions for
a job. In order to track exceptions, you need to enter the higher limit and lower limit for each
process variable. Editing of these parameters is, however, optional.
To edit a parameter:

· Click on the Limits tab located in the top of the window.

· A list of process variables and their corresponding parameters appears in the top grid.
· A list of profiles and their corresponding parameters appears the bottom grid.
· An undefined parameter is represented by four asterisks.
· Type in any new values in the appropriate column and process variable row -- over
striking the asterisks.
Primary process parameters are:

· Higher Limit - Enter a value that is higher than the normal operating range of the process
variable.
· Lower Limit - Enter a value that is lower than the normal operating range of the process
variable.
· Trigger Delay - This field is used to override the existing trigger delay as entered in
the Machines Setup window. Leave the asterisks if you want to keep the existing
delay.

Primary profile parameters are:

· Trigger Delay - This field is used to override the existing trigger delay as entered in
the Machines Setup window. Leave the asterisks if you want to keep the existing
252 SYSCON-PlantStar Help System

delay.
· Duration - This field is used to override the existing duration as entered in the Machine
Setup window. Cycle times for different jobs may vary, requiring a longer or shorter
duration. The sum of the trigger delay and the duration must be less than the cycle
time. Leave the asterisks if you want to keep the existing duration.
10.110 Editing process variables

· Choose the Shop Floor menu on the main Shop Floor Configuration window.
· Choose the Machine Setup option.
· Select a machine on the window.
· Click on the Edit process option button, located on the left hand side of the window.
· Click on the arrow to the right of the Variable index field. Choose from the list by
sliding the pointer down the list to the appropriate line. Release the mouse button.
 Functions 253

10.111 Editing production parameters

The Production tab lets you add, change or delete production parameters for a
given job.

Where can you find it?

Production parameters can be edited from the Current/Queue Job, Work

Orders, Product Standards, and Job Schedule Board windows.
Select a job to view.
Choose the Production tab
What do you want to know about?

Editing Parent Parameters

Editing Child Parameters
Editing Machine Parameters
Adding/Editing Multiple Materials
254 SYSCON-PlantStar Help System

10.112 Editing profile variables

· Choose the Shop Floor menu on the main Shop Configuration window.
· Choose the Machine Setup option.
· Select a machine on the window.
· Click on the Edit profile option button, located on the left hand side of the window.
· Select the profile you wish to view by positioning your mouse over the arrow to
the right of the variable index field, located on the left hand, bottom side of the
Machine Setup window.
· Slide the cursor down the list to the desired profile and click again.
10.113 Editing report definitions
· Click on the arrow to the left of the Report field. Select a report by moving the cursor
down the list to the desired item and click. The report's description and filename
appears.
· If you wish to edit the report's description or its name, go to step 3. If you wish to
edit a report's fields, titles, or view the report definitions, go to step 4.
· Enter the new name or description. Click on the Save button. An informational message
appears stating that reports definition file cannot be found. Click the OK button. This
message appears only when the name or description of a report is being changed.
· Click on the Load button. The Load button opens up the Crystal Reports
application. Edit any desired report definitions and save the changes within
Crystal Reports.
· Upon returning to the Custom Reports Manager program, click on the Save button.
 Functions 255

10.114 Editing setup sheets

Setup Sheet information can be added to product standards, work orders or currently running
jobs. There are two types of setup sheet information -- product portion and machine portion.
Both types are sent to the DCM.
To add setup information:

· Click on the "Setup Sheets" tab located in the top of the window.
· The setup sheets appear, allowing the entry of setup sheet information.
· Select the setup sheet to edit, product or machine, by tabbing to the "Product
Portion" or "Machine Portion" text fields.
· Type in setup sheet information directly into this field.

NOTE: When typing, the text field wraps words. The DELETE or BACKSPACE keys can be
used to erase characters. A maximum of 2600 characters can be typed in. This limit is for the
sum of the text in both the product and machine portions.
10.115 Enable a DCM
By clicking on the Enable Radio button you are allowing the DCM to communicate with the
host. While a DCM is disabled no communication with the host occurs and no data for any
machine defined for this DCM is collected. Some setup features like the number of machines
require that the DCM be disabled before changing.
10.116 Enabling a RIO on a machine
256 SYSCON-PlantStar Help System

In order for a machine to be able to collect data from the RIO the check box next to the
machine number must be selected. Once selected, the machine will retrieve all process
variables and profile data including cycle time from the RIO unit.

To enable a RIO on a machine, check the checkbox next to the selected machine.
10.117 Exporting data
Graph and table values may be written and stored in a file in the following windows:
· Labor Status
· Production Summary
· Job Summary
· Machine Log
· Overlay Profile
· Process Trend/SPC
· Process Summary
· Labor Forecasting
· SPC History
· Material Lot Tracking
To write values to a file:

· Enter the appropriate window and click on the appropriate button.

· The File Selection window appears.
· Move the cursor to the file name field. Type in the name of a file to save the graph
values. The default disk drive is the one you entered PlantStar from.
· You may change the disk drive by moving the cursor to the drives field. Click on the
desired drive.
· Click on the OK button when finished identifying the file name.

NOTE: Process Trend/SPC and Machine Log - These windows have two options:

which writes one process variable to a file or all process variables for the machine and
job.
Depending upon the window selected, the ASCII file created has several formats.

Process variable information is in the following format:

· Machine
· Job
· product
· Process Variable name (if the window allows variable selection)
· Time Stamp
· Values

The SPC History window has the following format:

· Job name
· Machine
· product
· Process Variable
· SPC Subgroup Size
 Functions 257

· Time stamp
· X-bar Value
· Range
· SPC values -- The number of values is based upon the SPC Subgroup Size.

The Profile window has the following format:

· Machine
· Job
· Product
· Profile Name
· Time Stamp
· Number of SPC points included
· X, Y coordinate (Each coordinate is on a separate line.)
10.118 Forcing a machine down
A machine can be forced into a down state from the Down Select field. Click on the arrow to
the right of this field. A list of down reasons appears. Select the desired reason by clicking
on its name. The machine will go down within the next machine cycle.
When a machine enters a forced down state, its associated DCM may or may not continue to
count parts and monitor process variable information. The action taken depends upon how
the down reason which triggered the "forced down" is defined in terms of its force down and
ignore cycles flags. These flags are set on the Down Reason Sets window.
10.119 Freezing profiles
Freezing the profile window stops data updates to the graph. The graph will not change
until the 'freeze' option is canceled.
To freeze the profile:

1. Click on the button.

2. Once selected, this button appears 'depressed' into the background of the window.
3. To cancel this feature, click on the icon again. It should appear not selected.
10.120 Getting a voice file
To get a new voice file:

· Click on the Get File button.

· The File Selection window appears.
· Move the cursor to the file name field.
· Type in the name of a file to retrieve. The default disk drive is the one you entered
PlantStar from.
· You may change the disk drive by moving the cursor to the drives field. Click on the
desired drive.
· Click on the OK button when finished identifying the file name.
10.121 Identifying machines with Product Standards
For a selected job or work order, machines with matching product standards are identified with
the button.
258 SYSCON-PlantStar Help System

· Click on the button.

· Select a current job or queued job on the job board by moving the cursor over the job.
Click on the job. The job's rectangle will turn yellow.
· If a standard was written for the designated machine and product, a symbol
appears next to the machine name.
10.122 Ignore criteria in a report
This feature is used to schedule a report that does not include a selection criterion. For
example, to schedule a "Job Queue" report at shift change, choose "Ignore Criteria", since the
shift is not criteria for the "Job Queue" report.
· Move the cursor down the report list to the desired choice.
· To temporarily disable a report, check the "Ignore Criteria" field to the right of the
"Report" field.
10.123 Including boot files from a boot set
Boot sets can consist of multiple boot files. PlantStar provides a list of default boot files from
which to choose to make up a boot set.

To specify which boot files to include in a boot set:

· Go to the Boot Sets window.

· Position your mouse over the box to the left of the boot file you want to include in the
set.
· Click on the box. An 'x' appears in the box if it is included in the boot set.
· To exclude the boot file from the set, click on the box again. The 'x' in the box
disappears.
· Click on the Update button to save your changes.
· Select the Save Session command under the File menu to transfer the new
information to the shop floor.
10.124 List All product standards
Retrieves all existing product standards.
 Functions 259

10.125 Logging in an employee

Users can login an Employee from the Labor Status screen, as well as the shop floor DCM's.
To login an Employee, click the Login button at the bottom of the screen. Once clicked, you
will be presented the following login dialog:

From this dialog, enter a valid employee id. Employees are defined in the Shop Floor
Configuration program. If the employee id was invalid, the users would be presented with a
pop up message "Invalid Employee". Once a valid employee id was entered, you will be
prompted for a machine that you wish to log into.

From this dialog, you can select a machine from the drop down list. The drop down list
consist only of the machines which belongs to the work center an employee is assigned.
Employee-Work Center relationships are defined at the Labor Setup window in the Shop
Floor Configuration program. Once a machine is selected, you will be prompted for a labor
category you wish to log into.

From this dialog you can select a labor category from the drop down list. The drop down list
consists only of the categories that have been assigned to the Employee Id entered.
Employee-Labor Category definitions are defined in the Shop Floor Configuration program.
Once a labor category has been selected, you can click the "Finish" button which will log you
260 SYSCON-PlantStar Help System

into the system.

NOTE: To Cancel out of the login process, click the "Cancel" button.
NOTE: No matter what shift is currently displayed in the shift selection, the employee will
always be logged into the current shift. Employees can only be added to previous shifts
from the Labor History window.
10.126 Logging out an employee
Users can logout an Employee from the Labor Status screen, as well as the shop floor DCM's.

To logout an Employee, click the record, in the grid, that contains the employee record to be
logged out. Once the record is selected, the entire row will change to a black background with
white text. Click the logout button, at the bottom of the screen. This will logout the selected
employee.

NOTE: The Logout button is only enabled when the shift selected is "Current Shift: Logged
In" and a row containing an employee record is selected. When other shifts or empty rows
are selected, the logout button is disabled.
10.127 Moving jobs around the schedule board
The Job Schedule Board window lets you rearrange jobs in a machine's job queue or
move queued jobs from one machine to another. A 'drag and drop' method is used for
scheduling.
When moving jobs around the job board, the job movement default which is defined on the
User Preference window is very important. It determines what information is moved with a
job when it is re-assigned to different machines. There are two methods offered:

· Keep the standard of the original machine - When a queued job is moved from one
machine to another, the machine-related job parameters defined for the queued job on
the originating machine are moved to the new machine. No changes are made.
· Keep the standard of the new machine - When a queued job is moved from one
machine to another, the machine-related job parameters defined for the queued job are
changed to match the job parameter values defined on the original product standard
created for the destination machine.
Once selected, the "default drag and drop" is activated as follows:

· Position the cursor over the job to re-schedule and click. The job rectangle becomes
yellow.
· Holding down the mouse button, drag the job rectangle to the new location on the job
board.
· Release the mouse button. The job automatically appears in the new location unless
you have moved a queued job to a current job position. If you are scheduling a
current job, a message appears if a job was previously scheduled in that position.
Click on the Current button or Queue button. If Current is clicked, you must decide
whether you want to suspend or end the currently running job. If you suspend a job, a
work order is created. The pieces to go of the suspended job will be transferred into
the Pieces Required field of the newly created work order.
· Click on the Commit button to save the new schedule.
 Functions 261

NOTE: The non-default job movement method is activated by holding down the SHIFT
key while dragging and dropping the job.
10.128 Ordering machines in the list
The up and down buttons enable you to put each machine within a display group into
any desired order. This order is used on all multiple machine windows.

· Select a machine from the Machines in Group list by clicking on it.

· Click on the up or down arrow button.
10.129 Playing an announcement
All existing or newly-created announcements can be played within the Voice
application.
To play an announcement:
· Open the desired configuration window under the Configure menu.
· Click on the Play command button.
10.130 Printing a report to the screen
· Select a report.
· Click on the View button.
· If any criteria windows appear, select the desired criteria fields.
· Always click on the OK button when finished selecting all desired parameters.
· A window appears displaying the selected report.
· To close the report window, click on the close button located in the upper right corner of
the window.
10.131 Rebuilding the display
This window is not updated every machine cycle. To view a forecast using the latest job
information, click on the Build button. Once clicked, PlantStar retrieves the most recent job
and shift information. A forecast is then provided based upon the retrieved information. Re-
click the Build button each time an up-to-date forecast is desired.
10.132 Recalling profiles
Recalls profiles saved from the Save Profile window. When the Recall button is clicked, a
second window appears. This window enables you to select a saved profile for display. Also,
when the Recall button is clicked, a new button appears -- the Clear button. The Clear button
clears the recalled profile from the graph area.
262 SYSCON-PlantStar Help System

10.133 Recording an announcement

· Click on the Record command button. The Record Voice File window appears.
· Turn on your microphone.
· Click on the Record command button. Begin speaking.
· When finished, click on the Stop button.
10.134 Refreshing the display
Users can use the Refresh button to force an update to the window as the data is static
once the window is opened.
10.135 Refreshing the lists
The work order and product standard lists are not updated automatically. At times, there
may be two or more people editing work orders and product standards. Newly created work
orders and product standards by one person will not necessarily be seen in another
person's lists. The Refresh button updates the lists, with the most recently created work
orders and product standards. Click on this button anytime you wish an updated the list.
10.136 Removing child jobs from a product standard
Child Jobs can be deleted from either work orders or product standards.

To remove a child job from a product standard, select the "Delete Child" button at the
bottom of the screen. This will remove the child job from the product standard.

NOTE: Product Standards cannot be saved with only one child job. This would be
considered a non- family job. To save, you will need to delete the last child job or add
another child job to continue.
10.137 Removing child jobs from a work order
Child Jobs can be deleted from either work orders or product standards.

To remove a child job from a work order:

· Use the mouse and right click over the work order list or the child parameter grid.
· Select "Remove Child" from the pop up menu. This will remove the child job from the
work order.

NOTE: Work Orders cannot be saved with only one child job. This would be considered
 Functions 263

a non- family job. To save, you will need to delete the last child job or add another child
job to continue.
10.138 Removing machines from a display group
The Remove button enables you to delete machines from an existing display group.

· Select a machine from the Machines in Group list by clicking on it.

· To select several machines next to each other, keep the mouse button pressed down
and move the mouse up or down. Then let go.
· To select several machines that are not next to each other in the list, press the
CTRL button, in combination with the mouse button, over each desired machine.
· Click on the Remove button.
· Click on the Update button.
· Select the Save Session command under the File menu.
10.139 Removing machines from a REU list
The Remove button enables you to delete machines from the list of accessible machines on
an REU. A machine can always be added back later.

· Select a machine from the Selected Machines list by clicking on it. To select several
machines next to each other, keep the mouse button pressed down and move the
mouse up or down. Then let go. To select several machines that are not next to each
other in the list, press the CTRL button, in combination with the mouse button, over
each desired machine.
· Click on the Remove button.
· Click on the Update button.
· Click on the Save Session command under the File menu.
10.140 Renaming a reason set
You can change the name of a reason set by simply typing over the existing name. The
name can be up to 20 characters in length.

· Click on the set name field.

· Type the new set name over the existing set name.
· Click on the Update button to save your changes temporarily.
· Click on the Save Session button under the File menu to immediately send your
changes to the shop floor.
10.141 Resizing columns
Columns on this display can be adjusted to fit the desired width.

This can be done by:

· Move the mouse over the column heading to resize.

· When the mouse cursor changes to a drag bar, press and hold the mouse button. This
will drag the column border.
· When the column border is in the appropriate place, release the mouse button.
10.142 Retrieve default product standard
Retrieves the existing default product standard.
264 SYSCON-PlantStar Help System

NOTE: Once retrieved, the default product standard can be edited and saved again as
the default product standard.
10.143 Saving process variables
To save your process variable information:

· Choose the Shop Floor menu on the main Shop Floor Configuration window.
· Choose the Machine Setup option.
· Select a machine on the window.
· Click on the process option button, located on the left hand side of the window. A
list of defined process variables displays.
· Select the process variable from the variable index field.

Click on the arrow to the right of this field.

· Select the desired variable from the list by clicking again.
· Type over or change any information you desire.
· Click on the Update button to save your changes.
· Select the Save Session command under the File menu.
10.144 Saving profile variables
To update your profile variable information:

· Choose the Shop Floor menu on the main Shop Floor Configuration window.
· Choose the Machine Setup option.
· Select a machine displayed in the window.
· Click on the edit profile option button, located on the left hand side of the window. A
list of defined profile variables displays.
· Select the desired variable index and variable name. To select a profile index, click on
the arrow to the right of the variable index field.
· Slide the cursor down the list to the appropriate index and click again. The
profile's name and related information appears on the window.
· Type over or change any information you desire.
· To send your changes to the shop floor, select the Save Session command under the
File menu.
10.145 Saving reason sets
The Update button changes an existing reason set or boot set's information.
 Functions 265

To update a set:

· Select the reason or boot set to update.

· After changing your information, click on the Update button.
· To send your changes to the shop floor immediately, click the Save Session button
under the File menu.
10.146 Saving your changes-Apply
Click on the Apply button in the bottom right hand corner. Alternatively you can click the OK
button and you will be prompted to save your changes. After saving, any necessary
adjustments will be sent to the DCM and other PlantStar clients.
10.147 Saving your changes-Update
Click on the Update button in the bottom right hand corner.

NOTE: In the Shopfloor Configuration Program, the Update button does not send the new
changes to the DCM or Communications Processor. (All changes are sent to the database
and the shop floor from the Save Session command under the File menu.)
10.148 Scheduling jobs by due date
· Make sure that the due date scheduling method is active. This method is activated by
clicking on the icon.
· If a vertical line marker , appears on the top of the Job Schedule Board, then the
"schedule by due date" method is active.
· The marker indicates the point in time when job scheduling by due date should begin.
Jobs which are scheduled to start to the right of this marker (on the job board) are
scheduled by due date. Jobs which start to the left of this marker are scheduled by the
earliest possible time -- immediately upon completion of the previous job. The marker
can be moved back and forth along the job board's time line. To move the marker, click
on the marker and hold down the left mouse button. Drag the marker to any desired
point along the time line. Release the mouse button. Upon release, all jobs to the right
of the marker will be re-estimated and re-scheduled according to job due dates.
· To schedule a new work order onto the job board, move the cursor to the work
orders list box, located on the bottom, left of the window.
· Click and hold down the left mouse button on the desired work order. Drag the work
order rectangle to its new location on the job board.
· Release the mouse button. The work order automatically appears in the new location.

· Click on the Commit button.

10.149 Scheduling jobs by earliest start date
· Make sure that the three due date scheduling icons are not active :
· If a marker appears on the top of the job board, then the "schedule by due date"
method is active.
· Click on the button to turn this scheduling method off.
· Move the cursor to the work orders list box, located on the bottom, left of the window.
· Click and hold down the left mouse button on the desired work order. Drag the work
order rectangle to its new location on the job board.
· Release the mouse button. The work order automatically appears in the new location.
266 SYSCON-PlantStar Help System

· Click on the Commit button.

·
10.150 Scheduling selected jobs by due date

This button changes the scheduling method of a highlighted job between the earliest
possible start method or the due date method. Once a job is highlighted (clicking on the job
highlights it and turns its job rectangle yellow), use this button to switch the job between the
two scheduling methods.
NOTE: The right click button on the mouse may be substituted for clicking the button (i.e.
it provides the same function).
NOTE: This button only works when the button is selected at the same time. Also, in
order to schedule a job by due date, the job must start to the right of the scheduling marker.
10.151 Search Product Standards
Retrieves any existing product standards using the job or product fields. If no job or product
name is provided, the Search button retrieves all existing product standards.
NOTE: As of PlantStar v4.10, this search no longer requires the key fields to match the
case of the expected result. In other words, the search is no longer case sensitive.
 Functions 267

10.152 Searching for a job

The Job Schedule Search window lets you quickly locate a specific job on the Job
Schedule Board window. Once the desired job is found, it is highlighted on the Job
Schedule window. This can be invoked by clicking the button on the menu bar.

An existing job or work order may be found by:

· Searching for a job or work order by job name

· Searching for a job or work order by product name
· Searching for a job or work order by material name
· Searching for a job or work order by tool name
· Searching for a job or work order by Due Date Before
· Searching for a job or work order by Due Date After
· Searching for a job or work order by Free Text
· Searching for a job or work order by Comment
· Searching for a job or work order by any 4 combinations of the above
· Listing all scheduled jobs and work orders

The searching method for this window is defined by the User Preference window. Exact
matching, left matching, or embedded matching schemes are available. Once a search is
initiated, any matching job's location (on which machine it is scheduled), its product name
and job name are displayed.

A job or work order can be found by initiating a search. Four different fields may be used in
the search -- Only one field is required.
268 SYSCON-PlantStar Help System

To initiate a search:
· Select a field to search on from the drop down list.
· Enter a search string.
· Click on the Search button.
· A list of jobs that match the given key(s) appears.
· Select from the list by clicking on a job.
· Click on the OK button.

How a search is performed depends upon the searching method defined on the User
Preference window. Searching methods can be left matching, embedded matching, exact
matching, and case sensitive. If left matching has been designated on the User Preference
window, then entering the word 'poly' (if material was chosen as the search criteria) would find
jobs that use 'polypropylene' and 'polyurethane'. If embedded matching is designated, then
entering the word '285' would find jobs using 'polyurethane 285 Black' and 'Acrylic V285-100
Clear'. Exact matching means that searching for 'polypropylene' would only find jobs using
'polypropylene'.
10.153 Searching material lots
The Search button enables you to scan the database for specific material tracking
information. Searching keys are provided for narrowing your search.
The following keys are availible for search:

· Tote ID
· Machine
· Job
· Product
· Tool
· Material
· From Date
· To Date
· Free Text 1
· Free Text 2
· Free Text 3
· Free Text 4

To search for material lot information:

· Type in the desired search criteria. If you want all information to be retrieved, leave
the searching keys blank.
· Click on the Search button.
· The lower half of the window lists all material lots matching the search keys.
10.154 Selecting a machine state
Select a machine state by clicking on the circle to the left of the desired state. The Monitor
window immediately displays any machines currently running in that state. The list of
machines may change with each machine cycle as machines go in and out of a selected
state.
NOTE: The All selection displays all machines within the selected display group,
regardless of their machine state.
10.155 Selecting a period interval
 Functions 269

A variety of scheduling options are available:

Daily Reports
· Go to the period field. Select the Daily choice from its selection list.
· Go to the shift field. Select a desired shift from its selection list.

Weekly Reports
· Go to the period field. Select the Weekly choice from its selection list.
· Go to the day of the week field. Select a desired day from its selection list.
· Go to the shift field. Select a desired shift from its selection list.

End-of-Shift Reports
· Go to the period field. Select the By Shift choice from its selection list.

End-of-Job Reports
· Go to the period field. Select By Job from the selection list.
10.156 Selecting a time scale
Five different time scales are available for viewing a machine's job schedule:

· 1-Hour
· 8-Hour
· Day
· Week
· Month

To select a time scale:

· Locate the time scale field is located in the middle of the Job Schedule Board's tool bar.
· Click on the arrow to the right of this field. Position the mouse pointer over the time scale
field.
· Choose the new time designation by sliding the pointer down the selection list to the
appropriate line and clicking again.
10.157 Selecting a year
Every work center schedule has multiple annual schedules. To select a specific year's
schedule and its work schedule assignments:

· Once on the Shift Schedule window, position the cursor on the arrow to the right of the
Year field.
· Choose the new year by sliding the pointer down the selection list to the appropriate line
and click.
· Upon selection, the Calendar and Weekly Schedules List reflects the work schedule
assignments for the visible work center and year.
10.158 Selecting criteria for a report
Report Criteria designate what type of information is included in a report. For example, a
job history report can include all jobs for a certain product or one specific job. A custom
report can be set up to include only information for a certain time period or for a certain
270 SYSCON-PlantStar Help System

machine.
Criterion fields are set up from the View and Print program.
To select criteria when printing a report:

· Select a report for printing.

· Click on the Print button.
· For each field that is designated as criteria for the custom report, a window appears.
· For each window, use the mouse pointer to select from the display lists. Always click
on the desired item. If more than one item is desired in a list, click on each item.
Selected items are highlighted.
· Click on the OK button.
NOTE: Each selection criteria is independent. The list of choices in the second criteria window
is not dependent of the first criteria of choices.
10.159 Selecting current/queue jobs
Current jobs and Queue jobs can be edited from the Edit Current\Queue Job
window.
To edit a Current Job:

· Click on the first job in the job list labeled "Current Job". The job list is located on the
left side of the window.
To edit a Queue Job:
· Click on the queue in the job list. This would be every job in the list, except the first job.
The first job is the current job, which is labeled "Current Job". The job list is located on
the left side of the window.
NOTE: These jobs can also be edited through the Job Schedule window.
10.160 Selecting display groups from the schedule board
· The display group field is located in the middle of the Job Schedule Board's tool bar.
· Click on the arrow to the right of this field.
· Slide the pointer down the selection list to the appropriate display group. Click.
· Only those machines in the display group are listed on the job board.
NOTE: If the All display group is selected, and there is more than one work center

defined with different shift schedules, then the Display Shift Schedule button
is disabled.
10.161 Selecting forecast intervals
The forecast interval field restricts the number of jobs displayed on the Tool Change window
to those that are estimated to be completed by the selected interval. For example, if the 1
Day interval is chosen, jobs that are estimated to be complete within 1 day from "now" are
listed in the table.
10.162 Selecting jobs from the schedule board
 Functions 271

A job may be selected, from the Job Schedule Board, in several ways:

· Position the mouse cursor over the desired job on the job board and click. The box
surrounding the job turns yellow when selected.
- or -
· Click on the machine on which the job is running or scheduled to run. A small
selection window appears. Click on the desired job name. The box surrounding the
job turns yellow when selected.
NOTE: Use the job board's scroll bars to find the job if you cannot see it. A small time scale
may make the queued job not initially visible. Change the time scale, if desired.
10.163 Selecting product standards
· Load the product standard list by clicking the "Refresh" button in the bottom right hand
corner. The Product Standard list is located on the left side of the window.
· Click on the desired standard in the Product Standard list.
- or -

· Click on the Load Std button.

· The Select Product Standard window appears.
· From this screen, you can search or scroll through the list of product standards.
· Once a child has been selected, click the "OK" to select the product standard.
· Alternatively, you can select the default product standard by clicking the
"Default" button and selecting "OK".
Once selected, the Product Standard window reappears with the job parameters of the
selected standard.
10.164 Selecting Report Criteria
Allows database fields to be designated as report criteria; Criteria designate what type of
information is included in a report. The fields selected as criteria must be actually used on the
report.
10.165 Selecting specific machines
The Selected List option enables the list of machines on the top right-hand side of the
window. Choosing machines from this list makes a Monitor window change its list of
machines to match your selection.
To select several machines next to each other, keep the mouse button pressed down and
move the mouse up or down. Then let go. To select several machines that are not next to
each other in the list, press the CTRL button, in combination with the mouse button, over
each desired machine.
10.166 Selecting users
You can view all users in the PlantStar system if you have administrator privileges:

· Select the User Accounts menu option from the User menu on the main Shop Floor
Configuration window.
· To select a user to view, position your mouse pointer over the User Name field. Click
on the arrow to the right of the field. Choose the new user you want by sliding your
272 SYSCON-PlantStar Help System

pointer down the selection list to the appropriate line. Click again. Upon selection, all
privileges will be displayed for the selected user.

The User Name field enables you to change the user name. If you desire, just type over the
name of the user that is currently selected. Click on the Save button to temporarily save the
new name for the selected user. Click on the Save Session command under the File menu
to permanently save all user changes.
10.167 Selecting/viewing tote details
Once a child job record has been selected in the "Job Detail" grid, the "Tote Detail" grid will
contain the tote boxes that were generated for the selected child job.
10.168 Sending a report to the printer
· Select a report.
· Click on the Print button.
· If any criteria windows appear, select the desired criteria fields. Always click on the OK
button when finished selecting all desired parameters.
· A window appears displaying the selected report.
· To print a report, click on the print.bmp button at the top of the window. The report is
routed to your default Windows printer.
10.169 Set report to display in HTML format
A report can be set to display in HTML format:

· Move the cursor down the report list to the desired choice.
· Check the "HTML" field to the left of the "File Name" field.
10.170 Setting down reason flags
There are four flags which can be set for each down reason:

· Force Down
· Ignore Cycle
· Auto Clear
· Force Scrap

To set flags for a down reason:

· Click on a flag field for the desired down reason.

· Type in either 'Y' or 'N'.
· Click on the Update button.
· To send your changes to the shop floor, select the Save Session command under the
File menu.
10.171 Setting report criteria
· Click on the arrow to the left of the Report field. Select a report by moving the cursor
down the list to the desired item and click. The report's description and filename
appears.
· Click on the Criteria button. This button brings up a second window which displays a list
of PlantStar tables from which criterion fields can be selected.
· Clicking on a table name displays its list of possible criteria. Select as many fields as
desired by clicking on the field name. Note that for each field selected, a window
 Functions 273

appears during the report printing process. These windows provide field selection lists.
For example, the job field is designated as a criterion for a report. When printing the
report, a user will be asked to select which specific production jobs to print. If start date
is also designated as a report criterion, a second window appears during the printing
process asking for a valid start date.
· Click on the OK button when finished selecting report criteria.
· Upon returning to the main window, click on the Save button. An informational
message appears stating that reports definition file cannot be found. Click the OK
button.
Criteria can also be set up for a report from within the Crystal Reports program. If fields are
also designated as criteria from the Custom Reports Manager program, then the affected
report is based upon BOTH sets of criteria.
NOTE: When selecting a report's criteria, i.e. what type of information will be included in the
report, the fields selected as criteria must be actually used on the report. For example, if a
report is designed to print job history information, it is invalid to select field information from
the shift history tables.
10.172 Sorting columns
Columns on this display can be sorted so that you can view the data displayed based on
the selected column.

· To sort the column, click once on the column heading that you wish to sort. This will
sort the column in an ascending order.

- also –

· To sort the column in a descending order, click the same column heading again.
274 SYSCON-PlantStar Help System

10.173 Storing profiles

Storing a displayed profile saves the graph snapshot onto the window. Future snapshots of
data points are then overlaid onto the 'stored' profile graph.
To store the profile:

· Click on the button.

· Once selected, this button appears 'depressed' into the background of the window.
· To cancel this feature, click on the icon again. It should appear not selected.
10.174 Toggling auto size and normal size
Auto Text Size forces all fields on a window to fit within the window's boundaries. If there is
a long list of machines within a display group, sometimes the text on this window is not
readable. The Switch to AutoSize button changes the size of the window's text -- making it
more readable.
To change between normal and auto text size on a window, click on the

Switch To Autosize button. This button acts like a toggle. Click on it

again to return to the previous text size.
10.175 Toggling Process and Profile view
Displays a machine's associated profiles and process variables. The profiles and process
variables display on the bottom of the window, directly below this button.
10.176 Toggling tool change view
Tool change information can be viewed for all jobs or just those jobs where there are tooling
changes from one scheduled job to the next. To view all scheduled job changes, click on the
circle to the left of the All Job Changes field. This field is located directly under the table.
To select only those jobs where there are tooling changes, click on the circle to the left of
the Tool Change Only field.
10.177 Undoing your changes
Click on the Restore button to undo any changes made on the window since the last save.
10.178 Updating a comm processor
The Update button saves any changes made on a window so that other shop configuration
windows can access the new information. The Update button does not send the new
changes to the DCM or Communications Processor. (All changes are sent to the database
and the shop floor from the Save Session command under the File menu.)

· Select the Communications Processor you wish to update.

· Change all desired information.
· Click on the window's Update button. If new information has been added, other shop
floor windows will reflect the change.
· To send your changes to the shop floor, select the Save Session command under the
File menu.
10.179 Updating a DCM
 Functions 275

The Update button saves any changes made on a window so that other shop configuration
windows can access the new information. The Update button does not send the new
changes to the DCM or Communications Processor. (All changes are sent to the database
and the shop floor from the Save Session command under the File menu.)

· Select the DCM you wish to update.

· Change all desired information.
· Click on the window's Update button. If new information has been added, other shop
floor windows will reflect the change.
· To send your changes to the shop floor, select the Save Session command under the
File menu.
10.180 Updating default Product Standard
To update the default product standard based upon the job on the previous window,
click on the Default button.

The Default button replaces the default product standard with the job parameters from the
previous window. Once the update is complete, the Save As Product Standard window
immediately returns you to the previous window.
NOTE: Altering the default product standard affects the future creation and import of work
orders.

NOTE: A family job cannot be saved as the default product standard. If a family job has been
selected, the Default button will be disabled.
10.181 Updating existing standards
To update an existing standard based upon the job on the previous window, click on
the Update button. The steps are:

· Highlight an existing standard in the Standards list box.

· Click on the Update button.
The Update button replaces the existing standard's parameters with the job parameters from
the previous window. Once the update is complete, the Save As Product Standard window
immediately returns you to the previous window.
10.182 Updating machines
The Update button saves any changes made on a window so that other shop configuration
windows can access the new information. The Update button does not send the new
changes to the DCM or Communications Processor. (All changes are sent to the database
and the shop floor from the Save Session command under the File menu.)

· Select the machine you wish to update.

· Change all desired information.
· Click on the window's Update button. If new information has been added, other shop
floor windows will reflect the change.
· To send your changes to the shop floor, select the Save Session command under the
File menu.
10.183 Updating schedules
276 SYSCON-PlantStar Help System

Many different types of changes can be made to a work center schedule from the Shift
Schedule window. Possible changes are:

· Assign a different shift schedule to a specific week on the Calendar;

· Change a start time, idle, or end idle time in a weekly schedule;
· Unassign a weekly schedule for a specific week on the Calendar;
· Change the name of a weekly schedule.

To make a change:

· Go to the Shift Schedule window.

· Move the cursor to the Work Center field. Choose the work center desired.
· Move the cursor to the Year field. Choose the year schedule desired.
· The weekly schedules, associated with the selected yearly schedule, appear in
the Weekly Schedules list.
· Make any necessary changes by referring to the appropriate on-line help section listed
below:
· Assign a different weekly schedule to a specific week Calendar week; Refer to the
“Assigning Weekly Schedules For A Year” help topic.
· Change a start, idle, or end idle time in a weekly schedule; Refer to the “Creating
Weekly Schedules” help topic.
· Unassign a work schedule for a specific week block on the Calendar; Refer to the
“Assigning Weekly Schedules To The Calendar Board” help topic.
· Change the name of a weekly schedule to change a schedule name, simply type over
the existing schedule name in the “Weekly Schedules List” field.
· Click on the Save button.
· The work center schedule is updated.
10.184 Updating users
The Save button changes a user's privileges.

To change a user's information:

· Go to the User Accounts window.

· Select the user from the User Name list box.
· Make your desired changes by clicking on the desired privilege boxes or change the
password by clicking on the Password button.
· Click on the Save button.
· Select another user for updating, if desired. Repeat steps 3 - 4.
· To permanently save all user changes, click on the Save Session command under the
File menu.

NOTE: If a user is currently logged into PlantStar when changes are made to his/her
privileges, he/she must log out and then log back in for any changes to take affect.

10.185 Viewing job summary information

 Functions 277

Job Summary information can be viewed from the Job Schedule Board

window. Summary information includes:

· Job
· Tool
· Product
· Material
· Required by Date
· Estimated Completion Time
· Hours To Go
· Child Count
· Pieces Required for each child job
· Comment
To view the job summary:
· Move the cursor to the job board and click on a job.

· Click on the Summary button on the menu bar.

· To close the summary information window, click on the Summary button again.

Alternate Method:
If you are already viewing a list of jobs on a machine, highlight a job by clicking the mouse.
Then click on the Summary button.
10.186 Viewing machine detail
Several windows are directly accessible from the Machine Status window. These are
accessible by double-clicking on a machine's rectangle to open the windows. The specific
window that is opened depends upon the current selected machine's running state and is
outlined in the following list:
278 SYSCON-PlantStar Help System

State Window
Assist State Assist Pareto Window
Down State Down Pareto Window
Fast State Job Summary Window
Idle State Machine Exception Window
Off-line State Machine Exception Window
Process Exception Process Summary Window
Production Exception Job Summary Window
Reject Exception Reject Pareto Window
Slow State Job Summary Window
Running State Job Summary Window
10.187 Viewing machine exceptions
You can access the Machine Exception window from the Exception Summary
window. To view detailed information about a machine's current exception states,
double-click on the machine name or anywhere within a machine's row of information.
10.188 Viewing machine status
The Machine Status window is accessible from the Display Group Status window. Double-
click on a display group's rectangle. The Machine Status window opens. It displays all
machines within the selected display group.
10.189 Viewing min and max values
To view the minimum value:

· Click anywhere on the far left-hand side of the window, outside of the graph borders,
but within the top and bottom lines of the desired graph.

To view the maximum value on any graph window:

· Click anywhere on the far right-hand side of the window, outside of the graph borders
but within the top and bottom lines of the desired graph.
10.190 Viewing production hours
· Production hours can be displayed on the job board by clicking on the button,
located on the window's tool bar.
· On the job board, production hours appear in parentheses next to the job name. For
jobs, production hours are calculated the same way as estimated completion time.
Calculation of production hours for slack time (the gray rectangles between
scheduled jobs which only appear if due date scheduling is active) are based upon
the current shift schedule and any idle periods that are defined.
NOTE: This button acts like a toggle. Click on it again to hide production hours.
10.191 Viewing the shift schedule
The shift schedule for a selected display group can be viewed on the job board. Click on the
button to display the shift schedule time line. The schedule appears at the top of
the Job Schedule Board directly below the time scale. Click again on the button to hide the
time line.

NOTE: The shift schedule time line can only be viewed if all the machines in the selected
 Functions 279

display group belong to the same work center. Also, the shift schedule time line does not
appear when the time scale for the job board is set for weeks and months.
10.192 Zooming selected profiles
A section of a profile can be exploded or "zoomed".

To zoom in:
· Select the zoom area by moving the mouse pointer to the beginning of the desired
profile section.
· Click and hold down the left mouse button while dragging the pointer to the ending
point of the desired zoom area. Once the ending point is reached, release the left
mouse button. The area to be zoomed is highlighted in black.
· The graph area automatically changes to display the desired profile section for all
displayed profiles.
To zoom out:
· Once in a "zoomed" state, click on either the or button to resume normal
mode viewing.
SYSCON - PlantStar System
User's Guide

Part

XI
 Glossary 281

11 Glossary
11.1 Actual multiplier
Job parameter which defines the number of pieces currently produced per machine cycle.
The range is from 0 up to the value of the standard multiplier. See also actual shot weight.
11.2 Actual rate
The actual number of net pieces (good pieces) produced per hour. The actual rate can be
calculated over a single shift or an entire job.

Actual Rate = (net pieces) / (Up Time)

11.3 Actual setup time
The actual time it took to set up a job to run on a machine. Setup time is accumulated
under a machine's down reason #2, which when selected at a DCM usually puts the
machine into a down state. Actual setup time is displayed in terms of hours and
minutes (hhh:mm). The range is 0:00 to 500:00.
11.4 Actual shot weight
Machine-based parameter which indicates the total amount of plastic currently used to fill a
single shot. Generally, if the actual multiplier changes on a job, the actual shot weight also
changes. This field's range is from 0.000 up to the value of the 999999.9.
11.5 ADC option
DCM parameter which configures the DCM for 0, 16, or 32 analog channels. A DCM may
only be configured for analog channels if the optional analog to digital board was purchased
and installed. Set this value to zero if the unit does not have an A to D card.
11.6 Administration privilege
This privilege grants users the ability to edit any user's account and privileges.
11.7 Analog filter
Digital filter setting used to reduce noise on an analog channel.
Filter Value:
0 = No Filtering
1 = Light filter, pressure transducers
2 = Moderate filter, position transducers
3 = Heavy filter
4 = Maximum filter, thermocouples
The recommended maximum value for pressure transducers is 2. The recommended
maximum value for temperature is 4.
11.8 Analog inputs
Analog inputs are electrical inputs that use variable voltages to model changes in real-world
conditions.
11.9 Announce flag
Flag that identifies the down reason, assist reason, machine state, or process variable which
should be announced. A check mark in the flag field turns on the specified announcement. For
process variables, the flag identifies which variable should be announced when it exceeds the
higher or lower limit. For down reasons, assist reasons, and machine states, the flag indicates
282 SYSCON-PlantStar Help System

an announcement should be made when the specified condition exists. To set this flag, click on
the box associated next to the desired item.
11.10 Announce machine flag
If the announce machine flag is checked on the machine announcement window, the
machine is marked for announcing.
11.11 Announcement delay
The amount of time to wait before re-announcing the same message. The range is 1 to 99
minutes.
11.12 Assist state
Selection of an assist reason by an operator at a DCM triggers the assist state for a
selected machine.
11.12.1 Assist period
The number of times (frequency) a machine entered an assist state. Assist periods are
recorded by specific reason.
11.12.2 Assist reason
Specific reasons available to the operator for requesting assistance. Assist time and
frequency are accumulated for each assist reason. Reason names can be up to 20
characters in length.
Sets of assist reasons are a user configurable feature. On keypad DCMs, only the first 9
characters are displayed. On EL DCMs, the first 7 characters are displayed.
11.12.3 Assist state colors
This button's image will change depending upon whether the machine is in the assist state.
Pressing this button, regardless of the current state, will display the Assist Select page in
the main frame of the browser screen.

Machine is not currently in the assist state.

Machine is in the assist state.

11.12.4 Assist time

The total number of hours an operator waited for assistance at a machine. Assist time is
recorded by specific reason. Format is hhh:mm.
11.13 Auto clear flag
Flag which determines whether the selection of a down reason automatically clears after a
machine has 3 consecutive up cycles;

If a machine enters a down state by the selection of a specific down reason, and that down
 Glossary 283

reason has the auto clear flag enabled, then the down selection is automatically cleared after
the machine has been up for three (3) consecutive cycles. Valid choices for this field are 'Yes'
or 'No'.
11.14 Auto logout
When set to 'yes' this setting automatically logs a person out of a DCM at shift change or
the start of an idle period.
11.15 Available triggers
The number of trigger events remaining. This count is based upon the types of process
variables defined for the displayed machine. The maximum number of trigger events for a
machine across all process variable source types is 50.
11.16 Average cycle
Average of some set of actual machine cycle times. Average cycle is computed several
ways. The current incomplete cycle is never included.
Job-to-date Average Cycle (includes current, incomplete shift):

Average Cycle = (UP TIME for the job) / (UP CYCLES for the job)

Shift-to-date Average Cycle

Average Cycle = (UP TIME for the shift) / (UP CYCLES for the shift)

Moving Average Cycle:

If cycle window = 0, then

Average Cycle = AVERAGE CYCLE
Else
Average Cycle = (CYCLE TM1 +.. .+ CYCLE TMn)
/ N where N = cycle window
The moving average cycle is compared to the standard cycle to determine machine state. A
machine is slow if the Average Cycle is:
Average Cycle > (Standard Cycle) + ((Cycle Tolerance) * (Standard Cycle) / 100)

A machine is fast if the Average Cycle is:

Average Cycle < (Standard Cycle) - ((Cycle Tol) * (Standard Cycle) / 100)
11.17 Average value
Mean value of a process variable. This value can be calculated for the current shift or
historical shift.
Average Value = (Total Value) / (Total Cycles)
11.18 Backup internet path
The backup path to a communications processor if a redundant network path exists. It is
284 SYSCON-PlantStar Help System

also an alternative path name for the primary internet path, if necessary. This path name
can be up to 20 characters in length.
11.19 Base model
DCM parameter which refers to the model type and/or number of the hardware installed in the
DCM.
11.20 Baud
This field refers to the speed at which information can be transferred through a COM (serial)
port. It is used for Engel, BetaMux, HPM CMD, JSW uPACS, Maco 4000, Maco 8000,
CAMAC, Netstal, RKC F900, Square D, Unilog 9000B, A & D Scale, Toshiba and Toyo
source types. For Toshiba PLCs, the baud rate should be set to 4800. For RKC F900 source
types, the baud rate should be set to 9600. For MACO 8000 sources, the baud rate should be
set to 9600. Unilog 9000B sources cannot be set higher than 9600 baud.
11.21 Bias
Zero offset used to convert analog and serial inputs or any received value into engineering
units. Bias and scale are used in the following formula to convert transducer output voltage
to engineering units.

Value = (Voltage * Scale) + Bias

To compute bias, use the following formula:

Bias = (High Value) - (Scale * (High Voltage))

Bias is displayed to 4 decimal places and can be positive or negative. Bias should be
0.0000 for all time duration variables. For Simulated sources, the bias is applied to the
simulated signal.
11.22 Bits
Configuration parameter which defines the serial interface being used. The bits field consists
of three parts:
Data bit - 7 or 8
Parity - None, Odd or Even
Stop Bit - 1 or 2

For Toshiba PLCs, the bits field must be set at 8-even-2. For Engels, the data bit should be 7
with even parity. For RKC F900 sources, the bits field should be set at 8-None-1. For MACO
8000 sources, the bits field should be set at 8-None-2. Unilog 9000B sources must be set at 8
data bits. Stop bits and parity can be selected in the control unit.
11.23 Block number
Block number for the process variable being monitored. For valid block numbers, refer to the
JSW Process Monitoring Parameters to Host Computer of uPACS-5000 & uPACS-5000D
manual.
11.24 Boolean set
This field is the name of the Boolean equation set assigned to a machine. Each machine
has at least one contact input. This set defines how the system interprets these digital
inputs.
 Glossary 285

11.25 Boot files

Binary files distributed with your system which contain software modules used by
DCMs and communications processor. These files are not used in the RTL/CIM
style DCMs.
11.26 Boot set
A group of boot files defined for a DCM or Communications Processor which are
downloaded upon coldstart. For a DCM or Communications Processor to function correctly,
its associated boot set must contain the appropriate boot files for all hardware and software
options installed. These files are not used in the RTL/CIM style DCMs.
11.27 Calendar board
The upper, middle part of the window displays a yearly calendar for the work center and year
visible in the upper right-hand corner. Each month is divided into weeks. One block
represents one week of the month, with the first Monday of each week displayed. Each block
is color-coded. The color represents the work schedule in effect for that week. The color code
is set in the Weekly Schedules field.
11.28 CAMAC address
This field is primarily used with CAMAC source types. It refers to a machine address. For
VLC controllers, this address is set at the VLC panel. For VSX controllers, this address is
set at the VSX panel. For XTL controllers, this address is set at the XTL panel. For 486
controllers, this address is set at the 486 panel. For most CAMAC sources, it is usually set
to 1.
11.29 Case sensitive matching
Searching methods are used on the Job Schedule and Job Schedule Search windows to
quickly find jobs and work orders. The case sensitive matching distinguishes between upper
and lower case when doing searches. For example, searches for the word "BATTERY' are
not the same as searches for the word "battery". If case sensitive matching is not turned on,
then case is ignored. The words "BATTERY" and "battery" are considered the same.
286 SYSCON-PlantStar Help System

11.30 Channel
Hardware path on which a DCM receives process variable and profile data. For analog
channel and thermocouple source types, the channel field refers to the analog channel
where the input signal is physically connected. The channel must match the analog channel
number (inside the DCM) where this input is connected. For Engels, this field refers to the
valid channel number for the Engel group being used. For simulated source types, the
channel field refers to the type of signal to be simulated. For BetaMux sources, the channel
field refers to the channel on the Gage Multiplexer which is currently selected.
11.31 Child count
The number of child jobs that are associated with a particular job. This value may range
from 1 to 12.
NOTE: A job with a child count of 1 is considered to be a non-family job.
11.32 Child job
A child job represents a sub-section of a multi-part job. This can be a particular cavity type
in a multi- cavity mold, or a particular die in a multi-die press operation. The number of child
jobs (child count) may range from 1 to 12.
NOTE: A one child job is not valid. When creating a work order or product standard, jobs
with only one child job cannot be saved. You will be prompted to either add another child
job or remove the current child job before saving.
11.33 Column number
The column number which corresponds to the process variable being monitored; Column
numbers refer to the location of the process variable within a Unilog 9000B output table.
Output tables can be customized so refer to your site's output file format.
11.34 Comm port
A serial port used to communicate with an exterior device.
11.35 Comm option
DCM parameter which refers to the number of communication ports available on the DCM.
Set this value to 5 if the optional 4 port serial card was purchased and installed.
11.36 Comment
Parameter used for general descriptive text. The comment field can be up to 50 characters
in length. In terms of job scheduling, this field is used by PlantStar to report an error if a
failure occurs.
11.37 Communications processor
Communications processors create a link between DCMs on the production floor and the
system's host computer. The "cp" ensures proper message routing and control between the
shop floor network and the TCP/IP network. The Communications processor field is an
alphanumeric that can be up to 20 characters in length. Only the first 6 characters will be
sent down to the attached DCM.

At least one communications processor must, therefore, be defined for the shop floor. A
communications processor can be linked to many DCMs, although a DCM must have one
and only one associated communications processor. Changes made to a communications
processor setup can affect each of its attached DCMs. In the case of the RTL-based DCM,
each RTL-DCM will also be its own Communications Processor and therefore there will be a
 Glossary 287

Communications Processor defined for each DCM.

The Communications processor should be one of the first elements of the shop floor which is
defined.

Recommended steps are:

1.) Create Boot Sets. These files are not used in the RTL/CIM style DCMs.
2.) Configure the communications processor
3.) Create Reason Sets
4.) Create Work Centers
5.) Configure DCMs
6.) Configure Machines
7.) Configure process variables on each machine if option purchased
8.) Configure profiles on each machine if option purchased
9.) Define display groups
11.38 Component percent
Product-based parameter indicating the percentage, by weight, of raw material used to
produce a product on a job. The total component percent for all materials used on one job
should equal 100. If there is only one material assigned for a job, then the component
percent is automatically set to 100. The range is 0.0 to 200.0.
11.39 Contact duration
Contact refers to the digital equation name or the number of the contact input used to
measure duration. The duration is the amount of time that this input remains closed. Up to
20 characters are available.
11.40 Contact input
A digital input used to mark the occurance of an exterior event. Contact input #1 is always
the cycle event of the machine.
11.41 CONV_VEC#
This field is primarily used for CAMAC VSX source types. The CONV_VEC number refers
to the location of the data to be monitored. Refer to the CAMAC Host Computer
Information Manual to select the correct CONV_VEC number. Type in the number
corresponding to the appropriate description.
11.42 Convert index
This field refers to the conversion index to be used for correct scaling of a monitored item. It is
used with CAMAC and Netstal process variables. For Netstal source types, refer to the Netstal
PLC Interface Table to select the desired index.
288 SYSCON-PlantStar Help System

11.43 Cost per hour

This field associates a dollar value to a labor category. This value is then used in labor
forecasting to estimate job costs.
11.44 Cp
Capability Index which indicates how well a process can do if it is centered midway between
the defined specification limits. The index is the ratio of the specification range to the process
capacity. In PlantStar, the CP is calculated only over the range of subgroups that are
currently displayed on a window's graph.
Cp = (Upper Spec - Lower Spec) / (6 * Standard Deviation)
11.45 Cpk
Index which reflects the relative probability of making a part outside of defined specification
limits -- i.e. the expected level of defects for a given part. In PlantStar, the Cpk is calculated
only over the range of subgroups that are currently displayed on a window's graph. The
calculation is:
Min ((X-bar Mean - Lower Spec), (Upper Spec - X-bar Mean))
3* Standard Deviation

11.46 Critical process variable

When a critical process variable falls outside of its defined limits, a critical process exception is
flagged. This flag can be used in digital equations to close an output contact or activate a light.
11.47 Current job
The job that is currently running on a machine. The current job is the first job listed on
the job schedule for each machine.
11.48 Current shift
The shift that is currently running, as defined in the Shift Schedule window.
11.49 Currently running jobs privilege
This privilege gives users the ability to edit job parameters for currently-running jobs
from the Job Schedule or Edit Current Job windows within the PlantStar Monitor
program.
11.50 CV
Abbreviation for Coefficient of Variation. This statistic is a measurement of precision that
does not depend upon any scale of measurement. In PlantStar, the CV is calculated only
over the range of subgroups that are currently displayed on a window's graph.
11.51 Cycle time
The measured length of time between consecutive closures of the primary contact. For
production data, cycle time is recorded to one tenth of a second and must be in the range of
0.5 sec to 248 days. For process data, cycle time has a selectable range and accuracy up
to one hundredth of a second.
11.52 Cycle tolerance
Parameter indicating the percent deviation from standard cycle time that is normal for a
job. See average cycle for a complete description. The range is 0.0 to 100.0 percent.
 Glossary 289

11.53 Cycle window

Product-based parameter defining the number of cycles used to compute average cycle
time. Cycle window can be set from 0 to 50. See average cycle for a complete description.
11.54 Data number
The data number refers to the item to be monitored for Toshiba source types. Refer to the
Toshiba PLC Information manual to select the item to be monitored. Type in the number
corresponding to the appropriate description.
11.55 Date range scheduled usage
The Date Range Scheduled Usage is the scheduled machine usage during the given
date range.
The date range is "12:00:00am" on the start date to "11:59:59pm" of the end date.
· To change the date range, type in a beginning or end date from which to search.
· Date format is in the form of "dd mmm yyyy" (i.e. "01 Jan 2003").
11.56 Date range usage
The Date Range Scheduled Usage is the machine usage during the given date range.
The date range is "12:00:00am" on the start date to "11:59:59pm" of the end date.
· To change the date range, type in a beginning or end date from which to search.
· Date format is in the form of "dd mmm yyyy" (i.e. "01 Jan 2003").
11.57 DCM
A Data Collection Module (DCM) describes the physical microprocessor-controlled unit which
is attached to a machine or group of machines. The DCM collects and monitors Real-Time
data such as machine state, rejected parts, and process variable values. This data is
transferred to the host database for display.
The DCM also provides an interface for the machine operator through either a Keypad (KP)
or Electroluminescent/Touch Screen (EL/TS) display, TouchPanel display (RTL-DCM), or
browser based interface. These options enable manipulation and/or viewing of various
machine operations.
DCMs are self-contained units. The DCM can operate independently of the host computer for
some period of time by maintaining its own copy of job queues and historical production
records in battery backed RAM. Some DCM configurations have communications processor
functionality built in and do not require a physical, external communications processor. This
includes all RTL-DCM type modules.

The DCM browser interface is available from any networked computer that has an
appropriate web browser installed.
11.58 DCM base address
This address is the name of the base address of the DCM, which is a combination of the
communications processor and the address of the DCM. This value must match the address
entered at the DCM unit. Valid values are 1 through 250.
For RTL type DCM’s the base address is automatically set to 1 and cannot be changed.
11.59 Debounce
290 SYSCON-PlantStar Help System

Number of ticks (1 tick = 1 tenth of a second) that a signal change will be ignored so that
bounce can be eliminated. This is used primarily to reduce false signals generated by line
noise.
11.60 Decimals
Specifies where to put the decimal point in a sampled value prior to applying a scale factor
and bias. For example, when the implied decimal position = 3, the inputs 0.4102, 0.410 and
0.41 are interpreted as 0.410. Valid decimal positions can be from 0 to 4.

For Netstal source types, the decimal value for the desired Parameter Number and
Convert Index must be obtained from Netstal's PLC Interface Table.
 Glossary 291

Netstal PLC Interface Table

S19 4 0 1.00 1
S11 5 0 1.00 1
T11 6 3 1.00 1
T02 7 3 1.00 1
T34 8 3 1.00 1
S00 9 0 1.00 1
T21 10 3 1.00 1
TH11 11 2 1.00 0
TH12 12 2 1.00 0
TH13 13 2 1.00 0
TH15 14 2 1.00 0
TH16 15 2 1.00 0
TH17 16 2 1.00 0
TH25 17 2 1.00 0
TH26 18 2 1.00 0
P21 19 0 1.00 0
P22 20 0 1.00 0
P23 21 0 1.00 0
P24 22 0 1.00 0
N21 23 2 1.00 0
N22 24 2 1.00 0
N23 25 2 1.00 0
N24 26 2 1.00 0
V01 27 2 1.00 0
V02 28 2 1.00 0
V03 29 2 1.00 0
V04 30 2 1.00 0
V05 31 2 1.00 0
S01 32 2 1.00 1
S02 33 2 1.00 1
S03 34 2 1.00 1
S04 35 2 1.00 1
S05 36 2 1.00 1
P12 37 3 10.00 0
P13 38 3 10.00 0
P14 39 3 10.00 0
P15 40 3 10.00 0
T12 41 3 1.00 1
T13 42 3 1.00 1
T14 43 3 1.00 1
T15 44 3 1.00 1
T39 45 3 1.00 1
292 SYSCON-PlantStar Help System

11.61 Delay Timer

The delay timer is used at the DCM in the Material Lot screen to specify the amount of time
in minutes that should elapse before a raw material change is to take effect on a job. The
default timer value is set to zero.

The timer does not begin counting down until the "RUN" button is pressed on the Material
Lot screen. A material change goes into effect when the timer value counts down to zero.
The "PAUSE" button can be used to temporarily stop the timer count down. When the time
expires, the current materials are replaced with the new materials and the event will be
recorded in the audit trail.
11.62 Derivative
Order of the derivative taken, with respect to time, of a profile channel. The first order
derivative of a position channel would result in a velocity profile. The second order
derivative would result in an acceleration profile. Select "none" if you do not want a
derivative.
11.63 Derivative smoothing
This is the size of the smoothing window used by the derivative algorithm. Values range from
1 to 8. A value of 1 gives a simple, point-to-point difference. A value of 8 gives maximum
noise damping, but also damps rapid (real) signal changes. Values of 2 or 3 are
recommended.
11.64 Descriptor
The parameter descriptor of the Maco-8000 source type;
11.65 Device address
Unique address of the unit being accessed; for Square D source types, the device address
refers to the unique address of the target Circuit Monitor. For RKC F900 sources, the device
address must be set to the 485 physical address and must match the address set on the
F900. Addresses are numeric integers.
11.66 Digital inputs
Electrical inputs that have two-states, high and low, to model changes in real-world
conditions.
11.67 Display group
A user-defined group of machines used to filter monitoring information on Monitor
windows. A machine can belong to any number of display groups. Each machine within
a display group must belong to the same work center.

Display groups are used as a way to customize what machines are shown on all monitoring
and historical windows. All machines that are attached to an enabled DCM are monitored. A
machine may not appear on a window, though, if it is not in the selected display group. Each
time a different display group is selected, the choice of machines offered by a window also
changes.
A machine can belong to more than one display group. An All display group exists even if
no display groups have ever been defined. This display group includes all defined
machines. It is automatically set up by the Shop Floor Configuration program. It cannot be
modified or deleted.
11.68 Display option
 Glossary 293

DCM parameter which refers to the type of DCM display. If an optional electro-luminescent
touch screen was purchased, choose EL/TS. Choices for RTL based DCMs are 10", 12", 15"
touch screens and none for a blind CIM.
11.69 Display type
The particular display type that has been installed on the DCM. The range of values
varies with the particular model type of the DCM.
11.70 Down state
A machine enters a down state when its current cycle time exceeds its established down
threshold. The down state ends when the current cycle time is once again less than the
down threshold
The down state can also be entered if the operator selects a down reason which is
configured to force a machine down.
11.70.1 Down cycles
Number of machine cycles counted while the machine is in a down state. A machine is
considered down whenever its cycle time is above the down threshold.
11.70.2 Down period
The number of times a machine has entered the down state. Down Frequency is recorded by
specific reason.
11.70.3 Down reason
Specific reasons available to the operator for classifying down time. Down time and down
frequency are accumulated for each down reason. Reason names can be up to 20 characters
in length. Sets of down reasons are a user configurable feature. On keypad DCMs, only the
first 9 characters are displayed. On EL DCMs, the first 7 characters are displayed. On
browser screens only the first 10 characters are displayed.
11.70.4 Down state colors
This button's image will change depending upon whether the machine is down, or if a down
reason is selected. Pressing this button, regardless of the current state, will display the Down
Select page in the main frame of the browser screen.

Machine is not currently down.

Machine is either down with no reason selected, or running with a reason selected.
294 SYSCON-PlantStar Help System

Machine is down and a reason has been selected.

11.70.5 Down threshold
Machine-based parameter which determines when a machine is considered down. Set this
to a value greater than the cycle time. When the cycle time of a machine exceeds the down
threshold, the machine is classified as down. The machine continues in the down state until
it completes a cycle below the down threshold. The range is 0.5 to 3276.7 seconds.
11.70.6 Down time
The total number of hours a machine has been in the down state. Down time is recorded by
specific reason.
11.71 Drag and drop options
Determines what happens when a job or work order is moved from one machine to another
machine on the Job Schedule window. The option selected as the default is automatically
enforced. To activate the other option on the Job Schedule window, use the "drag/drop
method" in conjunction with the SHIFT key.

· Keep the standard of the original machine - Each queued job or work order has its own
set of product-related and machine-related job parameters. When a job or work order is
re-scheduled from one machine to another, these parameters move with them. If this
method is the default, then all job parameters are based upon the originating machine.
They are not modified to accomodate the new machine.

· Use the standard of the new machine - When this method is used as the default for
moving jobs or work orders, machine-related job parameters are verified. If the
destination machine has different values for any of the machine-related parameters,
they are replaced. For example, the originating machine's standard cycle is 30 seconds.
The destination machine's standard cycle is 15 seconds. The standard cycle parameter
for the re-scheduled job is automatically changed from 30 to 15.
11.72 Duration
The length of time in seconds that a profile will be collected. The sum of the trigger delay
and the duration must be less than the cycle time. Up to 1000 samples can be taken
during a collection period.
 Glossary 295

11.73 Element number

Allen Bradley data table files contain multiple elements. The element number identifies which
element corresponds to the process variable being defined.
11.74 Embedded matching
Searching methods are used on the Job Schedule and Job Schedule Search windows to
quickly find jobs and work orders. The embedded matching search method finds jobs or work
orders that have the specified string of characters somewhere in the name. For example, if
the letters "an" were entered in the product name field on the Job Schedule Search window,
PlantStar would find the following:

· flange
· handle
· ankle brace
· paint can
11.75 Employee id
A unique numeric code used to identify an employee.
11.76 Employee name
A name that corresponds to a selected employee id. This field is 30 characters and may
contain letters and numbers.
11.77 End date
Precise time at which the system stopped monitoring the task selected. End date is
formatted as dd/mmm/yy.
11.78 End time
Precise time at which the system stopped monitoring the task selected. End time is
formatted as dd/mmm/yy hh:mm.
11.79 Estimated completion time
Time estimated to finish a job. The job is complete when total net pieces for the job equals the
pieces required. The estimated completion time is computed using the shift schedule and
hours to go to determine the estimated date and time the job will end.

If the shift schedule does not include any idle period, the estimated completion time would be:

· Estimated Completion Time = Current Date and Time + Hours to Go

If the shift schedule does include idle periods, the estimated completion time would be:

· Estimated Completion Time = Current Time + Hours to Go + Scheduled Idle Time

296 SYSCON-PlantStar Help System

11.80 Event type

The type of event to display on the window. Events types are:

· Job
· Shift
· Down state
· Assist state
· Process exception
· Employee login and logout
· Material

To select an event type, click on the arrow to the right of the Event field. Slide the mouse
down to the desired event type and click again.
11.81 Exact matching
Searching methods are used on the Job Schedule Board's search windows to quickly find
jobs and work orders. The exact matching search method finds jobs or work orders that
exactly match the specific string of characters entered. For example, if the product name
"battery" is entered as a search string, PlantStar would find jobs where the product name is
"battery".
11.82 Exception state
The exception state (or alternately machine state) of a machine is determined by a set of
exception flags. Each flag indicates one possible exception condition. The exception flags
are prioritized as follows:
Most windows show the machine state as the highest priority exception flag which is true.
Use the Machine Status window to see all exception flags for a machine.
11.83 Exception time
The time of day when an exception state was entered. The time is displayed in an hh:mm
format if it happened within 24 hours. If it happened greater than 24 hours ago, the exact
day is displayed.
11.84 Excess material
The amount of material wasted on a job. If runners and scrap are re-fed on a job, the amount
of excess material is equal to zero. Otherwise, excess material calculations are based upon
reject weight or shot size.
11.85 Exit privilege
The exit privilege lets a user leave a PlantStar program and return to the Window's desktop.
11.86 Extended down and reject reasons
An extended down and reject reason option can be purchased from PlantStar. This will
extend the down and reject limit to one hundred sixty (160) reasons for each set.
11.87 Family job
A job that has two or more child jobs associated with it.
11.88 Fast state
The fast, slow, and standard machine states are basic indicators of machine performance.
For each machine cycle, the cycle tolerance is monitored. The tolerance is the percent
 Glossary 297

deviation of a job from its normal standard cycle time. An average cycle is computed and a
comparison is made using the cycle tolerance and standard cycle values. If the average
cycle is less than the resultant value, the machine is considered fast.
11.89 File number
The identification number of the Allen Bradley data table file. Only whole numbers are
acceptable.
11.90 File type
One character abbreviation which identifies the format of the data stored in an Allen Bradley
data table file; Examples are N for integer values or F for floating point values.
11.91 FN code
Function Number for the Maco-4000; MACO 4000 functions are identified as follows:
01H Sequence
02H Temperature
03H Hydraulic
20H Display Handler
25H Display Processor
26H Cartridge
27H Communications Processor
28H Keyboard Processor
30H RS-232 Communications
38H RS-485 Communications
40H Data Handler
11.92 Force down flag
Flag which determines if a down reason forces the machine into a down state. While in
this forced down state, a machine's attached DCM continues to count parts and monitor
process variables. All time is accumulated as down time. The machine appears in a down
state regardless of its actual cycle time.
11.93 Force scrap flag
A down reason may be associated with a reject reason via the Force Scrap flag. Valid
choices for this field are either "No" or the reason index of a reject reason (as defined on the
Reject Reason Sets window). If a reject reason index is entered, parts are automatically
rejected and accumulate under the associated reject category. For example, if the Force
Scrap flag is set to 5 for down reason #2, then whenever down reason number 2 is selected,
all parts are rejected and accumulate under reject reason #5.
298 SYSCON-PlantStar Help System

11.94 Forecast interval

The forecast interval field restricts the number of jobs displayed on the Tool Change window
to those that are estimated to be completed by the selected interval. For example, if the "1
day" interval is chosen, jobs that are estimated to be completed within 1 day from "now" are
listed in the table.
11.95 Forecast types
Forecast types are used to determine the effect a labor category has on the job to which it
was assigned. There are two forecast types: setup and production. Setup forecast types
will only be used during the setup time that was assigned to the job. Production forecast
types will be used only during the rest of the job, that falls outside of the jobs initial setup
portion.
11.96 Free text
Parameter which contains user-designated information. The PlantStar system provides you
with up to four customizable fields. The titles of the free text fields can be set up from the
User Defined Labels window.

The free text fields are also available as descriptive fields for bar coded tote labels. Bar
code labels are printed in conformance with the AIAG bar code standard. Each free text
field can be up to 20 characters in length.
11.97 Full access privilege
If the Full Access box is checked, a user can add, delete and edit any PlantStar window
and its information associated with the checked privilege (the privilege located on the
same row as the Full Access box).
11.98 Gain
Multiplier used to amplify or extend the range of an analog signal. Always use the largest
gain which will keep the signal within the 0 to 10V input range. For example, if a transducer
generates a 0 - 30 mV signal, use a gain of 300 to amplify the input signal to 0 - 9V for
digitizing. For simulated sources, the gain is applied to the simulated signal.
Standard gain factors are 1, 2, 3, 10, 20, 30, 100, 200, and 300.
11.99 Gross pieces
The number of total pieces produced on a job, including both net and rejected pieces.
11.100 High value
The highest value recorded for a process variable during the current shift.
11.101 Higher limit
Highest value of a process or profile variable that is normal for the current job. If a process
or profile variable exceeds its high threshold, the machine will be in process exception for
that cycle.
11.102 Historical job
A job which has been completed and whose data is available for analysis.
11.103 Historical shift
A shift that has been completed and whose data is available for analysis.
11.104 Hours to go
 Glossary 299

Total hours and minutes estimated to finish a job. The job is complete when total net pieces
for the job equals the pieces required. Before 5% of the pieces required have been made,
Hours To Go is calculated as follows:
Hours to Go = Remaining Setup Time + ((Pieces to Go) / (Standard Rate))
After 5% of the pieces required have been made, the following formula is
used:

Hours to Go = (Pieces to Go) / (Actual Rate)

For maintenance jobs, Hours To Go is equal to the actual setup time remaining.
NOTE: If the job scheduled is a family job, the Hours to go will indicate the expected run
time of the longest running child job.
11.105 Hours worked
The total number of hours an employee worked. This is the difference between the
employee's start and end time.
11.106 HTML
Hyper-Text Markup Language – This is the language that web pages are written in.
They are displayable in a web browser.
11.107 Identifier
A three character identification which is associated with a process variable; For HPM CMD
sources, a list of standard identifiers is available from the HPM CMD manual. For RKC F900
sources, identifiers are user-defined.
11.108 Idle period
The time when the machines are not scheduled to operate. During an idle period, the DCM
ignores all inputs from the machine. Only idle time will be accumulated.
11.109 Idle state
A machine is considered idle if it is following a shift schedule that has an idle period defined
or if its job is set to idle. A job is idle if its job parameters -- schedule factory and schedule
now -- are both set to "NO".
11.110 Idle time
The time that is accumulated while a machine is idle. See Idle Period.
11.111 Ignore cycle flag
Flag which determines whether a DCM ignores the primary contact when in a forced down
state.
If a machine is in a forced down state (as set by the Force Down flag), and the Ignore Cycle
flag is set to "Yes", a machine's attached DCM stops counting parts and monitoring process
variables. Monitoring is resumed only when the machine exits the down state.
11.112 Index number (JSW source type)
Index number within the block which identifies the process variable being monitored; For
valid index numbers, refer to the JSW Process Monitoring Parameters to Host Computer of
uPACS-5000 & uPACS-5000D manual.
300 SYSCON-PlantStar Help System

10.113 International support

PlantStar uses the Windows regional settings to define valid input on date, currency and
decimal input controls. All displays and reports will also use the regional settings of the
computer they are currently running on. Please see the available settings by going to contol
panel->Regional and Language Options and clicking the customize button. The screen is
displayed above.
11.114 IP address
Logical ethernet/internet address -- this address can be a logical name or in dotted quad
notation (192.168.100.100).
11.115 Isolated A to D
When checked the RIO's boot set will contain the files necessary for use with an isolated
analog to digital converter card.
11.116 Job
A fully specified set of job parameters for monitoring the production of a specific quantity of
a specific product. The general term "job" is used to describe the current job running on a
machine, a queued job or a work order.
11.116.1 Job board
 Glossary 301

Displays the current job queues for all machines within a selected display group. Each row
represents a machine's job queue and each rectangular block is a scheduled job. The first
rectangular block on each machine is its active job. The remaining jobs form a linear list of
jobs waiting to be run on the machine. The block length indicates the expected run time for
the job. Green rectangular blocks indicate that a job is estimated to complete on time. Red
and orange blocks indicate late completion times.
11.116.2 Job changes
Number of times a new job has been started, on the selected machine, during the given time
period.
11.116.3 Job history size
DCM parameter which sets the number of job change records which should be stored locally
at the DCM. All DCMs have the capability for local data storage. This capability allows the
DCM to hold data while the host computer is either down or busy -- minimizing data loss. It is
recommended that the history sizes be set so that three days of history be stored locally. If
the DCM is in communication with the host then these histories are not used.
11.116.4 Job key
Selects existing product standards based upon the entered job name. Partial or complete
searches can be done.

NOTE: As of PlantStar v4.10, this search no longer requires the key fields to match the
case of the expected result. In other words, the search is no longer case sensitive.
11.116.5 Job name
A user-defined name that identifies a current job, queued job, work order, or product
standard. Job name is an alphanumeric string of up to 20 characters.
11.116.6 Job parameters
Refers to a collection of parameters which define how to monitor performance and progress
for a job on a specific machine. Job parameters are made up of product-specific and
machine-specific information.
11.116.7 Job primary label
Determines how the Job Schedule Window displays jobs on its scheduling chart. Jobs
are either identified by job name or by product name.
11.116.8 Job start time
Precise time at which the system started to monitor a job on a machine. Start time is
formatted as dd/mmm/yy hh:mm.
11.116.9 Job-to-date
The data available for a current job from the time that is was started to the present time.
11.117 Job queue
A linear list of jobs that are scheduled for a machine. This list does not include the current
job. The first queue position holds the next job to be run on the machine.
11.118 Job queue size
Parameter which sets the size of the DCM's local job queue. There are two “job queue size”
parameters within your system. This queue size determines the number of jobs that a DCM
operator can view or start at the DCM.
The second job queue size parameter is the one defined for the host computer (currently set
302 SYSCON-PlantStar Help System

to 100). It is not editable.

11.119 Job Summary - graph view

The Graph View displays a graph of the selected column in the grid view. There is one
vertical bar per shift. Bar height represents the column selected.
11.120 Job Summary - grid view

The first row of the table provides shift-to-date information for the current shift and job. The
middle rows display shift data for up to four completed shifts, depending upon how long a job
 Glossary 303

has been running. The next row provides shift totals for the last four shifts available. Job-to-
date totals for all columns are then calculated in the last row of the table. The color of the
window background reflects the machine's running state.
11.121 Labor category
Labor categories which one or more can be assigned to an employee.
The PlantStar system provides up to 30 of these customizable fields. The names of the labor
categories can be set up from the Labor Setup window. When an employee attempts to login,
they are presented with a list which consist only of the categories to which they have been
assigned. Employee Labor categories are user-defined employee-Labor Category definitions
are also defined in the Labor Setup window.
11.122 Labor data privilege
Allows this user to view/modify data contained in the Labor Definition Screen.
11.123 Labor Forecast - graph view

The Labor Forecast window is used to accurately forecast, by work center and shift, the
number of employees needed in a given Labor Category. This forecast is based on current
jobs and queued jobs scheduled.
11.124 Labor Forecast - grid view
304 SYSCON-PlantStar Help System

The Labor Forecast window is used to accurately forecast, by work center and shift, the
number of employees needed in a given Labor Category. This forecast is based on current
jobs and queued jobs scheduled.
11.125 Labor history size
DCM parameter which sets the number of labor history records which should be stored
locally at the DCM. All DCMs have the capability for local data storage. This capability
allows the DCM to hold data while the host computer is either down or busy -- minimizing
data loss. It is recommended that at least three days of history be stored locally.
11.126 Language
The language option allows the users to select their language preference.
11.127 Last value
The process variable measurement taken during the most recent completed cycle.
11.128 Left matching
Searching methods that are used on the Job Schedule and Job Schedule search windows
to quickly find jobs and work orders. The left matching search method finds jobs or work
orders that start with a specific string of characters. For example, if the product name
"battery" is entered as a search string, PlantStar would find the following:

· battery
· battery clip
· battery housing

If the word "batter" was entered, the left searching method would also find "batteries" in
addition to the matches above.
 Glossary 305

11.129 Linearization type

Indicates the type of linearization which is required to condition an analog input channel for
use as a process variable. Most commonly used to linearize thermocouple inputs.
However, other non-linear transducers may require a linearization type.

For pseudo variables, the linearization type may be:

· the maximum value
· time that the maximum value occurred
· the minimum value
· the time that the minimum value occurred
· the range (max - min)
· the mean value
· the average of the selected profile
· a value range.

For thermocouples, the linearization type refers to the type of thermocouple that is
connected to the DCM.

If your input device is, a pressure transducer, linear potentiometer or any other linear
device, select linear transducer. The Newport8005 dewpoint option is a non-linear device
which is designed to monitor compressed air and plastic air drying systems.
11.130 Login privilege
This privilege gives a user access to the PlantStar Monitor, PlantStar Shop
Configuration, and PlantStar Reports programs.
11.131 Lot end time
The time when an active Material Lot ID was either replaced with another lot ID or
one of the material components changed within the material formula.
11.132 Lot start time
The time when a Material Lot ID was entered at the DCM through a bar code reader or a
touch screen. The start time is recorded upon the expiration of the DCM-entered lot delay
period.
11.133 Low value
The lowest value recorded for a process variable during the current shift.
11.134 Lower limit
If a process or profile variable is below its lower limit, the machine will be in process
exception for that cycle.
11.135 Lower spec
The lower control limit assigned to a process variable. When this limit is exceeded the
machine will enter a process exception state.
11.136 Machine
The machine on the shop floor that is being monitored. Each DCM may monitor one or
more machines. The machine name can be up to 8 characters in length. The name can
include numbers and characters.
A machine setup describes the connection of a DCM to a machine on the factory floor. Every
306 SYSCON-PlantStar Help System

machine must

· have one and only one associated DCM,

· have a set of down reasons, assist reasons, and reject reasons,
· be defined, if it is to be monitored,
· belong to one and only one work center

The work center in which the machine belongs is important. A machine follows the shift
schedule of its work center. Scheduling of jobs is done by work center.

There are several important points that need to be explained about creating and deleting
machines. Once a machine is created, it is considered the same machine until it is deleted.
Even if it undergoes a name change, it is still considered the same machine. Once a machine
has been deleted, the same machine can never exist again. If a new machine is created with
the same name, it is not considered the same machine. Because of this rule within PlantStar,
a machine with historical production records should be deleted only if it is to be permanently
removed from the system. If its future is uncertain, the machine should not be deleted. It
should be disabled so that it can be reactivated later.
11.136.1 Machine cycle
The time duration between closures of the primary contact inputs. The elapsed time is
measured and identified as cycle time. Window displays are normally updated at least once
per machine cycle.
11.136.2 Machine index
This field is the index of the machine on a DCM. On multiple machine DCMs, this number
may be as high as 16. For example, a DCM-4 has indices 1 through 4. A single machine
DCM (DCM-1) has an index of 1.
11.136.3 Machine parameter
Refers to a collection of parameters which define how to monitor performance and
progress for a job on a specific machine. Examples of machine parameters are standard
cycle, down threshold, and refeed runners.
11.136.4 Machine running state
Fast, slow or standard running state.
11.136.5 Machine state
The status of how a machine is performing. See the exception state definition for more
complete details.
11.136.6 Machine state colors
All monitoring windows display the state of a machine by color. On machine-specific
windows, the background color of the window represents the machine state. Monitoring
windows which list multiple machines displays the machine state for each machine by the
color of the name’s background. On DCMs, the colored lights represent the machine states.
A machine's state is determined by a set of exception flags. Each flag indicates one possible
exception condition. The following table lists each machine state and its associated color. The
highest priority state determines the color displayed. The states are listed below in order of
priority, with the highest of importance listed first.
 Glossary 307

A machine can be in one or more states at a time. It can have a process or production
exception and be in the assist state. Process and production exception states can also co-
exist on the same machine at the same time. The following list provides a general overview of
machine states and their relationships to each other.
· The off-line state is mutually exclusive from all other machine states.
· If a machine is idle, all other states, except off-line, are excluded.
· If a machine is down, it can still be in assist or have a process and/or production
exception.
· A machine can be fast, slow, standard, or down.

Other combinations not specifically mentioned above are possible.

There are many ways that machines can enter or exit a certain state. Selection of an assist
reason by an operator at a DCM triggers the respective state for the selected machine.
Process exceptions occur when a process variable measurement is outside of an assigned
limit, either high or low. A machine can go in or out of a process exception state with each
new cycle value.

Production exceptions occur when a machine's “pieces to go” is negative (too many pieces
have been made) or when its job-to-date percent rejects is greater than its reject threshold for
the current job. Once these two relationships are no longer true, a machine exits the
production exception state.

There are two ways a machine can enter an idle state. A machine becomes idle if it is
following a shift schedule that has an idle period defined. For the duration of the idle period,
the machine is classified as idle. The second way a machine can become idle is by
suspending its job. To suspend a job, set the job parameters Schedule Now and Schedule
Factory both to No. The idle state stays in effect until these job parameters are changed.
The down state is entered when the average cycle time exceeds the down threshold. The
down state ends when the average cycle time is once again less than the down threshold.
The down state can also be entered if the operator selects a down reason which is
configured to force a machine down.

The fast, slow, and standard machine states are basic indicators of machine performance.
For each machine cycle, the cycle tolerance is monitored. The tolerance is the percent
deviation of a job from its normal standard cycle time. An average cycle is computed and a
comparison is made using the cycle tolerance and standard cycle values. If the average
308 SYSCON-PlantStar Help System

cycle is greater than the resultant value, the machine is considered to be running slow. If the
average cycle is less than the resultant value, the machine is considered fast.
Moving Average Cycle
The moving average cycle is compared to the standard cycle to determine the fast state/slow
state of a machine.
The machine is slow if:

(Average Cycle) > (Standard Cycle) + ((Cycle Tolerance) * (Standard Cycle) /1 00)

The machine is fast if:

(Average Cycle) < (Standard Cycle) - ((Cycle Tolerance) * (Standard Cycle) /1 00)
The "Your System" Icon

When your system is iconized, the icon displays on the bottom of the workstation
monitor. The top three circles signal exception states for any machine listed on an open
window. For example, if you open the Machine Performance window and then iconize your
system, the icon blinks if one of the machines displayed on the window goes into exception.
Exceptions displayed from the icon are down, assist, production exception, and process
exception.
11.136.7 Machine usage
A percentage indicator of how much the machine was up during the given time period. This
statistic is calculated for an entire job or a single shift.
Machine Usage = (Up Time) / (Up Time + Down Time + Idle Time)
11.137 Maintenance job
A non-production job which has the job parameters with pieces required = 0 and its standard
rate = 0. The standard setup time for the job is used to define the duration of the
maintenance job. The "Setup" down reason (reason #2) should be selected on the DCM for
the entire duration of the job so that actual setup time can be measured and compared to
standard setup time.

For maintenance jobs, estimated completion time is equal to the actual setup time remaining.
11.138 Manning factor
Manning Factors are a numeric representation of man hours required per shift, for a
selected job. Manning Factors can be added to product standards, work orders, queued
jobs or currently running jobs. The manning factors assigned to jobs are used in the
Labor Forecasting window to generate the labor requirements, by shift, for each labor
category.
11.139 Material component
Parameter which indicates the name of a raw material. All material components must be
assigned a component percent. Lot IDs can be assigned to material components at the
DCM. A material name can be up to 20 characters in length.
11.139.1 Material formula
The material components that make up a particular material. Material formulas may contain
 Glossary 309

from 1 to 4 components.
11.139.2 Material lot history size
DCM parameter which sets the number of material lot history records which should be stored
locally at the DCM. All DCMs have the capability for local data storage. This capability allows
the DCM to hold data while the host computer is either down or busy -- minimizing data loss.
It is recommended that around three days of history be stored locally.
11.139.3 Material lot ID
A user or vendor-defined identification number that uniquely specifies a raw material lot.
Lot IDs are entered at the DCM through a bar code reader or the touch screen. The Lot ID
is an alpha-numeric string of up to 20 characters.
11.139.4 Material name
Parameter which indicates the name of a single material or a material formula. If your
system's multiple material option has been purchased, up to four raw material components
can be attached to a material formula. All material components must be assigned a
component percent. Material names can be up to 20 characters in length.
11.139.5 Material required
The estimated weight of a material component necessary to meet the production targets for a
job. There are three primary formulas for calculating the amount of material required. The
formulas are dependent upon whether runners and/or scrap are being re-fed for a job.

· Whenever runners are being re-fed, then the amount of material required is
based upon the number of pieces remaining.
· If scrap is being re-fed but not runners, then calculations are based upon the
number of pieces remaining plus estimated rejects and the amount of excess
weight per actual shot size.
· If neither runner nor scrap is being re-fed, then the amount of material required is based
upon the number of shots remaining plus estimated rejects.
All calculations take into consideration actual reject percents if a job is current and more
than 5% complete. There is one exception to this rule, however. If both runners and scrap
are being re-fed, reject information is not applicable.
11.139.6 Material used
The amount of a material component, in weight, which has been used by the current job. If
runners and scrap are re-fed on a job, the amount of material used is based upon net pieces.
If only runners are re-fed on a job, then the amount of material used is based upon gross
pieces. If neither is being re-fed, then shot size is taken into consideration.
11.140 Max assist time
The maximum amount of time available for a specific machine, job, shift and
material lot.

Max Assist Time = Up Time + Down Time + Idle Time

11.141 Max cycle time

The Max Cycle Time field is primarily used with Duration and Cycle Time process variables. It
sets the maximum time of a machine cycle. It also sets the level of accuracy for cycle time
values up to one hundredth of a second. For example, 3276.5 seconds means that the
310 SYSCON-PlantStar Help System

maximum time for a machine cycle can be up to 3276.5 seconds and that cycle time values
should be recorded up to an accuracy of one tenth of a second.
Note: The higher the maximum cycle time, the lower the level of accuracy. A maximum time
of 3276.5 seconds sets the level of accuracy to one tenth of a second. A maximum time of
327.65 sets the level of accuracy to one hundredth of a second.
11.142 Maximum family size
Specifies the maximum number of child jobs that a machine, defined for this DCM, may
have for any one job.

The range is from 1 to 12 child jobs.

11.143 Memory
The amount of memory installed in the DCM. The range of values varies with the particular
model type of the DCM.
11.144 Memory area
Current memory control area; For RKC F900 sources, set the memory area to K0.
11.145 Memory required
Displays of the estimated memory required by the DCM with the selected options. If this value
appears in yellow then the estimated memory exceeds the available memory and
unpredictable results may occur. This should be used as a guideline.
11.146 Module address
The module address containing process variable data. Each module must have an address
assigned to it. Addresses are assigned by jumpering of Terminals 50 through 53 on the
module terminal block and by grouping the modules according to function and then
assigning consecutive addresses within each function group. Refer to the Maco-800 Module
Installation and Wiring Procedures manual for valid module addresses. The parameter type
field also offers possible module address data values.
11.147 Monitor number
The monitor number refers to the “subject” to be monitored for the Toyo source type. Refer
to the Toyo Table of Monitor Data to select the desired monitoring subject. Type in the
number next to the appropriate description.
11.148 Moving average cycle
The moving average cycle is compared to the standard cycle to determine the fast state/slow
state of a machine.
The machine is slow if:

(Average Cycle) > (Standard Cycle) + ((Cycle Tolerance)*(Standard Cycle) / 100)

The machine is fast if:

(Average Cycle) < (Standard Cycle) - ((Cycle Tolerance)*(Standard Cycle) / 100)
11.149 Multiple login
When set to 'yes' this setting allows an employee to login onto more than one machine at a
time.
11.150 Net parts counting
 Glossary 311

An alternate method of counting parts produced on a machine. Using this method, all parts
produced are considered rejects and will be placed in reject reason #2. When a quantity of
parts are known to be good then a signal is sent to move the net parts multiplier quantity of
parts, as defined in the job parameters, from reject reason #2 to finished parts. Note that the
terms "net pieces" and "Net Parts" are used interchangeably.
11.151 Net parts multiplier
Job parameter which indicates the number of good (net) parts to be counted each time the
net parts input contact is closed. If you are not using net parts counting, leave the value at
zero (0). The range is 0 to 99999. If a value other than 0 is entered then all parts made will
be put in reject reason #2. (See net parts counting for a full explanation)
11.152 Net pieces
The number of good pieces that have been produced on a job. Net Pieces is displayed in a
variety of forms -- for an entire job, for a single shift, or totaled for all machines on a single
shift. When Net Pieces is displayed for an entire job, the current, incomplete shift is included.
The standard method for calculating net pieces is:
Net Pieces = (Gross Pieces) - (Total Rejects)

See net parts counting for an alternate method.

11.153 No access privilege

If the No Access box is checked, a user may not do whatever is listed under the Privilege
List in that row. For example, if the no access column is checked for the Change Work
Order Data privilege, the user will not see the Work Orders window under the Schedule
menu within the Monitor program. Specifically, no access on the following privileges means

· Schedule Jobs and Shifts - User will not see the Job Schedule or Shift Schedule
window within the Monitor program.
· Change Down/Assist/Reject Data - User will not see the Down Time Editor,
Assist Time Editor and Parts Count Editor windows within the Monitor program.
· Configure The Shop Floor - User will not have the Sets, Group, and Shop Floor
menus available for use within the Shop Floor Configuration program.
· Clear Process Trend Data - The Clear button on the Process Trend/SPC window
is disabled within the Monitor program.
· Change Product Standards Data - User does not have the Product Standards
window in the Monitor program.
· Change Work Order Data Privilege - User does not have the Work Order window
within the Monitor program.
11.154 Non-family job
A job that has no child jobs associated with it.
11.155 Offline state
A machine is considered offline when its associated DCM is no longer in communication with
the PlantStar host computer. This does not mean that data is not being collected, unless the
DCM itself has lost power. It could be a result of network issues between the host and the
DCM.
11.156 One RIO for all machines
312 SYSCON-PlantStar Help System

When checked this DCM has one RIO configured and it will communicate with each
machine. When unchecked this DCM has a single RIO configured for each machine.
11.157 Operator efficiency
A percentage indicator of how many good versus rejected parts a selected employee is
producing. This statistic is calculated for a single shift.

The formula is:

(Net Pieces / Gross Pieces) * 100

For current shift calculations, the total part count for the employee is unknown, so
"Current Shift" is displayed instead of a percentage.
11.158 Operator start options
Specifies what if any job in the job queue the operator may start. The settings are none, any
job in the queue, idle job only, any job in the queue and idle job.
11.159 Operator utilization
A percentage indicator of how many hours a selected employee was logged into the
machine versus the total number of hours for a shift. This statistic is calculated for a single
shift.

The formula is:

(hours worked / shift length) * 100

For current shift calculations, the hours worked for the selected employee is unknown, so
"Current Shift" is displayed instead of a percentage.
11.160 Ordered histogram
A histogram is a way of summarizing data that are measured on an interval scale (either
discrete or continuous). In an Ordered Histogram, bars are displayed from left to right in
descending order, in effect highlighting the main points.
11.161 Other status
Any machine state information other than down, assist, process exception or production
exception. An example is a machine in an off-line state.
11.162 Overrun
A machine is in an overrun state whenever the current job's "pieces to go" is negative (i.e.
net pieces are greater than pieces required).
11.163 Parameter number
This field refers to the item to be monitored; For Netstal sources, refer to the item number in
the Table of PLC Interfaces. For MACO 8000 sources, refer to the Host Communications
Protocol manual provided with the MACO 8000 controller documentation from Barber-
Coleman.
11.164 Parameter type
The parameter type for the Maco-8000 source. The following list of data items is provided
courtesy of PlantStar. There are other data values you may want. These will have to be
researched in the Host Communications Protocol manual provided with the MACO 8000
 Glossary 313

controller documentation from Barber-Coleman:

module param param decimal

Variable address type descriptor number places
Nozzle Temp 17 0 0 0 0
Front Temp 17 0 0 1 0
Center Temp 17 0 0 2 0
Rear Temp 17 0 0 3 0
Cycle Time 01 7 0 23 2

11.165 Part weight

Job parameter defining the weight of the material required to produce 1 piece of a product.
The range is 0.000 to 999999.999 units.
11.166 Parts per minute
The average number of net pieces (good pieces) produced per minute. The rate can be
calculated over a single shift or an entire job.

Parts per Minute = ((Net Pieces) / (Up Time)) / 60

11.167 Percent down
Percentage of machines in a display group that are down.
11.168 Percent process exception
Percentage of machines in a display group with a process variable exception.
11.169 Percent production exception
Percentage of machines in a display group with a production exception.
11.170 Percent rejects
Percentage indicator of how many pieces have been rejected across all reasons. This
value is calculated for an entire job, a single shift, or all machines on a single shift. When
calculated for an entire job, the current, incomplete shift is included. The formula is:
((Total Rejects) / (Gross Pieces)) * 100
11.171 Percent slow cycles
Indicates the number of slow cycles as a percentage of total cycles. This value is
calculated for the current shift as:

Percent Slow Cycles = ((Slow Cycles) / (Total Cycles)) * 100

11.172 Percent variance
Amount of random variance that is desired in a simulated signal as a percentage of the
original signal value. The range is 0 to 100 percent.
11 .173 Pieces required
Job parameter which defines the total number of good pieces required to complete a job. The
range is 0 to 999999999. A value of 0 would normally be used only for a maintenance job.
11.174 Pieces to go
314 SYSCON-PlantStar Help System

Pieces still required for the job to meet its production target.

This value is calculated as:

Pieces To Go = (pieces required) - (net pieces)

A production exception is triggered when "pieces to go" becomes negative.

11.175 PLC
Progammable Logic Controller – This refers to the particular machine controller that the
DCM will communicate with.
11.176 Polarity
The type of setpoint -- unipolar or bipolar; Unipolar values have a range from (0000H) to
(FFFFH) or (0 to 65535) decimal. Bipolar values have a range from (8001 H) to (7FFFH) or (-
32767 to 32767). Refer to the MACO 4000 RS-232 Digital Communications Instruction
Manual for further information.
11.177 Port number
The DCM communications port to use for monitoring a serial process variable. For simulated
source types, select an unused port number from the selection list. For Engels, it refers to
the communications port (on the DCM) where the serial link is connected. For RKC F900
sources, the port number should typically be set to 1. Port 0 (Zero) only works with Ethernet
DCMs.
11.178 Post-down delay
Amount of time to wait before designating unassigned down time to Down Reason #1.
The delay period can be from 0-30 minutes.
When a machine enters a down state, down time is accrued under the down reason selected
by an operator. At times, a machine enters a down state and no down reason is specified. If
no down reason is specified and the machine exits the down state, an operator has the
length of the post-down delay period to assign a reason. If the post-down delay period
expires and still no down reason has been specified, all accrued down time is allocated to
Down Reason #1. For example, a machine's post-down delay period is set to 5 minutes.
While running a job, the machine enters a down state. No reason is given. The machine then
exits the down state. An operator has 5 minutes from the time the machine started running
normally to designate a down reason for the "unassigned" down time. If the delay is set to
zero (0) and an operator does not select a specific reason, down time is automatically
accrued under Down Reason #1.
11.179 Primary contact
The contact used to measure cycle time. A primary contact is required for each
machine being monitored.
11.180 Primary internet path
This is the symbolic name (exactly as it appears in the hosts file) or the Internet address (in
dot notation) of the Communications Processor or the RTL based DCM. Examples include
CP3 or 128.0.1.3 This path name can be up to 20 characters in length.
11.181 Print reports privilege
 Glossary 315

This privilege grants users the ability to print shift-to-date, job-to-date, end-of-shift, end-
of-job, and shop configuration reports via the PlantStar Reports program.
11.182 Process trend privilege
This privilege grants users the ability to clear historical process variable data from the
Process Trend /SPC window within the PlantStar Monitor program.
11.183 Process variable
Each machine has a set of process variables and profiles. A process variable is a physically,
measurable quantity or characteristic that is collected by a DCM. Most process variables are
collected once during each machine cycle. Examples of cyclic process variables are
temperatures, pressures, time durations, and PLC readings. Some process variables are not
directly related to machine cycles. Examples of non-cyclic process variables are manually
operated scales and gauges. Process variable names can be up to 20 characters in length.
There are several categories of process variables. A process variable's type is
determined by the source of its input signal:

· Cycle Time - Obtained through the primary contact input. Cycle time is the
time between consecutive closures of this input. This is always the first
process variable.

· Analog Channel - Obtained by reading one of the analog channels within a DCM.
The applied signal may originate from a pressure transducer, linear potentiometer
or another linear device.
· Duration - Obtained through an additional contact input. A duration variable measures
the length of time that a contact input was closed. One example is hold time.
· Serial Communication - Obtained through a serial communications link with the
machine's controller. This type of process variable requires a specific software driver.
An example is an Engel PLC.
· Pseudo - Obtained by reviewing a profile. This may be the maximum, the time that
the maximum occurred, the minimum, the time that the minimum occurred, the range
(max - min), or the average of the selected profile. Examples include peak pressure,
peak time, stroke, and cushion.

· Thermocouple - Obtained by reading an analog channel where a J or K thermocouple

is connected. This is used in temperature measurements.

A profile is a rapidly changing process variable, such as pressure or position. For a profile, a
machine's DCM collects a set of up to 500 points per machine cycle. Profiles are mostly
collected from analog transducers. Some PLC's are capable of collecting and transmitting a
profile.
11 .183.1 Process exception
Indicates that a process variable measurement is outside of the assigned limits, either high or
low.
11.183.2 Process exception state colors
This button's image will change to indicate that a process variable measurement is
outside of the assigned limits, either high or low.
316 SYSCON-PlantStar Help System

The various states are described below. Pressing this button, regardless of the current
state, will display the Process Summary page in the main frame of the browser screen.

Normal: All of the machine's process variable measurements are within the assigned limits.

Process exception: At least one of the process variable measurements is outside of the
assigned limits, either high or low.
11.183.3 Process index
A number used to show the number of process variables in exception. The index
column has no connection with the defined index of a process variable.
11.183.4 Process log
Indicates the type of process variables to be included on the Machine Log window within the
Monitor program and on DCM Log screens. Three options exist -- All, Critical or None. The
All option reports all process variables for a machine. The Critical option displays only those
process variables marked as critical. The None option turns off the reporting of process
alarms.
11.183.5 Process variable parameter
An optional job parameter that defines the limits for a process variable. This includes the low
and high limits, and a trigger delay. The trigger delay will override the default value that was
entered in the Machine Setup Window.
11.184 Product
Job parameter which identifies the product to be manufactured. This parameter can be
up to 30 characters in length.
11.184.1 Product parameter
Refers to a collection of parameters which define how to identify and monitor performance/
progress of a specific product. Examples of product parameters are material, part weight,
standard shot weight, and standard rate factor.
11.184.2 Product key
Selects existing product standards based upon the entered product name. Partial or
complete searches can be done.
NOTE: As of PlantStar v4.10, this search no longer requires the key fields to match the
case of the expected result. In other words, the search is no longer case sensitive.
11.185 Product standard
A template of parameters which is copied into a work order. A product standard is
made up of product-specific parameters and machine-specific parameters.
 Glossary 317

11.186 Product standard privilege

This privilege enables users to create, delete, and edit product standards.
11.187 Production data
All data collected by the PlantStar system during a particular job and/or shift.
11.188 Production efficiency
A percentage indicator of how well the machine is performing. This statistic is calculated for
an entire job or a single shift.
The formula is:
(((Net Pieces) / (Standard Rate)) * ((Up Time) + (Down Time))) * 100

For job-to-date calculations the current, incomplete shift is included.

11 .189 Production exception

A machine is in the production exception state whenever one or more of the following is
true:
· Pieces to go is negative (more pieces have been made than were required);
· Job-to-date Percent Rejects > Reject Threshold.
11.189.1 Production exception state colors
This button's image will change to indicate that a machine is in the production exception
state.
The various states are described below. Pressing this button, regardless of the current
state, will display the Production Summary page in the main frame of the browser
screen.

Normal: The job still has pieces to make and the reject level is within the specified threshold
limit.

Production Exception: A job is in production overrun when Pieces To Go is negative (more

pieces have been made than required).
A job is in reject exception because Job-to-date percent rejects exceeds the reject threshold.
11.190 Production performance
Percentage indicator of how close a machine is running to its standard rate of
production.
Production Performance = ((Actual Rate) / (Standard Rate)) * 100
318 SYSCON-PlantStar Help System

Performance is considered standard when this value is 100%.

11.191 Production time
Total scheduled runtime that has elapsed for a job. This value is calculated for an entire job
or a single shift. The formula is:

Production Time = (Up time) + (Down Time)

Format is hhhh:mm.

11.192 Profile
Rapidly changing process variable, such as pressure or position, for which the DCM
collects a set of up to 500 points on each machine cycle. The profile name can be up to 20
characters in length.
11.192.1 Profile parameter
An optional job parameter that defines the limits for a profile. This includes a trigger delay
and duration. The trigger delay and duration set in the job editor overrides the default
values that were entered in the Machine Setup Window.
11.192.2 Pseudo end
A pseudo variable can be defined for an entire machine cycle or a segment of a cycle. The
end field indicates the event which, after the trigger delay elapses, terminates the collection
of a profile. The event can be a profile value, duration, trigger event, or the end of the
profile itself (i.e. the end of the cycle).
11.192.3 Pseudo start
A pseudo variable can be defined for an entire machine cycle or a segment of a cycle. The
start field indicates the event which, after a trigger delay elapses, starts the collection of a
profile. The event can be a profile value, trigger event, or the start of the profile itself (i.e. the
start of the machine cycle).
11.192.4 Pseudo variable
A process variable that draws its values from the analysis of a profile. The following pseudo
variables are available:
· Max Value
· Time of Max Value
· Min Value
· Time of Min Value
· Value Range
· Average Value
· Mean Value
· Area
11.193 PVAR History
Process variable history data is data collected for a particular process variable and stored for
analysis.
11.194 Queued job
The job that is scheduled but not currently running on a machine. The current job is the
job that is currently running.
 Glossary 319

11.195 RAM size

DCM parameter which describes the amount of volatile memory in the DCM. The size must
match the amount of RAM physically installed in the unit.
11.196 Range
The difference between the highest and lowest values within the subgroups that are currently
displayed on a window's graph.
11.196.1 Range control limits
Blue dashed lines which mark the extent of range variation in the process variable displayed.
The extent of variation is based upon the amount that could be expected if only common
causes of variation were present. Control limits are based upon actual process variation in
terms of the range of subgroups that are currently displayed on a window's graph.
11.196.2 Range max
The highest value which represents the difference between the maximum and minimum
values in a sample. In your system, the Range Max is calculated over the range of
subgroups that are currently displayed on a window's graph for a specific process variable.
11.196.3 Range mean
The average of all ranges over a set of subgroups. In your system, the Range Mean is
calculated over the range of subgroups that are currently displayed on a window's graph.
11.196.4 Range min
The lowest value which represents the difference between the maximum and minimum
values in a sample. In your system, the Range Min is calculated over the range of
subgroups that are currently displayed on a window's graph for a specific process variable.
11.197 Real-time
Processing and displaying real world events in a continuous and timely fashion.
11.198 Reason set
Down reasons, assist reasons and reject reasons are attached to machines from reason sets.
A reason set is a group of up to 160 down, 160 reject, or 20 assist reasons that are grouped
together and assigned as a unit to a machine or to several different machines. Note that a
single reason set contains only one category type of reason (down, assist or reject).
Certain down and reject reasons have special meanings attached to them:

· Down Reason One - The first reason is the default down reason. Time is accrued to
this reason when a machine is down and the operator has not selected a specific
reason. A post-down delay period can be set, though, from the Machine Setup window
that delays the accruing of "unspecified" down time to Down Reason #1.

· Down Reason Two - The second down reason clocks actual setup time. PlantStar
compares this time with a job's standard setup time.

· Reject Reason Two - PlantStar uses the second reject reason to accumulate
the difference between gross pieces and net pieces when Net Parts Counting is
in effect.

The various reasons which are defined may later be selected by an operator at a
DCM or by automated equipment using contact inputs to a DCM.
320 SYSCON-PlantStar Help System

11.199 Re-feed runners

Machine-based parameter which indicates whether all runners produced by a job are re-
ground and re- fed at the machine. "Yes" specifies that all runners are reused immediately at
the machine. "No" specifies that runners produced on a job are not re-fed at the machine for
a job.
11.200 Re-feed scrap
Machine-based parameter which indicates whether rejected pieces produced by a job are
re-ground and re-fed at the machine. "Yes" specifies that all rejects are reused
immediately at the machine. "No" specifies that rejects produced on a job are not re-fed at
the machine for a current job.
11.201 Register number
The register number of a Square D source type's Circuit Monitor. Circuit Monitors (CM) have
two types of registers -- Read-only registers and Write/Read registers. Read-only registers
contain values calculated on raw data sampled by CMs. Write/Read registers contain user-
defined parameters that are downloaded or changed from a host. Refer to the Square D
PowerLogic Circuit Monitor manual for register numbers.
11.202 Reject reason
Specific reject reason against which the system charges operator entries. Reason names can
be up to 20 characters in length. On keypad DCMs, only the first 9 characters are displayed.
On EL DCMs, the first 7 characters are displayed. On browser based DCMs the first 10
characters are displayed.
11.202.1 Reject count
The number of total rejects for a shift or job.
11.202.2 Reject exception
A machine state in which the number of rejects as a percentage of total pieces exceeds
the reject threshold percentage for the current job.
11.202.3 Reject multiplier
Product parameter which defines the number of pieces added to the reject count whenever
a remote reject contact input is closed for a job. Remote rejects are assigned to specific
reasons based upon the digital equation set. The range is 1 to 9999.
11.202.4 Reject percent
Percentage indicator of how many pieces have been rejected across all reasons. This
value is calculated for an entire job, a single shift, or all machines on a single shift. When
calculated for an entire job, the current, incomplete shift is included. The formula is:

((Total Rejects) / (Gross Pieces)) * 100

11.202.5 Reject threshold
Product-based parameter which sets the maximum acceptable reject percentage for a job.
A production exception is triggered if job-to-date rejects exceeds this value. The range is
0.0 to 100.0 percent.
11.202.6 Reject state colors
This button's image will change depending upon whether the machine is in a production
exception state due to actual rejects exceeding the reject threshold as defined in the
cuurent job. Pressing this button, regardless of the current state, will display the Assist
 Glossary 321

Select page in the main frame of the browser screen.

The machine is not currently in the Production Exception state due to an excess of rejects.

The machine is currently in Production Exception due to an excess of rejects.

11.203 Required by
Job parameter which defines the date by which a job must meet its production target. The
format is mm/dd/yy. Dates up to the year 2050 are acceptable.
11.204 REU
An REU is a remote entry unit. This is an independent device which enables the entry of reject
counts, down time and assist time for up to sixteen (16) machines. As of version 4.10, this
feature is no longer supported as it has been replaced by the browser based DCMs.
11 .205 RIO
Remote Input/Output device. This device is used to collect analog data from a machine.
11.206 Running state
This reflects the current state of the machine. If the last cycle of the machine is within
the cycle tolerance the running state will be normal
11.206.1 Running state colors
This button's image will change depending upon the current running status of the machine.
The various states are described below. Pressing this button, regardless of the current state,
will display the Job Summary page in the main frame of the browser screen.

Normal: The machine is cycling within the standards defined by the job.

Fast: The machine is running faster than the standards defined by the job.
322 SYSCON-PlantStar Help System

Slow: The machine is running slower than the standards defined by the job.

Idle: The machine is currently set to be in the idle state.

Blank: The machine is currently in the down state and therfore has no running status.
11 .207 Scale factor
Multiplier used to convert analog and serial inputs into engineering units. Bias and scale
are used in the following formula to convert transducer output voltage to engineering units:
Value = (Voltage * Scale) + Bias

To compute the scale factor, use the following formula:

Scale = (High Value - Low Value) / (High Voltage - Low Voltage)

where voltage must be in the range of 0 to 10.

This field requires an input value significant to three decimal places. Values can be positive
or negative. For Netstal source types, the scale factor for the desired Parameter Number and
Convert Index must be obtained from Netstal's PLC Interface Table. For simulated sources,
the scale factor is applied to the simulated signal. For Engels, the scale factor is applied to
the received value.
11.208 Schedule factory
The schedule now and schedule factory parameters work in conjunction. The
following table represents the possible combinations of values and the effect they
have on the job when it is scheduled to run.
 Glossary 323

Schedule Now Schedule Factory Result

No No The job is set to idle.
No Yes The job runs according to the shift schedule.
The job ignores the shift schedule and 24-hour
Yes No
production is assumed.
The job runs according to the shift schedule.
Yes Yes (Schedule now is ignored)

11.209 Schedule jobs and shifts privilege

This privilege grants users the ability to schedule jobs via the Job Schedule window and to
create shift schedules via the Shift Schedule window.
11.210 Schedule now
The schedule now and schedule factory parameters work in conjunction. The
following table represents the possible combinations of values and the effect they
have on the job when it is scheduled to run.

Schedule Now Schedule Factory Result

No No The job is set to idle.
No Yes The job runs according to the shift schedule.
The job ignores the shift schedule and 24-hour
Yes No
production is assumed.
The job runs according to the shift schedule.
Yes Yes
(Schedule now is ignored)

11.211 Schedule reports privilege

This privilege grants users the ability to schedule end-of-shift and end-of-job reports via the
PlantStar Reports program. If scheduled, these reports print automatically at the user-
designated time.
11.212 Schedule selected job by due date
This button changes the scheduling method of a highlighted job between the earliest possible
start method and the due date method. Once a job is highlighted (clicking on the job
highlights it and turns its job rectangle yellow), use this button to switch the job between the
two scheduling methods. The right click button on the mouse may be substituted for clicking
the button (i.e. it provides the same function).

NOTE: This button only works when the button is selected at the same time. Also, in
order to schedule a job by due date, the job must start to the right of the scheduling marker.
324 SYSCON-PlantStar Help System

11.213 Scheduled idle time

The amount of idle time assigned within the Shift Schedule window, for a given date range.
11.214 Scheduled jobs
Work orders that have been assigned to the job queue of a specific machine. Scheduled
jobs wait in the job queue until they are started by the machine operator or from the monitor
job schedule board.
11.215 Scheduled machine usage
A percentage indicator of how much the machine was up during the given time period. This
statistic is calculated for an entire job or a single shift.

Scheduled Machine Usage is computed much like machine usage, except it ignores the
scheduled idle time during the given time period.

Scheduled Machine Usage = (Up Time) / (Scheduled Up Time)

11.216 Scheduled up time
The amount of up time assigned within the Shift Schedule window, for a given date range.
11.217 Set name
The name for the group of reasons. Up to 20 reasons can be in any given set. If the
extended down and reject option is enabled then the down and reject reasons can number
up to 160 with the up to 20 assist reasons. There is no limit to the number of sets.
11.218 Setup sheet
Setup sheet information can be added to product standards, work orders, queued jobs or
currently running jobs. Setup sheets can be printed in reports, viewed at a workstation, or
viewed at the DCM.
Setup sheets consist of two parts -- a general product portion and a specific machine
portion. For all jobs, the maximum number of characters allowed for instructions is 2600
combined, as both portions are sent to a DCM as a single instruction sheet.

A free form field is used for typing in information on the Setup Sheet window. On browser
based DCMs the setup sheet can contain HTML code and will be displayed as such. This
allows the insertion of hyperlinks and other html objects in the setup sheet.
11.219 Setup time
The length of time required to prepare the machine to run a particular job. This time is
ignored by the machine usage calculations.
Setup Time information can be added to product standards, work orders, queued
jobs or currently running jobs.
11.220 Shift
Shifts define the start and end times of work periods. Shifts can be defined within the Shift
Schedule window.
NOTE: Defining shifts within PlantStar is not required but it does provide the flexibility to
control part of the job process. If shifts are not defined, all jobs are assumed, by PlantStar, to
run 24 hours a day 7 days a week.
11.220.1 Shift count
 Glossary 325

The number of shift records PlantStar should attempt to retrieve for the given selection
criteria.

NOTE: If the shift count exceeds the number of actual shift records, PlantStar will only return
the actual shift records found.
11.220.2 Shift history size
DCM parameter which sets the number of shift history records which should be stored locally
at the DCM. All DCMs have the capability for local data storage. This capability allows the
DCM to hold data while the host computer is either down or busy -- minimizing data loss. It is
recommended that at least three days of history be stored locally.
11.220.3 Shift ID
Name assigned to a daily shift. Each weekly shift schedule has 6 shifts available for
scheduling each day. The shift name can be up to four characters in length.
11.220.4 Shift idle period
The time scheduled, during a shift, when the machines are not scheduled to operate.
During an idle period, the DCM ignores all inputs from the machine. Only idle time will be
accumulated.
11.220.5 Shift length
The length of the shift is the total working hours in the shift, as setup in the Shift
Schedule window. Idle times scheduled during the shift, are not counted in the total
working hours.
11.220.6 Shift schedule
Shift schedules define the start and end times for work shifts, idle times for holidays or
weekends, and any other events when jobs should not be running or have special needs.
Shift schedules are not required but they do provide the flexibility to control part of the job
process. If shift schedules are not created, all jobs run all the time.
Shift schedules are created for a work center. Each work center has multiple schedules -
- one for each year desired. Each year’s schedule may have up to 12 different weekly
work schedules.
The Shift Schedule window is used to create, assign, delete and change work center
schedules.
11.220.7 Shift-to-date
The data available for a job from the time the current shift started to the present time.
11.221 Shop floor privilege
This privilege grants a user access to defining shop floor configuration parameters such as
machine definitions, DCMS, work centers, and down reasons. Specifically, all windows under
the Sets, Groups, and Shop Floor menus are affected.
11.222 Shot size
The weight of all materials used in a single cycle of the machine. This number should
include both parts and runners.
11 .223 Shuttle boot set
When selected the RIO's boot set will include the files necessary for use with a shuttle type
machine.
326 SYSCON-PlantStar Help System

11.224 Slow state

The fast, slow, and standard machine states are basic indicators of machine performance.
For each machine cycle, the cycle tolerance is monitored. The tolerance is the percent
deviation of a job from its normal standard cycle time. An average cycle is computed and a
comparison is made using the cycle tolerance and standard cycle values. If the average
cycle is greater than the resultant value, the machine is considered slow.
11.225 Source
This field defines the source of the data or analog signal.
To set the source:
· Click on the Edit Process field.
· Select the number of the desired process variable/profile via the Variable field.
· Position your cursor on the Source field. Choose from the selection list by clicking the
arrow to the right of the list. Slide your pointer down the list to the appropriate line.
Release your mouse button.
· Click on the Update button.
· Select the Save Session command under the File menu to send process variable
definitions to the shop floor.
11.226 SPC
Abbreviation for Statistical Process Control. There are two levels of SPC support. The basic
SPC option supports SPC collection by DCMs, Real-Time SPC alarms, and real-time SPC X-
Bar and Range Charts. The extended SPC option supports advanced SPC capability studies,
including normal, non-normal, and multi-variate analysis.
11.226.1 SPC alarms
SPC Alarm abbreviations (n = SPC History Size):
XCL - Last X-bar value not within control limits RCL - Last Range value not within control limits
INC - Last 8 X-bar values were continuously increasing DEC - Last 8 X-bar values were
continuously decreasing ABV - Last 8 X-bar values where above the mean.
BLW - Last 8 X-bar values were below the mean. UTR - Last n X-bar values show an
upward trend.
DTR - Last n X-bar values show a downward trend.
RSM - Within the last n X-bar values, a RUNSUM exceeded 4.
11.226.2 SPC Graph Area
The window displays a line chart of the SPC values collected for a specific process variable.
It includes two graphs. The top graph is a plot of X-bar values and the bottom is a plot of the
associated range values. The X-axis is the time at which the SPC values were recorded. The
number of values graphed may be a subset of the total collected.
To view the maximum value for a graph, click anywhere on the far right-hand side of the
window, outside of the graph borders but within the top and bottom lines of the desired
graph. To view the minimum value of a graph, click anywhere on the far left-hand side of
the graph, outside of the graph borders. To view actual values, click in the middle of the
graph area.
11.226.3 SPC history size
 Glossary 327

DCM parameter which defines the number of SPC samples to be stored locally at the DCM.
11.226.4 SPC interval
Job parameter which defines the minimum time between SPC samples. Individual sample
intervals may be longer if enough valid process data has not been collected for a complete
SPC subgroup. The range is 0 to 500 minutes. A value of 0 disables SPC collection.
11.226.5 SPC subgroup
The number of data points collected during a specified length of time. This length is
defined in the SPC Interval. This value ranges from 0 to 8.
11.226.6 SPC subgroup size
Job parameter which defines the number of process data points required to make an SPC
sample. Because the statistical methods used in SPC do not support variable subgroup
size, this parameter cannot be changed once a job has been started. The range is 0 to 8.
A value of 0 disables SPC collection for the entire job.
11.227 Specification limits
The highest and lowest values accepted by Engineering Standards. In your system,
specification limits are equivalent to the high limits and lower limits for a job.
11.228 Standard completion time
The total amount of hours and minutes required to finish a job given the standard
production rate. Before 5% of the job is completed, standard completion time is
calculated as follows:
Standard Completion Time = Remaining Setup Time + ((Pieces To Go) / (Standard Rate))

After 5% of the pieces required have been made, the following formula is used:

Standard Completion Time = (Pieces To Go) / (Standard Rate)

For maintenance jobs, standard completion time is equal to the setup time remaining.
11.229 Standard cycle
Machine-based parameter defining the normal machine cycle time for a job. When a
machine is up, your system uses cycle tolerance and standard cycle to determine whether
the red (signifying slow cycles), green (signifying normal cycles), or yellow (signifying fast
cycles) performance light should be on. See Average Cycle for more details. The range is
0.5 to 3276.7 seconds.
11.230 Standard deviation
A measure of the spread of individual values around the mean of a sample or the average
amount of variation from one part to the next. In your system, the standard deviation is
calculated over the range of subgroups that are currently displayed on a window's graph.
11.231 Standard multiplier
Product parameter defining the maximum number of pieces produced per machine cycle for a
job. The value of the actual multiplier cannot exceed the value of the standard multiplier. The
range is 0 to 9999.
11.232 Standard production time
Calculation indicating the expected amount of time to produce the required number
328 SYSCON-PlantStar Help System

of pieces.
Standard Production Time = Pieces Required / Standard Rate
11.233 Standard rate
Calculation which defines the number of good pieces normally produced per hour. This value
reflects the expected long term average rate of gross production and rejects.
Standard Rate = ((Standard Rate Factor * Standard Multiplier) / Standard Cycle) * 3600
11.234 Standard rate factor
Product parameter indicating the ratio of good pieces expected to be produced per hour as
compared to the theoretical maximum for a job. The range is 0.0 to 100 percent.
11.235 Standard setup time
Machine-based parameter defining the expected time necessary for setting up a job to
run on a machine. Standard setup time is compared with actual setup time for
reporting purposes. This parameter is displayed as hours and minutes (hhh:mm). The
range is 0:00 to 500:00.
11.236 Standard shot weight
Machine-based parameter which indicates the total amount of plastic used to fill a single shot
for a job. The range is from 0.000 to 999999.9.
11.237 Start date
Precise date at which the system started monitoring the task selected. Start date is
formatted as dd/mmm/yy.
11.238 Start time
Precise time at which the system started monitoring the task selected. Start time is
formatted as dd/mmm/yy hh:mm.
11.239 Suspend
The current job may be suspended when another job is started. The suspended job becomes
a work order and the remaining pieces to go for the job becomes the pieces required for the
work order. A job that is in overrun may not be suspended as the pieces required are
negative.
11.240 Switch code
To allow a BetaMux to send DCM information for more than one process variable. A selector
switch must be connected to the DCM's contact inputs. The selector switch must be a binary
coded switch. This type of switch will have five connections. Four of the five contacts should
be marked 1, 2, 4 and 8. The fifth is a common. The following is an example of how to
connect a selector switch to the contact inputs.
Selector Switch DCM
Switch #1 IN5+
Switch #2 IN6+
Switch #4 IN7+
Switch #8 IN8+
Common IN5-
The selector switch contacts #1, 2, 4 and 8 must connect to four consecutive contact inputs.
11.241 System icon
 Glossary 329

When the PlantStar system is minimized, the icon displays on the bottom of the
workstation monitor. The top three circles signal exception states for any machine listed on an
open window. For example, if you open the Machine Performance window and then minimize
the program, the icon blinks if one of the machines displayed on the window goes into
exception. Exceptions displayed from the icon are down, assist, production exception, and
process exception.
Moving from left to right, each circle represents the following when blinking:

· First Circle (Flashes Magenta) - Production Exception or Process Exception

· Second Circle (Flashes Blue) - Down State
· Third Circle (Flashes Yellow) - Assist State
11.242 Tool
Job parameter which identifies the molding tool to be used. This parameter can be up to 20
characters in length.
11.243 Total cycles
Total number of machine cycles counted by a DCM over the job or shift. This includes both
up cycles and down cycles.
11.244 Total rejects
The total number of pieces rejected on a machine, regardless of reason. This value is
displayed for an entire job, a single shift, or all machines on a single shift. When displayed for
an entire job, the current, incomplete shift is included.
11.245 Tote box
A tote box is a set number of parts that are traceable as a unit.
11.245.1 Tote box size
Product-based parameter defining the number of pieces in a tote box. This field
provides two capabilities:
· When a job's tote count is equal to the tote size, tote label printing can be generated.
· A DCM can be configured to generate a contact output each time a job's tote size
number of pieces has been made. To disable this capability (i.e. disable the contact
output), set the tote box size to 0.
This field's range is 0 to 99999.
11.245.2 Tote end time
The time of day when a job's tote box count became equal to its tote box size or when an
operator pressed the tote change button at the DCM.
11.245.3 Tote history size
DCM parameter which sets the number of tote history records which should be stored locally
at the DCM. All DCMs have the capability for local data storage. This capability allows the
DCM to hold data while the host computer is either down or busy -- minimizing data loss. It is
recommended that about three days of history be stored locally.
11.245.4 Tote ID
An identification number that is assigned to a tote box. Once a tote box is full, ie. a job's tote
count is equal to its tote box size; a new ID is assigned for the next tote box. An operator
pressing the tote change button at the DCM also triggers the creation of a new Tote ID for
330 SYSCON-PlantStar Help System

the next tote box.

Tote IDs are unique to a single machine and are automatically generated by your system.
They can be used for the tracking of material component lots to a specific tote box.
11.245.5 Tote pieces
The number of pieces in a tote. Each tote is identified by a unique tote id.
11.245.6 Tote reject
Product-based job parameter which indicates whether to subtract rejected pieces from a job's
current tote count. Both manually and automatically rejected parts will be subtracted. Valid
choices are 'Yes' or 'No'.
11.245.7 Tote start tim
The time of day when a tote box started to be filled.
11.246 Trigger delay
The amount of time to wait after the trigger event before collecting a process variable or
initiating the collection of a profile. The range is 0.0 to 999.9 seconds.
11.247 Trigger event
The event which, after trigger delay elapses, starts the collection of a process variable or
initiates the collection of a profile. The value can be the name of a digital equation or the
number of a contact input.
For analog channels, thermocouples, and simulated process variables, this field refers to
a contact which triggers the reading of a process variable. Up to 20 characters is
available.
11.248 Ty-Decimal
Upper and lower type codes. These codes identify specific values, setpoints, control relays,
or ASCII strings for MACO 4000 data transmission. The three left-most digits should be
selected from the following list and are defined as the Type Upper Byte:
OxH is a value
1XH is a Setpoint
2XH is a Control
Relay 4XH is an
ASCII string
The two right-most digits of this field are associated with the Type Lower Byte. Refer to
the MACO 4000 RS-232 Digital Communications Instruction Manual for valid choices.
11.249 Unassigned child jobs
A child job that has not been assigned to a family job.
Unassigned child jobs can be imported through the "Work Order Import" program or
created in the Work Orders window.

NOTE: These jobs must be assigned to a work order before they can be run on a machine.
11.250 Units
Name of the engineering units to which a process variable or profile variable has been
scaled. All duration variables are measured in seconds. Temperature is usually measured in
degrees F (DEG F), pressure in pounds per square inch (PSI), speed in centimeters per
minute (CPM), and flow in gallons per minute (GPM), to name a few examples.
 Glossary 331

11.251 Up cycles
Number of machine cycles counted while the machine is up (i.e. not down or idle).
11.252 Up time
The total number of hours a machine has been running (i.e. not down or idle).
11.253 Upper spec
The upper control limit assigned to a process variable. When this limit is exceeded the
machine will enter a process exception state.
11.254 User name
The name of a user that will be used as a login name for your system. A user name can be
up to 20 characters in length and can include characters or numbers.
11.255 Value
The exact point at which the collection of a pseudo variable is initiated or terminated.
11.256 Variable long name
Long text name of the process variable or profile being defined. This name can be up to 20
characters in length.
11.257 Variable short name
Short text name of the process variable or profile being defined. This name can be up to 8
characters in length. The short name is used on various graphs and on DCMs.
You can change the short name any time you wish just by typing over the current name in the
field.
11.258 View only privilege
If the View Only box is checked, a user can view but not edit any PlantStar window
associated with the activity of the privilege (the privilege located on the same row as the View
Only box). For example, if View Only privileges are granted for the Schedule Jobs and Shifts
privilege, a user may open the Job Schedule and Shift Schedule windows within the Monitor
program, but they may not edit anything.
11.259 Voice file name
A standard Windows wave form message file which contains an announcement
message. The file name is 8 characters in length with a .wav extension.
11.260 Weekly schedules list
The Weekly Schedules List identifies the weekly schedules that have been or can be
defined for a calendar year and work center. Each year schedule can have up to 12
different weekly work schedules. Each work schedule is color-coded to identify it on the
Calendar table. The 'none' work schedule is always listed first.
11.261 Weekly shift chart
When a weekly schedule is highlighted in the Weekly Schedules list, its running and idle
times are displayed in this area. Up to six work shifts can be defined. Their start times are
displayed in columns 1 through 6. The last four columns show two possible sets of idle
periods.
Times and shift titles are changeable. Times are on a 24 hour clock. Shift names can be
up to 4 characters in length.
332 SYSCON-PlantStar Help System

11.262 Weight per part

Job parameter defining the weight of the material required to produce 1 piece of a product.
The range is 0.000 to 999999.999 units.
11.263 Work center
User-defined groups of machines which share the same shift schedule. Since a machine
can only execute one shift schedule, it can only belong to one work center. Machines in the
same work center always appear together on the same End-of-Shift reports.
11.264 Work order
Work Orders are essentially jobs that have been defined but not yet scheduled. In order to
schedule jobs, you must first create a work order. A work order consists of a set of job
parameters. These parameters define the job. They include such things as the number of
pieces required and the standard rate at which the pieces will be produced.
11.265 Work order privilege
This privilege enables users to create, delete, and edit work orders.
11.266 X-axis
The horizontal axis of a graph.
11.267 X-axis Value
The X-axis Value appears at the bottom right and left hand corner of the Process/Trend
SPC window. The X-axis Value represents:

· The X-axis Value in the bottom left hand corner displays the time of the oldest
process or SPC value.
· The X-axis Value in the bottom right hand corner displays the time of the most
recent process or SPC value
11.268 X-bar
Blue dashed lines which mark the extent of average variation in the process variable
displayed. The extent of variation is based upon the amount that could be expected if only
common causes of variation were present. Control limits are based upon process variation in
terms of the range of subgroups that are currently displayed on a window's graph.
11.268.1 X-bar Control Limits
Blue dashed lines which mark the extent of average variation in the process variable
displayed. The extent of variation is based upon the amount that could be expected if only
common causes of variation were present. Control limits are based upon process variation in
terms of the range of subgroups that are currently displayed on a window's graph.
11.268.2 X-bar Max
The highest value of the mean values in a sample. In your system, the X-bar Max is
calculated over the range of subgroups that are currently displayed on a window's graph for
a specific process variable.
11.268.3 X-bar Mean
The average of the mean values in a sample. In your system, the mean is calculated only
over the range of subgroups that are currently displayed on a window's graph.
11.268.4 X-bar Min
The lowest value of the mean values in a sample. In your system, the X-bar Min is calculated
 Glossary 333

over the range of subgroups that are currently displayed on a window's graph for a specific
process variable.
11.269 Y-axis
The vertical axis of a graph.
SYSCON - PlantStar System
User's Guide

Part

XII
 Release Notes 339

12 Release Notes
For each major and minor release, PlantStar has release notes.
These release notes include:
· new features within the current version
· bug fixes
· known problems
·

**************************************************************************************************
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VERSION4.20
**************************************************************************************************
**************************************************************************************************
V4.20 Installation

PlantStar v4.20 can be installed as a new system or as an upgrade to

PlantStar v4.10 or later. Data compatibility with earlier systems requires
the host computer be upgraded to PlantStar v4. 10 prior to installation of
v4.20 as a maintenance release.
NOTE: For those users that have installed Windows 2000, or XP the
operating system login MUST be set to have administrative privileges in
order to install ANY PlantStar client programs. In addition, we have a
known issue in regards to .dll registration on some systems that require
the administrator account to run the client software and open all screens
at least once to insure proper .dll registration. This issue is under
investigation and a methodology is being prepared to eliminate this
inconvenience in the future.

V4.20 New Features

Browser - Process Journaling

This interface allows operators and shop floor people to record problems and corrective
actions.

DCM - Flash Drives

The RTL based data collection modules now come in a diskless version. This feature uses
flash memory cards instead of a hard drive.
DCM - Journaling File System

This new file system will automatically restore itself to its previous state in the event of an
uncontrolled shutdown.
340 SYSCON-PlantStar Help System

Host - E-mail

We have added a new feature to our host that allows us to send e-mails from any program
running on the server.
Host - Import/Export

We now provide multiple machine specific standards to be imported in any one import file.
Our end-of-shift export utility can now notify you of any machines that have failed to report
the end-of-shift event. Our export utility can now be set to perform an incremental export.
Automated Archiving -

The archiver program can be set-up to automatically store data over a given interval at a
specified time.
Labor Required Displayed on the Schedule Board -

The total labor hours required for a given shift can be displayed on the job schedule board.
This option can be enabled from the User Preferences screen in the Monitor program.

Maco 6000 Host Interface -

This protocol uses 485 based serial communications to collect process data direct from the
Maco 6000 controller.
International Support -

The date, currency, and decimal numeric fields used for input and display in all PlantStar
monitor screens and reports now use the locale settings that have been configured in
Windows control panel.
Crystal Reports v11.0 -

All PlantStar reports have been updated to the latest version of Crystal Reports.
Voice Program -

PlantStar's voice program has been modified to eliminate delays in making

announcements. Now when any event occurs that requires a voice announcement, the
response will be immediate.

V4.20 Bug Fixes

No bugs have been reported since the release of 4.10r11.

V4.20 Features No Longer Supported

As of 4.20 PlantStar will no longer support the os9 style M-CIMs. This
 Release Notes 341

includes EL/TS, keypads, and REU units. If you have these style units then
the hardware will need to be upgraded before 4.20 can be applied to your
system. Contact you sales representative for further information.

**************************************************************************************************
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V E R S I O N 4.10r11
**************************************************************************************************
**************************************************************************************************

V4.10r11 Installation

PlantStar v4.10r11 has been released as a minor revision to make feature

enhancements and bug fixes available to PlantStar customers.
The upgrade path is the same as v4.10 in that a customer must be
at v4.00 before upgrading to this version.
NOTE: For those users that have installed Windows NT, 2000, or XP the
operating system login MUST be set to have administrative privileges in
order to install ANY PlantStar client programs. In addition, we have a
known issue in regards to .dll registration on some systems that require the
administrator account to run the client software and open all screens at
least once to insure proper .dll registration. This issue is under
investigation and a methodology is being prepared to eliminate this
inconvenience in the future.

V4.10r11 New Features

Monitor - Job Schedule Board

The job schedule board's search functionality has been expanded to search on all of the
fields contained in the filter function. This allows for greater flexibility in searching for
specific jobs with the schedule board and work order list.

Monitor - Multiple Material Formula

For users with the multiple materials option, the work order/job material formula fields will
allow up to 1 decimal place to be used.
Host - Backup

The maintenance backup will now optimize the database.

Host - Backup

The backup script will now disconnect any ODBC connections to the database before
running. This eliminates deadlock and resource conflicts associated with backing up the
PlantStar database. Any program that connects via ODBC will need to have its connection
342 SYSCON-PlantStar Help System

re-established after the backup is complete. PlantStar recommends waiting at least 1 hour
from the time backup starts until the ODBC program attempts to reconnect.
Host - Import

Work order import has an option added that prevents the current job from being modified.
Product standard import now allows more than 2600 product standards to be imported at any
one time. It now allows the importation of multiple machine specific product standards.

Host - Export

Production export now has an option to eliminate a parent record of a family job from the
export if its data is not related to production.
DCM - Shot Tracker

A cycle logging option has been created that will timestamp and log information from the
DCM for each cycle. This data is being placed into a .csv file to ease importation into most
pc based spreadsheet and/or database programs. The logging files are located on the
DCM’s hard drive and named with the following convention, machine_name_day_shiftID.csv.
This convention allows for the recording of data for the previous week to remain on the
harddrive. Users can use an ftp client, or other related program to retrieve these files from
the DCM’s harddrive for importation and review.
DCM - Xtreem interface

An interface to the Cincinnati-Milacron Xtreem controller has been added to our already
extensive collection of machine interfaces. This interface requires a Windows based pc to
proxy the data between the machine controller and the PlantStar DCM. This was due to the
fact that Cincinnati- Milacron uses a Windows based Active-X control to access its Xtreem
controller.
DCM - OPC client

An OPC client has been added to collect process variables from OPC compliant machine
controllers and auxiliary devices. The OPC client requires a Windows based pc to proxy the
data between the OPC Server and the PlantStar DCM.
Browser - Job Update screen

In response to customer's requests the Job Update browser screen at the DCM now
allows for the editing of the reject multiplier as well as the editing of the actual multiplier.
This gives the user one screen to adjust the cavitation of the mold in the event of a cavity
no longer being used.
Browser - Reject Screen

The reject browser screen has been modified so that weights of less than 1 can be entered
when rejecting parts based on their part weight instead of by part count.

V4.10r11 Bug Fixes

 Release Notes 343

Monitor - General

An error that allowed for multiple pop-up message windows to be displayed and causing a
run-time error #400 to occur has been corrected.

Monitor - Tool Change / Material Forecast

An error opening the tool change or material forecast screens when more than 200 records
are being displayed has been corrected.
Monitor - OEE

The down time was being used both in the availability and productivity portions of the OEE
calculation resulting in a double adjustment when a machine was down. Down time has
been removed from the performance factor in calculating OEE.
Monitor - Job Schedule Board

Many non-critical errors in the schedule board were being ignored by the program causing
unexpected results. These errors will now be reported by a pop-up window when
encountered. If this occurs, a screen capture should be taken and forwarded to PlantStar
customer support so that the underlying cause can be determined and corrected.

Monitor - Work Order

An invalid default required by date has been fixed.

Host - Product Standard Import

A fix has been made to properly update or insert machine specific portions of the product
standard when imported.
A problem associated with fixed length fields when parsing an import file has been corrected.

Host - Work Order Import

During import disabled, machines are no longer checked when attempting to find matching
jobs in the current job or queued jobs.
A problem associated with fixed length fields when parsing an import file has been corrected.
DCM - General

A memory corruption of the job queue has been found and corrected. This bug was related
to unexpected/missing rejects being displayed and as the next job on the Job Summary
browser page displaying a large number of "ÿÿÿ" characters.
DCM - RIO2 Driver

The driver for the RIO2 analog card has been rewritten to correctly reload the card with the
proper gain and offset settings if a communication error occurs. This was seen by users as
erroneous data being captured for analog process variables and as a flattening of the profile
curves. In addition, an error displaying a spike in the first reading of the profile has been
corrected.
344 SYSCON-PlantStar Help System

DCM - Tote Count

The tote count field is now saved so that the count can be recovered in the event of a power
loss or a cold start of the DCM.

**************************************************************************************************
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V E R S I O N 4.10
**************************************************************************************************
**************************************************************************************************

V4.10 Installation

PlantStar v4.10 can be installed as a new system or as an upgrade to

PlantStar v4.00 or later. Data compatibility with earlier systems requires
the host computer be upgraded to PlantStar v4.00 prior to installation of
v4.10 as a maintenance release.
NOTE: For those users that have installed Windows NT, 2000, or XP the
operating system login MUST be set to have administrative privileges in
order for that workstation to install and run the View and Print Application.

V4.10 New Features

General

Although there have been a number of minor changes, the focus of V4.10 is
Family Tooling and Labor Tracking.

Family Tooling is designed to allow the collection and tracking of data by

child tool. Management will receive a much more detailed picture of
production, reject, history, and pieces made for each family tool. Family
Tooling allows up to twelve child jobs running, at one time, on a machine.
Labor tracking is designed to forecast, collect, and report labor hours
by machine, job, shift, or employee. Labor is collected and tracked by
personnel logging in and out at a DCM. The same person or people
can be logged onto one or many machines at the same time
depending on the work being done. For these reasons, it is not a time
and attendance system. It will provide a window to where and how
labor is used on the shop floor. Management will receive a much more
detailed picture of the time spent on setup, maintenance, idle time,
wait time and other assigned labor categories. It can also report time
spent, at the machine, by support personnel. As a job history is
developed the job history labor reports can be used to forecast staffing
 Release Notes 345

requirements on a shift or weekly basis.

Monitor - Machine Status

Machine Status displays all of the child jobs on a rotating basis. The
child job displayed will start at the first child job and rotate to the next
child job, with each end of cycle. All data displayed, in the machine
cell, would be for the current child job. If no child jobs are found, the
data displayed would not rotate. It would always display the parent
jobs information. The machine cell would turn cyan if the current child
job was in production exception.
Monitor - Production Summary

Production summary displays one line of summary for each child job.
If child jobs are not present, the data displayed is based on the
parent job.

Monitor - Material Usage

The “Pieces To Go” displayed is a summary of all the child jobs. If

child jobs are not present, the data displayed is based on the parent
job.
Monitor - Job Summary

A drop down has been added underneath machine for selecting child jobs.
Job data displayed is a summary for the child job selected. If no child job is
present, the child drop down displays "No Family Data Defined" and the
data displayed is based on the parent job.
Monitor - Reject Pareto-Pie

A drop down has been added underneath machine for selecting child jobs.
Reject data displayed is a summary for the child job selected. If no child
job is present, the child drop down displays "No Family Data Defined" and
the data displayed is based on the parent job.

Monitor - Job Schedule Board

The schedule bars now represent the length of time for the child that
will take the longest time to complete. If the job is a non-family job, the
calculations are based on the parent job. Job Summary displays the
pieces to go for each child job. A set of "Child Jobs" tabs were added
to the Job Parameter Editor.
The Job Parameter Editor allows the editing of jobs opened from the Job
Schedule Board. It also added the ability to assign a labor category and
manning to each job. Manning factor is the number of man hours needed
to complete the job for the selected labor category. These can be entered
into a job by selecting the new labor button at the top of the job parameters
screen.
Monitor - Edit Current Job
346 SYSCON-PlantStar Help System

"Child Jobs" tabs added for the editing of child jobs. Reformatted screen
for enhanced usability. Moved machine parameters onto their own grid.
Now allows the editing of queue jobs as well as current jobs. Added the
ability to assign a labor category and manning factors to each job. Added
a new field "Idle". This is a field that allows for setting of a jobs idle state
from the PC Client.
Monitor - Edit Work Order

"Child Jobs" tabs added for the editing of child jobs. Reformatted screen
for enhanced usability. Moved machine parameters onto their own grid.
Added the ability to assign a labor category and manning to each job.
Added a new field "Idle". This is a field that allows for setting of a jobs
idle state from the
PC Client.
Monitor - Edit Product Standard

"Child Jobs" tabs added for the editing of child jobs. Reformatted screen for
enhanced usability. Moved machine job parameters onto their own grid.
Added Add/Delete Child buttons for the adding/removal of child records
from a product standard. NOTE: Child records can only be added or
removed from a product standard. The number of child records cannot be
changed once created as a Work Order, Job Queue, or Current Job. Added
a product standard list that displays all of the product standards on the left
hand side of the screen. This allows for easier navigation among product
standards. Enhanced the search performance for product standards.
Product Standard searches can now be done in a much shorter period of
time. Added the ability to assign a labor category and manning to each job.
Added a new field "Idle". This is a field that allows for setting of a jobs idle
state from the PC Client.
Monitor - Tool Change

Pieces To Go and Estimated Completion Time are based on the child job
that will take the longest time to complete. If the job is a non-family job,
the calculations are based on the parent job.
Monitor - Historical Reject Pareto Pie

A drop down has been added underneath machine for selecting child jobs.
Reject data displayed is a summary of the child job selected. If no child
job is present, the child drop down displays "No Family Data Defined" and
the data displayed is based on the parent job.
Monitor - Part Count Edit

A drop down has been added underneath machine for selecting child
jobs. Part count data displayed is a summary of the child job selected. If
no child job is present, the child drop down displays "No Family Data
Defined" and the data displayed is based on the parent job.
 Release Notes 347

Monitor - Material Lot Tracking

Material Lot Tracking has been modified to show tote part and tote
totals for each child job.
Monitor - Labor Status

Labor Status is a new screen that allows the viewing of current employees
logged in. Selecting a work center from the drop down, in the upper left
hand corner, will fill the grid with a list of current employees logged in, for
the selected work center. The grid displays the employees name,
machine, labor category, login date, login time, and hours worked. An
additional feature of the labor status screen is the ability to logout an
employee. To logout an employee, use the mouse to select the employee
from the grid and click the logout button at the bottom.
Monitor - Labor Forecast

Labor Status is a new screen that displays the calculated man-hours

needed per shift. The calculations are based off the manning factors
assigned to the job scheduled to run in the selected time frame. The
Labor Forecasting screen is split into two views: Grid View and Graph
View. The Grid View displays one cell for each shift and labor category.
For a given shift and labor category the cell displays the required
manning factor. The Graph View graphs the man hours required for a
given labor category. There is one point on the graph for each shift in the
selected date range.
Monitor - Labor History

Labor History is another new screen that allows the viewing, modification, and deletion of
labor records for shifts that have already completed. Labor history records are by work center,
machine, job, and shift. These are selected from drop downs at the top of the screen. Once a
valid selection has been made, the grid will display the employee records for the selection.
The grid displays the employee name, labor category, date/time logged in, date/time logged
out, down time, reject count, and part count. All fields can be edited, except for employee
name. To delete an employee record, select the delete check box, in the grid, on the desired
record. Changes are not saved until the <Save> button has been selected. To disregard
changes, select the <Restore> button.
Configuration - DCM Configuration

A new field was added to DCM Configuration called "Max. Family Size".
This allows the modification of the maximum number of child jobs allowed
running on a machine, at the same time. The range is from 1 to 12. Also, a
new field was added to show memory used with current configuration. This
modification will limit saving of data to data that does not exceed installed
memory of the DCM. The calculations for memory use do not include bin
sets. Memory overrun may still occur if the bin set used is very large.
Configuration - Labor Configuration

The Work Center screen was updated. A tabbed grid control was added to
348 SYSCON-PlantStar Help System

allow for the entry of Labor category and employee information. Note
clicking on the command buttons on the bottom of this screen affects the
work center not the individual employees or labor categories. (i.e. New,
Delete, Restore, etc.) Also, the DCM set-up screen was updated. A tabbed
grid control was added to aid in the setting up of DCMs correctly. A tab for
COM port setup was added as well as a tab to allow for editing contact
inputs. Modifications to the DCM set-up screen were also made to enhance
error correction in the configuration process.
View & Print Reports

All reports now support family tooling. Reports display totals based
on both parent and child information.
New Labor Reports:

1. Labor by Job--Labor history by job. Selection by job and job

ending date range
2. Labor by Shift--Labor history by shift. Selection by display
group and shift starting date range.
3. Labor Definitions--Labor category and employee definitions
for all work centers.
Host - Import

All import programs now support the new field "Family Name". "Family
Name" should be assigned to each family set of records to distinguish
them as a family. Also, the "Family Name" should be the job name of
the parent record. "Family Name" must be included in import files that
wish to import family jobs. Also, all import programs now support the
new field "manning factor", as it applies to jobs. Added a new
employee import program to import employees’ definitions.
Host - Export

All import programs now support the new field "manning factor", as it
applies to jobs. Job Que export will export manning factors. Labor
categories, as it exports data for shift history, will also export labor
history for all valid “end-of-shift”. For this 115 has to be specified with -f
option (as we specify 111 for exporting shift history data)
DCM - RTL

The DCM-RTL now has the ability to view and track each individual child
tool production. Also, the DCM-RTL now has a popup display for entry
and viewing of Labor related data (Login, Logout, etc.). The DCM-RTL can
also obtain login/logout data from a barcode scanner.

DCM – EL Menu

Also, the EL DCM's now has a popup display for entry and viewing of
labor related data (Login, Logout, etc.). The DCM-RTL can also
 Release Notes 349

obtain login/logout data from a barcode scanner.

Browser - Job Summary screen

Defaults to showing a family view of a job. This view gives a summary

display of each child in the family with color details. Added button to
allow selection of a specific child to view its details.
Browser - Job Update

For family jobs a new button was added to select each child. When
child is displayed you can modify its actual multiplier.
Browser - Reject Update

Button was added to select individual children. When selected each child's rejected
parts can be modified. The reject numbers are now entered through two dropdown
menus instead of a keypad, works similar to the Job Update screen. This allows for
greater compatibility with various browser software.
Browser - Job Summary, Machine Summary and Job Queue

Pieces required displayed in a job summary format will display

'Family' for all family jobs.

V4.10 Bug Fixes

Browser – Job Summary

Job Summary was modified to show number of parts in red when job or
child in overrun. Reject percent displays in red when percent of rejects
exceeds limits.
Browser – Job Setup

Job Setup was modified to allow for more than 80 columns in a

single line. Embedded links now work correctly when a 'T' is placed
within the link.
Browser - Down, Assist, Reject

Button text was modified to improve alignment and consistency with

previous versions.

V4.10 Notes

Monitor - Job Summary

Job Summary does not change to previous shift automatically. For

example, if you entered reject parts into Part Count Editor, your
changes would not be displayed until you press the "Build" button at the
350 SYSCON-PlantStar Help System

bottom. All changes to the current shift are updated by Job Summary
automatically, without a screen rebuild.

V4.10 Features No Longer Supported

DCM – Keypad and EL Menu

Keypad and EL Menu's do not support family tooling jobs.

Host - Reports

Host Reports are no longer supported.

REU

REU are not supported in this release.

**************************************************************************************************
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V E R S I O N 4.05
**************************************************************************************************
**************************************************************************************************

V4.05 Installation

PlantStar v4.05 can be installed as a new system or as an upgrade to PlantStar

v4.02. Data compatibility with earlier systems requires the host computer be
upgraded to PlantStar v4.00 prior to installation of v4.02 as a maintenance release.
This upgrade uses a method to significantly lower the impact on shop floor data
collection in larger systems. The older v4.00 - v4.02 software is compatible enough
with the new v4.05 system that data collection can continue on the shop floor
during the upgrade. The last step of the upgrade is to reload each DCM in turn with
the new software. Overall this may take several hours but it results in each DCM
loosing only 5 minutes of data collection time. No backups, job schedule changes
or shift schedule changes should be made during this process. The low impact
method will not be available on all future upgrades but will be used whenever
possible.

V4.05 New Features

General

Although there have been a number of minor changes the focus of V4.05 is
labor tracking and management. Labor tracking is designed to forecast,
collect, and report labor hours by machine, job, shift, or employee. Labor is
collected and tracked by personnel logging in and out at a DCM. The same
 Release Notes 351

person or people can be logged onto one or many machines at the same
time depending on the work being done. For these reasons, it is not a time
and attendance system. It will provide a window to where and how labor is
used on the shop floor. Management will receive a much more detailed
picture of the time spent on setup, maintenance, idle time, wait time and
other assigned labor categories. It can also report time spent at the
machine of support personnel. As a job history is developed the job history
labor reports can be used to forecast staffing requirements on a shift or
weekly basis.
Client - Labor Scheduling

Added the ability to assign a labor category and manning to each job.
Manning factor is the number of man hours needed to complete the job
for the selected labor category. These can be entered into a job by
selecting the new labor button at the top of the job parameters screen.
Client - Labor Status

Labor Status is a new screen that allows the viewing of current logged in
employees. Selecting a work center from the drop down, in the upper left
hand corner, will fill the grid with a list of current logged in employees, for
the selected work center. The grid displays the employees name,
machine, labor category, login date, login time, and hours worked. An
additional feature of the labor status screen is the ability to logout an
employee. To logout an employee, use the mouse to select the employee
from the grid and click the logout button at the bottom.
Client - Labor History

Labor History is another new screen that allows the viewing,

modification, and deletion of labor records for shifts that have already
completed. Labor history records are by work center, machine, job, and
shift. These are selected from drop downs at the top of the screen. Once
a valid selection has been made, the grid will display the employee
records for the selection. The grid displays the employee name, labor
category, date/time logged in, date/time logged out, down time, reject
count, and part count. All fields can be edited, except for employee
name.
To delete an employee record, select the delete check box, in the grid, on the desired record.
Changes are not saved until the <Save> button has been selected.
To back out changes, select the <Restore> button.
Client - Labor Configuration

The Work Center screen was updated. A tabbed grid control was added to
allow for the entry of Labor Category and Employee information. Note
clicking on the command buttons on the bottom of this screen affects the
work center not the individual employees or labor categories. (i.e. New,
Delete, Restore, etc.) Also, the DCM set-up screen was updated. A tabbed
grid control was added to aid in the setting up of DCMs correctly. A tab for
COM port setup was added as well as a tab to allow for editing contact
352 SYSCON-PlantStar Help System

inputs. Modifications to the DCM set-up screen were also made to enhance
error correction in the configuration process.
Client - View & Print Reports

New Reports:
1. Labor by Job--Labor history by job. Selection by job and job
ending date range
2. Labor by Shift--Labor history by shift. Selection by display
group and shift starting date range.
3. Labor Definitions--Labor category and employee definitions
for all work centers.
Host - Import

All import programs now support the new field "manning factor", as it
applies to jobs. Added a new employee import program to import
employees’ definitions.
Host - Export

All import programs now support the new field "manning factor", as it
applies to jobs. Job Queue Export will export manning factors and labor
categories. It also will export labor history for all valid “End-of-Shift”, as
it exports data for shift history. For this 115 has to be specified with -f
option (as we specify 111 for exporting shift history data)
Host - Reports

The labor definitions (Labor Category, Forecast Type, Auto Logout,

Multiple Login, and Labor Cost) are shown for all the work centers in
Host Full-Reports. The manning factor for each labor category is
shown for all the jobs in the Host Full-Reports. (Manning factor is
reported only when it is greater than Zero).The summary reports
remain as before.
Host - Archiving

The archive utility will now support archiving to a CD-R, CD-RW, or an

external file.

DCM - EL & LCD

The DCM-EL and DCM-LCD now have a display screen for entering and
viewing Labor data. This screen allows login/logout and viewing the current
workforce on a machine by machine basis. The DCMs also support login/logout
using a barcode scanner.
DCM - RTL

The DCM-RTL is capable of serving web-pages containing its job data to any client
PC running a standard browser. The data shown on the DCM-RTL is available for
viewing nearly anywhere. Along with this comes the ability (on the 12" RTL-DCM)
 Release Notes 353

to place links in the Job Setup Sheet that point to web-based data of any kind
(Documents, pictures, video, etc). The DCM-RTL now has a popup display for entry
and viewing of Labor related data (Login, Logout, etc). The DCM-RTL can also
obtain login/logout data from a barcode scanner.

V4.05 Bug Fixes

Client - View & Print Reports

The Current Job Parameters Summary Report and the Job Queue Job
Parameters Summary Report were corrected for a problem of printing
multiple rows of the same data for machines defined in multiple display
groups.
Host - Work Order Import

Fixed a problem with the work order import where it would occasionally
create duplicate work order for records that were not in the system.
Host - Archiving

The archive utility would exit with errors when it encountered incomplete job data.
The utility has been made more robust to handle missing or unexpected SPC,
shift, tote, and material lot records.
DCM

Setup sheets for the current job or next job were sometimes not available
for viewing at the DCM. The DCM would ignore auto-reject inputs on a
“net parts” job if the rejects would cause the shrinkage category to go
negative. This is now permitted to better handle the resets which occur at
job and shift change.

V4.05 Known Problems

Archiving

The archive utility will not export labor history. Also, there is a limitation to
archiving the first 2000 records for each record type (e.g. SPC, material
tracking, and tote snap shots) that are associated with a job. The
remaining records will not be archived and will remain in the database.

**************************************************************************************************
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V E R S I O N 4.02
**************************************************************************************************
**************************************************************************************************
354 SYSCON-PlantStar Help System

V4.02 Installation

PlantStar v4.02 can be installed as a new system or as an upgrade to

PlantStar v4.00 or v4.01. Data compatibility with earlier systems requires
the host computer be upgraded to PlantStar v4.00 prior to installation of
v4.02 as a maintenance release.
This upgrade uses a new method to significantly lower the impact on
shop floor data collection in larger systems. The older v4.00/4.01
software is compatible enough with the new v4.02 system that data
collection can continue on the shop floor during the upgrade. The last
step of the upgrade is to reload each DCM in turn with the new software.
Overall this may take several hours but it results in each DCM loosing
only 5 minutes of data collection time. No backups, job schedule changes
or shift schedule changes should be made during this process. The low
impact method will not be available on all future upgrades but will be
used whenever possible.

V4.02 New Features

General

A completely updated edition of the Spanish language translations for

the client PC, DCM, and host reports has been incorporated.

Installation of the client software, including View & Print, on Windows

2000 and Windows Millennium Edition has been tested and is now
supported.

The Screen Shot utility will no longer be distributed or supported. If you already
have Screen Shot installed from a previous release, you may continue to use it
for as long as it works in your environment. For new PC's we recommend
getting one of the many shareware or commercial screen printing products.
ClipTrakker (www.cliptrakker.com) is a full featured shareware program.
PrintScreen32 (www.surf.to/provtech) is a bare bones screen printing program.
SnapShot (v2.02) systems have been enhanced to support licensing of
up to 8 users and 50 machines. Also SnapShot now supports a wider
variety of DCM hardware.
When forecasting the completion or duration of a queued job the
PlantStar algorithms now use actual multiplier instead of standard
multiplier to estimate the production rate. This allows scheduling
personnel to account for a known condition that will prevent all cavities
in a mold from being used.

Job Scheduler
 Release Notes 355

The "justify all" button has been changed to toggle left and right
like the "justify 1" has always done.

The four user text fields have been added to the job summary popup window.
Machine Status Display

The machine status display now uses larger fonts in the machine status blocks
when showing only the machine name. This was done to make large display
screens on the plant floor easier to read from a distance.
Import / Export

A special utility has been developed for sending PlantStar production

data to the Data Technical Research (DTR) TMM business system. This
is an optional utility which is available for a licensing fee.
A new command line option (-a) has been added to the work order import
utility (woimp). When this option is used only new work orders are
processed from the import file. Any existing work orders (either running,
queued, or unscheduled) will not be updated. This option can be helpful
when there are a lot of suspended jobs (where the pieces required gets
changed to pieces remaining) and change orders to outstanding jobs are
infrequent.

Another command line option (-u) has been added to the work order
import utility (woimp). This option is used when importing job queues to
specific machines and queue positions. When this option is used and the
specified queue position for a job is zero, the current job on the
associated machine will be stopped and the new imported job will be
started as the current job. This option should be used with caution. In
most cases the work order import is run automatically once per day. New
jobs will be started at the DCM as per the import file regardless of what
product is actually running at the machine. In nearly all cases it is best for
the operator to do routine job changes at the machine to confirm what the
machine is actually doing.
DCM

The new color touchscreen DCM-RTL has been fully integrated for
production tracking into the basic operation of the system. Many
additional features and improvements will be developed over the
coming months.
On the DCM-RTL-10 and DCM-RTL-12 the touch screen calibration item
under the "diag" menu is now available to update touchscreen calibrations.

V4.02 Bug Fixes

General PC Client
356 SYSCON-PlantStar Help System

Some of the display screens, including Machine Utilization and Job

Summary, would be cut off when maximized at certain resolutions.

In V4.01 the Pieces to Go field on some workstation screens were

incorrectly changed to show 0 when the job was in overrun. These have
been restored to show the amount of overrun produced as a negative
number.
Server Reports

Machines were occasionally reported missing off end-of-shift production

reports. This only applied to the server-generated text reports (not to
View & Print reports).
The Shop Floor Reports program would exit with an error when
attempting to generate a detailed product standards report.
View & Print Reports

View & Print would exit with run time error 6 when an internal sequence
number got larger than was expected.

View & Print would exit with run time error 6 when automatic reports
were still scheduled after a display group had been deleted.
Import/Export

European date formats were not being handled correctly on the work
order import utility.
The work order import utility had several problems relating to the use of
the clear-and-replace (-c) option. The behavior of this feature was
changed enough that the original lower case option (-c) was changed to
an upper case letter (-C). This was done to force all installations using
clear-and-replace to inspect and re-evaluate how the option works in
their environment.
It was discovered that the work order import utility would not always
match the correct machine specific details when filling out an imported
work order.
Job Scheduling

The job queue estimation program, which updates estimated completion

times for export purposes, had several related problems which kept it from
generating accurate and timely estimates under certain conditions.
The Job Schedule Board would sometimes not refresh itself correctly after
committing changes to the schedule. All changes would have been saved
correctly and upon exiting and re-entering the schedule board everything
would appear normal.
In the Job Schedule Board the length of individual job bars would not
always change length when the time scale was changed.
 Release Notes 357

A problem was fixed which would occasionally allow a hidden space

character to be included at the beginning of the job name. This would
cause errors when the job parameters were exported to other computers
at the end-of-shift.
In the various screens where job parameters could be edited there was a
problem with values from one field being transferred to another field when
the job was saved. This most often with the material name field where the
word "Yes" would overwrite the material name or the material name would
overwrite another field.
Voice

Several customers have had problems with portions of their voice

announcements not playing. This problem turned out to be an
incompatibility between wave file formats as PC sound has evolved from 8-
to 16- and 32-bit sound cards. Wave files recorded with more recent sound
card drivers cannot be merged with older files. This problem has been
solved by playing each file separately in sequence rather than trying to
merge them into one continuous file for playing. Newer workstations are
fast enough to handle this without pause. There is one other side-effect
which some customers may experience. Wave files recorded with different
hardware and drivers often play back at different volumes. Some may find
that portions of an announcement are too loud or too quiet compared to
the rest. The only remedy for this is to re-record the entire announcement
set using the same hardware and sound drivers.

V4.02 Known Problems

A last minute problem was found in the job schedule board when a large
number of jobs are placed in the queue of a single machine. The normal
limit is 100 jobs per machine on the job schedule board. However, a fatal
exception would occur in the program before this limit was reached. As a
temporary patch for v4.02 the limit has been reduced to 75 jobs per
machine. This problem will be corrected and the limit restored to 100 in the
next release.
Under, as yet undetermined conditions. some of the process thresholds on
a job can be set to 0. This can happen to thresholds that were set for alarm
as well as ones that had no limit set. The cause of this problem is still under
investigation.
All events which occur at the DCM are logged and show up in the DCM
machine log display as they should. But sometimes a few of them do not get
transferred to the server database and hence do not show up on workstation
displays. The cause of this problem is still under investigation.
358 SYSCON-PlantStar Help System

**************************************************************************************************
**************************************************************************************************
V E R S I O N 4.01
**************************************************************************************************
**************************************************************************************************

V4.01 Installation

PlantStar v4.01 can be installed as a new system or as an upgrade to

PlantStar v4.00. Data compatibility with earlier systems requires the host
computer be upgraded to PlantStar v4.00 prior to installation as a
maintenance release.
Since the DCM cold end offset between isolated and non-isolated A/D
converter has been standardized, users with the isolated A/D cards that
upgrade from v4.00 to v4.01 will require the corresponding hardware
modification to their isolated A/D cards.
View & Print and Design Manager have been upgraded to support Crystal
Reports 7.0. Since some of the functionality has been dropped, Crystal
Reports 6.0 can not be supported. It is recommended that users of Design
Manager should upgrade all their custom report templates to avoid any
adverse affects.

V4.01 New Features

Job Scheduler

Reload button has confirmation prompt prior to discarding changes and

reloading schedule.

View & Print

Vies & Print now allows multi-select on criteria. Added work center
and display group criteria for selection of machines. Date criteria
dialog boxes now default to current date. Templates are reloaded
from host when a report is run to allow easier viewing of new
templates.
Report Definitions

Standard reports templates have upload options as part of PC install

program and do not require reloading of Ingres or View & Print.
 Release Notes 359

DCM

When the 'Down' menu is selected the DCM automatically jumps to the
group of 20 down reasons which has the current selected down reason.

V4.01 Bug Fixes

DCM
Blank down reasons at DCM after cold boot has been corrected.
Off-line DCM could cause a com failure on CP units. The host has been
adjusted to allow for this situation.
DCM cold end offset between isolated and non-isolated A/D converter
has been standardized. This upgrade coincides with a hardware change
requirement to isolated A/D cards.

If a machine is down at shift change the DCM display doesn't update to

show the piece counters reset to 0. This has been corrected so the
display always updates at shift change.

General PC Client

Machines that are idle and down will no longer show up on displays
that are filtering to view down machines.

"Version mismatch" when specifying INI file on command line has been fixed.

Saving a job as a product standard would give an invalid standard error

on the first try, and then work on the second try. This has been fixed.
The Shop Floor Monitor program was much slower than previous
versions and had noticeable hesitations when entering data. The program
has been re-optimized to increase speed and reduce hesitation.

The quick load option caused a "No jobs are scheduled for any
machines" error when opening the tool change screen.
The user definition window prompts to save changes on close even if the
update button was pressed.
The Shop Floor Monitor would occasionally exit with "Run-time Error 5".
The vertical scroll bar on setup sheet edit windows was missing.
Some of the real-time display screens would immediately roll up the
machine or process selection list after it was dropped down, not allowing
enough time to select a different item.
The CAMAC-486/VSX pvar definition was expanded to allow a Convert
Index of between 0-79. Previously, its maximum value was 29. Also,
some annoying text entry problems were cleaned up with that particular
field.
Job Schedule Board
360 SYSCON-PlantStar Help System

Job Schedule Board now displays machines in alphabetic order when

selecting the "<all Machine>" option.
Job Schedule Board has been improved for error recovery and
number of work orders.

Job Schedule Board shift patterns are displayed correctly after an idle period.

The Job Schedule Board dividing bar between work orders and machine
schedule would return to its default setting after editing job parameters.
Customer setting will now be remembered.
Improvements in the Job Schedule Board were made to handle
scheduling by multiple personnel.

A 'required by date’ in a prior year for which the shift schedule had been deleted caused
problems in Job Schedule Board. It displayed an error message saying the "job will be
scheduled in 1890". This has been fixed.
Resize handles were missing on the job summary popup window.

The title on the job list popup box was not showing the correct machine name.

When a work order was scheduled and then found in the job search dialog
it would still be listed as a work order instead of scheduled on a machine.
Job Schedule Board did not auto-scroll or smooth scroll.

A security hole has been corrected in the Job Schedule Board. A user
with view-only permission could change display groups and be prompted to
commit changes.

View & Print

View & Print as well as the standard report templates have been
extensively re-worked to correct multiple report problems. This includes
the handling of suspended jobs and shift breaks.
View & Print will now allow database backup and maintenance to proceed
without interference.

Installation

Ingres can now run in a directory other than the default (C:\OPING).

The installation program will now retain monitor's user preferences during upgrade.
The free disk space checks during PC installation did not take into
account browsing to a different drive.

Voice
 Release Notes 361

The voice application work center is preserved during upgrade installation.

The shortcuts created for the voice application in the Start menu do not
have the home folder as the working path. This causes a failure when
looking for the wave files. This problem has been fixed.
Backups

Communication problem on host computer after short backups have been resolved.

After a backup the host computer only ejects CD-R disks. Prior
software also ejected the CD-RW disks.
Archiver

The archiver program has been fixed for date range problem and Y2K issue
where every date was within the 6-month cutoff time.
The archiver program was getting fatal errors on Material Lot and
Tote Box History. This problem has been fixed.

V4.01 Known Problems

Screen Shot on Windows NT systems does not function when minimized or in the
background. To use with Windows NT, keep it normal size and visible
on the screen.
When View & Print displays a report on screen, printing of the report
causes the screen not to be re-painted when scrolling. This is a problem
within Crystal Report. Workaround is to view the report prior to printing.

**************************************************************************************************
**************************************************************************************************
V E R S I O N 4.00
**************************************************************************************************
**************************************************************************************************

V4.00 New Features

General

PlantStar is now an entirely 32-bit application, and as a consequence

will no longer run under Windows 3.x. PlantStar relinquishes focus
during long operations (such as logging in) and allows the user to go
to other open applications and work until the process is done.

PlantStar is now multi-lingual (for the Monitor and Reports programs) and
supports English, French and German. At this time the Voice option and
the Shop Floor Configuration program are available only in English.
362 SYSCON-PlantStar Help System

New Monitor Screen

Machine Utilization Summary

A new screen has been added under the monitor menu which displays a
summary of machine utilization for both a given date range and for any shifts
started within 24 hours of the start time for the last completed shift. Machine
utilization is defined as up time divided by the sum of up time, down time and
idle time. Scheduled utilization is a similar calculation, only idle time is
excluded. Thus it is derived by dividing the up time by the sum of the up time
and down time. The date range can be changed and the screen will be
updated when the Build button is pressed. The current machine state is also
displayed and updated in real time. A print button on this screen allows the
summary to be printed to a Windows printer. The machines displayed can be
filtered by display group, exception type, or by machine name.

Multilingual Monitor

INI file specification for language

The PlantStar Monitor now supports not only the English language, but
French and German as well. To accomplish this, the user can go to the
"Preferences" screen and choose the language that will be used by the
monitor program. Simply changing the "English" value to "French" or
"German" will cause the PlantStar program to reload those language
definitions (if they are not already present) the next time that the program
starts up. The user will have to restart the program once the language files
have been loaded, as the program will be unable to use most of the strings
until it gets the definitions from the database.

After the restart, the new language should be intact. A message box will
pop up alerting the user of the need to restart the program after a
language change.
DCMs

Idle job start from DCM

The operator is now able to start an idle job at the DCM (for such things as
scheduled maintenance). To enable this option, the machine must be
setup in the Shop Floor Configuration to allow this activity. Once
enabled, the operator has only to go to the "Queues" screen and press the
"Start Idle Job" button. A warning message will come up to make sure that
this operation is the intended one, and then the current job will be either
suspended or ended (depending on operator choice).
Utilities

Export programs now have AS/400 support

Both f2kexp and f2kjqexp now support the -r option, which will right
justify all non-text fields in the output. This was designed for
 Release Notes 363

customers that require fixed numerical format from within a fixed-

width formatted export. This feature will not pad the numerical output
with zeros, however. Also, any text field is still left-justified.
A Note on older export templates

In one of the previous 2.3x versions, a new field was added to the
database to distinguish between varying types of exports. If you are
using exports that were written prior to PlantStar 2.30 or Portrait 1.00,
you will need to contact SYSCON Customer Service and have them
update your export templates for you. If you experience any problems
with your imports or exports after the upgrade, contact SYSCON
Customer Service as soon as possible.
Multiple Logins

INI file specification via Command Line

PlantStar now supports running multiple copies of the Monitor program

simultaneously. This allows users on WAN's to be logged in to multiple
hosts concurrently. For multiple host login, a new INI file should be
created in the WINDOWS directory for each host to be accessed
remotely. Each of these INI files should have the following entry placed
into the "main" section:
multi_instance=yes

The multiple instance capability is OFF by default. Each new INI file
should also have its "hosts" entry set to the proper IP address or host
name. To run PlantStar for a remote host, the name of the proper INI
file should then be specified on the command line.
Add-On Features

New Custom Reports Option

A custom reports feature is now available within PlantStar. This new

option provides the ability to create custom reports using Seagate
Crystal Reports 7.0 and 6.0 formats and share those reports among
PlantStar workstations. This option provides for a centralized location
for all of your customized reports. This feature augments the Standard
Reports program.
Delta Type Process Variable

A new type of process variable has been introduced which allows one
process variable to represent the difference between two other process
variables.
Monitor Quick-load Feature

Quick-load is a feature that bypasses some of the initialization for

screens that take quite some time to load, such as the Job Schedule
Board and the Machine Utilization Screen. If the "Enable Quick
364 SYSCON-PlantStar Help System

Load" option is selected in the Monitor's "Preferences" screen, the

following screens will load without any information selected: Job
Schedule Board, Machine Utilization and Tool Change. To get
them to calculate information, the user must select either a display
group, a work center, or a valid date range. These actions will cause
the respective form to reload their data.
Thermocouple Scale

A scale was added to the Thermocouple Process Variable configuration

screen that will account for a level shift on the thermocouple.

Print & View Refresh Button

A "Refresh" button was added to the report list screen to allow the user
to check for changes made via the Design Manager without logging out
of Print & View and reopening the application.
DCM Screen Saver Enable/Disable

There is now a selection on the DIAGS menu of the DCM/EL that will
allow the user to disable/enable the screen saver.

V4.00 Bug Fixes

SPC histories from ended jobs were showing 0 for the upper and lower
spec limit values. They had non-zero values when the job was current,
but went to 0 (not *) when the job ended. This has now been fixed, and all
upper and lower limits are retained after the job is committed to history.
The date format on the Machine Log screen has been changed to an
internationally ambiguous format, to account for overseas customers.

Editing a job by double-clicking it from the Schedule Board, after

scrolling to the right one screen, causes the shift legend to recalculate
incorrectly. The shift legend was that of the initial screen, not the
current one. This has been fixed.
When the time changes, due to Daylight Savings Time, the REU's were
not getting updated with the new time. This has now been remedied.
The Work Order screen now automatically refreshes after a new work
order is saved, to eliminate the problem of a new work order
overwriting the previously selected work order if the Refresh button
was not pressed.

The Process Summary screen now clears leftover color bars that were
 Release Notes 365

orphaned when viewing a machine with fewer process variables than the
previously viewed machine, and that previous machine had some out-of-
range values.
If a user creates a second work order by copying the previous work
order, and that previous work order was created from a product
standard, and the user changes the selected machine, they are asked
if they would like the machine portion overwritten from the product
standard. However, instead of overwriting the machine portion only, the
entire work order is overwritten. This is no longer the case. Only the
machine-specific portion will get overwritten.
The backup.f2k script now handles command line typing errors in a more
robust manner. An error message is now output.

The free_check.sh script has been updated to properly monitor space on

a 2-disk system.
The work order import and product standard imports are now fully Y2K compliant.
The archiver program now only allows the user to archive data that is
older than 6 months. This was to remedy a problem that was leaving
partial job records in the database, leading to inconsistent data. This
also remedies a problem with the archiver purging the entire history if the
"jobs finishing prior to" date was set to 01-01-2000.

When configuring an REU, pressing the "New" button clears all the
fields, instead of retaining the data from the previously defined
REU.
All DCM programs now have adequate stack space, and all stack-related
program exits have been taken care of.
The user is now able to use the command button functionality of the main
Monitor window in the event that the "Host is not Available". Previously,
only the File->Exit option would allow the user to close the program.
The KP70 bin set now has the proper sequence number in the database.

V4.00 Known Problems

Currently it is possible to include SPC information for an individual job on

a machine that has an SPC History Size of 0. The Process Trend/SPC
screen will return a value of "No Data Available" and no SPC data will be
returned, even though it is asked for by the job parameters.
On Windows 95/98 when using a file server login scheme that
overwrites the AUTOEXEC.BAT file upon every successful login, the
Ingres/Net Client will fail to operate correctly. This is due to the fact that
366 SYSCON-PlantStar Help System

the Ingres/Net Client relies on path statements put in the

AUTOEXEC.BAT file at installation time. A remedy can be
accomplished by modifying the "main" AUTOEXEC.BAT file that gets
copied to every system. For Novell-specific fixes, please contact
SYSCONPlantStar Customer Service for assistance.
SYSCON - PlantStar System
User's Guide

Part

XIII
 Index 368

13 Technical Support Contact

If you have a question about your system, look through the System Administrator's Guide
or consult on-line help. If you cannot find an answer, please contact Customer Service.
If you call, please be at your computer and have the appropriate product documentation at
hand. Be prepared to give the following information:
· The version number of your system that you are using
· The type of hardware you are using, including network hardware
· The exact wording of any messages that appeared on your workstation
· What happened and what you were doing when the problem occurred
· How you tried to solve the problem

Our Support Phone Number is: 574-232-3900 Ext. 265

For additional contact information please visit us on the web at www.syscon-intl.com

Email can be sent to:
Information Requests - marketing@syscon-intl.com
Support Requests - support@syscon-intl.com
 Index i

About PlantStar ... 55, 107, 120, 125, 130, 218 Assist Time Editor ..................................... 103
Activating an attention announcement .... 220 Assist_Pareto_Pie ....................................... 99
Actual multiplier ........................................ 284 Attention Announcement .......................... 112
Actual rate .................................................. 284 Auto clear flag ........................................... 286
Actual setup time ....................................... 284 Auto logout ................................................ 286
Actual shot weight ..................................... 284 Average cycle ............................................ 286
ADC option ................................................. 284 Average value ............................................ 287
Adding a DCM ............................................ 220 Backing Up the System ............................. 174
Adding a labor category ............................ 220 Backup internet path ................................. 287
Adding an employee .................................. 220 Base model ................................................ 287
Adding an employee to labor history ....... 220 Baud ........................................................... 287
Adding child jobs....................................... 221 Bias ............................................................ 287
Adding machines to a display group ....... 222 Bits ............................................................. 287
Adding machines to an REU list ............... 222 Block number ............................................ 288
Adding users.............................................. 222 Boolean set ................................................ 288
Adding/editing multiple materials ............ 223 Boot files .................................................... 288
Adjusting gross or net pieces................... 223 Boot set ...................................................... 288
Adjusting reject counts ............................. 223 Boot Sets ..................................................... 44
Adjusting start/end date ............................ 223 Browser Interface ........................................ 25
Adjusting start/end time ............................ 223 Calendar board .......................................... 288
Adjusting times.......................................... 223 CAMAC address ........................................ 288
Administering the Host ............................. 166 Case sensitive matching ........................... 288
Administration privilege ............................ 284 Changing a comm processor's name ...... 225
Analog filter................................................ 284 Changing a machine's name .................... 225
Analog inputs............................................. 284 Changing a report ..................................... 226
Anchoring selected job ............................. 224 Changing an existing work center's name
Announce flag............................................ 285 ................................................................ 226
Announce machine flag ............................ 285 Changing child jobs .................................. 226
Announcement delay ................................ 285 Changing com port settings ..................... 226
Application Notes ...................................... 184 Changing contact input settings .............. 227
Arange Icons .............................................. 186 Changing display groups.......................... 227
Archiving Data ........................................... 171 Changing down, assist and reject data.... 227
Arrange Icons .............................. 54, 105, 118 Changing end date .................................... 229
Arrange Windows ................ 54, 105, 118, 186 Changing forecast start date .................... 229
Arranging Windows and Icons ................. 186 Changing forecast views .......................... 229
Assigning a report file name ..................... 224 Changing general DCM settings............... 230
Assigning an employee to a labor category Changing graph types ............................... 230
................................................................. 224 Changing jobs ........................................... 230
Assigning child jobs.................................. 225 Changing labor categories ....................... 230
Assigning weekly schedules .................... 225 Changing machines .................................. 231
Assist Announcement ............................... 115 Changing material components ............... 231
Assist Pareto / Pie .......................................68 Changing number of plotted values ......... 231
Assist period .............................................. 285 Changing number of reasons displayed .. 231
Assist reason ............................................. 285 Changing number of shifts ....................... 231
Assist Reason Sets .....................................42 Changing passwords ................................ 232
Assist Select .............................................. 138 Changing preferences............................... 232
Assist state ................................................ 285 Changing process graph modes .............. 232
Assist state colors ..................................... 285 Changing process variables name ........... 232
Assist time ................................................. 286 Changing profile graph modes ................. 233
 ii SYSCON-PlantStar Help System

Changing profile variables name .............. 233 Creating REUs ........................................... 240
Changing rescaling options ...................... 233 Creating unassigned child jobs................ 240
Changing RIO settings .............................. 235 Creating weekly schedules ....................... 241
Changing shifts ......................................... 235 Creating work center schedules............... 241
Changing start date ................................... 235 Creating work centers ............................... 242
Changing Text Sizes.................................. 118 Creating work orders ................................ 242
Changing the x-axis................................... 235 Creating Work Orders ............................... 188
Changing tools .......................................... 236 Critical process variable ........................... 291
Changing user-defined labels ................... 236 Current / Queue Jobs .................................. 83
Changing View Options............................. 187 Current job ................................................. 291
Changing work centers ............................. 236 Current shift ............................................... 291
Channel ...................................................... 289 Currently running jobs privilege .............. 291
Child count ................................................. 289 Custom Reports ........................................ 122
Child job ..................................................... 289 Customizing the work order list ............... 242
Child Navigation ........................................ 134 CV ............................................................... 291
Clearing machines ..................................... 236 Cycle time .................................................. 291
Clearing process history information ...... 236 Cycle tolerance .......................................... 292
Clearing search fields ............................... 236 Cycle window............................................. 292
Clipping the graph ..................................... 236 Data number .............................................. 292
Closing the window-Close ........................ 237 Date range scheduled usage .................... 292
Closing the window-OK-Cancel ................ 237 Date range usage ...................................... 292
Coldstart a DCM ......................................... 237 DCM ............................................................ 292
Colors ......................................................... 187 DCM base address .................................... 293
Column number ......................................... 289 DCM Browser Interface ............................. 132
Comm option ............................................. 289 DCM Setup ................................................... 50
Comm port ................................................. 289 Debounce ................................................... 293
Comm Processor Setup ..............................49 Decimals .................................................... 293
Comment .................................................... 289 Delay Timer ................................................ 295
Committing a schedule ............................. 237 Deleting a comm processor...................... 243
Communications processor ..................... 289 Deleting a custom report from PlantStar . 244
Component percent ................................... 290 Deleting a DCM .......................................... 244
Configure Menu ......................................... 112 Deleting a labor category .......................... 244
Configuring the Host ................................. 161 Deleting a labor record ............................. 244
Contact duration ........................................ 290 Deleting a scheduled report ..................... 244
Contact input ............................................. 290 Deleting an employee................................ 245
CONV_VEC# ............................................... 290 Deleting display groups ............................ 245
Convert index............................................. 290 Deleting jobs from the schedule board.... 245
Copying a product standard ..................... 237 Deleting machines ..................................... 245
Copying an announcement ....................... 238 Deleting process variables ....................... 246
Cost per hour ............................................. 291 Deleting profile variables .......................... 246
Cp ............................................................... 291 Deleting reason sets ................................. 246
Cpk ............................................................. 291 Deleting REUs............................................ 247
Creating a comm processor ..................... 238 Deleting schedules .................................... 247
Creating display groups ............................ 238 Deleting unassigned child jobs ................ 247
Creating machines..................................... 239 Deleting users............................................ 247
Creating new standards ............................ 239 Deleting work centers ............................... 247
Creating process variables ....................... 239 Deleting work orders and product standards
Creating product standards ...................... 239 ................................................................ 248
Creating profile variables .......................... 239 Derivative ................................................... 295
Creating reason sets ................................. 240 Derivative smoothing ................................ 295
 Index iii

Descriptor .................................................. 295 Exception Summary ............................ 63, 110

Design Manager ........................... 26, 128, 129 Exception time ........................................... 299
Device address .......................................... 295 Excess material ......................................... 299
Digital inputs .............................................. 295 Exit ................................. 38, 59, 109, 124, 130
Discarding a schedule ............................... 248 Exit privilege .............................................. 299
Display group............................................. 295 Exporting data ........................................... 258
Display Group Setup ...................................46 Extended down and reject reasons.......... 299
Display Group Status ..................................60 Family job .................................................. 300
Display option ............................................ 296 Family Molding ............................................ 25
Display type ............................................... 296 FAQ ............................................................ 188
Displaying standard spc statistics ........... 248 Fast state ................................................... 300
Down Announcement ................................ 114 Features Summary ...................................... 31
Down cycles ............................................... 296 File Menu........................................ 36, 58, 109
Down Pareto / Pie ........................................67 File number ................................................ 300
Down period ............................................... 296 File type...................................................... 300
Down reason .............................................. 296 FN code ...................................................... 300
Down Reason Sets ......................................41 Force down flag ......................................... 300
Down Select ............................................... 136 Force scrap flag......................................... 300
Down state ................................................. 296 Forcing a machine down .......................... 259
Down state colors ...................................... 296 Forecast interval........................................ 301
Down threshold ......................................... 297 Forecast types ........................................... 301
Down time .................................................. 297 Free text ..................................................... 301
Down Time Editor ...................................... 102 Freezing profiles........................................ 259
Down_Pareto_Pie ........................................98 Frequently Asked Questions .................... 188
Drag and drop options .............................. 297 Full access privilege ................................. 301
Duration...................................................... 297 Functions ................................................... 220
Editing child parameters ........................... 249 Gain ............................................................ 301
Editing employee records ......................... 249 Getting A Screen Capture ......................... 190
Editing jobs from the schedule board ...... 250 Getting a voice file .................................... 259
Editing labor categories ............................ 250 Getting Started ............................................ 26
Editing labor manning factors .................. 251 Glossary ..................................................... 284
Editing machine parameters ..................... 252 Gross pieces .............................................. 301
Editing parent parameters ........................ 252 Groups Menu ............................................... 45
Editing process and profile limits ............ 253 Help Active Window .... 55, 106, 119, 125, 218
Editing process variables ......................... 254 Help Contents .............. 54, 106, 119, 124, 219
Editing production parameters ................. 255 Help Index .................... 54, 106, 119, 124, 219
Editing profile variables ............................ 256 Help Menu .................... 54, 106, 119, 124, 130
Editing report definitions .......................... 256 Help Search ................. 55, 106, 119, 125, 219
Editing setup sheets.................................. 257 High value .................................................. 301
Element number ........................................ 298 Higher limit ................................................ 301
Embedded matching ................................. 298 Historical job ............................................. 302
Employee id ............................................... 298 Historical shift ........................................... 302
Employee name ......................................... 298 History Menu ............................................... 93
Enable a DCM............................................. 257 Host Log Files............................................ 176
Enabling a RIO on a machine.................... 258 Hours to go ................................................ 302
End date ..................................................... 298 Hours worked ............................................ 302
End time ..................................................... 298 HTML .......................................................... 302
Estimated completion time ....................... 298 Identifier ..................................................... 302
Event type .................................................. 299 Identifying machines with Product
Exact matching .......................................... 299 Standards ............................................... 260
Exception state .......................................... 299 Idle period .................................................. 302
 iv SYSCON-PlantStar Help System

Idle state ..................................................... 302 Logging into your PlantStar system ........ 195
Idle time ...................................................... 302 Logging out an employee ......................... 262
Ignore criteria in a report .......................... 260 Login privilege ........................................... 309
Ignore cycle flag ........................................ 303 Logo Link ................................................... 135
Including boot files from a boot set ......... 260 Logout .................................................... 38, 59
Index number (JSW source type) ............. 303 Lot end time ............................................... 309
International support ................................. 303 Lot start time ............................................. 309
IP address .................................................. 304 Low value ................................................... 309
Isolated A to D ........................................... 304 Lower limit ................................................. 309
Job .............................................................. 304 Lower spec ................................................ 310
Job board ................................................... 304 Machine ...................................................... 310
Job changes............................................... 304 Machine Announcement ........................... 117
Job history size ......................................... 304 Machine cycle ............................................ 310
Job key ....................................................... 304 Machine Exception .............................. 72, 111
Job name.................................................... 304 Machine index............................................ 310
Job parameters .......................................... 304 Machine Log ................................................ 74
Job primary label ....................................... 305 Machine Logs ............................................ 158
Job queue .................................................. 305 Machine Navigation ................................... 134
Job queue size ........................................... 305 Machine parameter .................................... 310
Job Schedule Board ....................................80 Machine Performance ................................. 71
Job Schedule Data Export ........................ 180 Machine running state .............................. 310
Job Scheduling Concepts ......................... 191 Machine Setup ............................................. 51
Job Setup ................................................... 152 Machine state............................................. 311
Job start time ............................................. 305 Machine state colors ................................. 311
Job Summary ....................................... 65, 135 Machine Status ............................................ 61
Job Summary - graph view ....................... 305 Machine usage........................................... 312
Job Summary - grid view .......................... 306 Machine Usage ............................................ 73
Job Update ................................................. 153 Main Frame ................................................ 135
Job-to-date ................................................. 305 Maintenance job ........................................ 312
Journals ..................................................... 159 Manning factor........................................... 313
Knowledge Base ........................................ 184 Material component................................... 313
Label Printing...............................................25 Material Forecast ......................................... 89
Labor category........................................... 306 Material formula......................................... 313
Labor data privilege................................... 306 Material Lot ................................................ 156
Labor Forecast.............................................90 Material Lot Data Export ........................... 181
Labor Forecast - graph view ..................... 307 Material Lot Detail ....................................... 97
Labor Forecast - grid view ........................ 308 Material lot history size ............................. 313
Labor History ...............................................94 Material lot ID ............................................. 313
Labor history size ...................................... 308 Material Lot Tracking .................................. 96
Labor Login ................................................ 154 Material Lot Tracking Concepts ............... 196
Labor Menu ..................................................48 Material name ............................................ 313
Labor Setup..................................................48 Material required ....................................... 313
Labor Status.................................................62 Material Usage ............................................. 66
Language ................................................... 308 Material used ............................................. 314
Last value ................................................... 308 Max assist time .......................................... 314
Left matching ............................................. 308 Max cycle time ........................................... 314
Linearization type ...................................... 309 Maximum family size ................................. 314
List All product standards ........................ 260 Memory ...................................................... 314
Loading a Product Standard onto a Job .. 193 Memory area .............................................. 314
Logging in an employee ............................ 261 Memory required ....................................... 314
 Index v

Menu Clock ................................................ 134 Process Announcement ........................... 116

Menu Frame ............................................... 133 Process exception..................................... 321
Module address ......................................... 315 Process exception state colors ................ 321
Monitor Menu ....................................... 60, 110 Process Graph ........................................... 144
Monitor number ......................................... 315 Process index ............................................ 321
Moving average cycle ................................ 315 Process Journal .......................................... 25
Moving jobs around the schedule board . 262 Process log ................................................ 321
Multiple login ............................................. 315 Process Select ........................................... 142
Net parts counting ..................................... 315 Process SPC .............................................. 144
Net parts multiplier .................................... 315 Process Summary ............................... 78, 141
Net pieces .................................................. 315 Process Table ............................................ 143
Netstal PLC Interface Table ...................... 294 Process Trend / SPC ................................... 77
No access privilege ................................... 316 Process trend privilege ............................. 320
Non-family job............................................ 316 Process variable ........................................ 320
O.E.E. .......................................................... 196 Process variable parameter ...................... 321
Offline state ................................................ 316 Product....................................................... 321
One RIO for all machines .......................... 316 Product key................................................ 322
Operator efficiency .................................... 316 Product parameter .................................... 322
Operator start options ............................... 317 Product standard....................................... 322
Operator utilization .................................... 317 Product Standard Matching ...................... 190
Options Menu............................................. 117 Product standard privilege ....................... 322
Ordered histogram .................................... 317 Product Standards ...................................... 86
Ordering machines in the list.................... 263 Product Standards Import ........................ 178
OSI Model ................................................... 198 Production and/or Process Data Export .. 179
Other status ............................................... 317 Production data ......................................... 322
Overlay Profile .............................................75 Production efficiency ................................ 322
Overrun ...................................................... 317 Production exception ................................ 322
Parameter number ..................................... 317 Production exception state colors ........... 322
Parameter type ........................................... 317 Production performance ........................... 323
Pareto/Pie Charts ................................... 67, 98 Production Summary .......................... 64, 151
Part weight ................................................. 318 Production time ......................................... 323
Parts Count Editor ..................................... 104 Profile ......................................................... 323
Parts per minute ........................................ 318 Profile Cross .............................................. 148
Percent down ............................................. 318 Profile Overlay ........................................... 147
Percent process exception ....................... 318 Profile parameter ....................................... 323
Percent rejects ........................................... 318 Profile Store ............................................... 149
Percent slow cycles................................... 318 Profile Tiled................................................ 146
Percent variance ........................................ 318 Pseudo end ................................................ 323
Pieces required .......................................... 318 Pseudo start .............................................. 324
Pieces to go ............................................... 318 Pseudo variable ......................................... 324
PlantStar Products ......................................26 PVAR History ............................................. 324
Playing an announcement ........................ 263 Queued job ................................................ 324
PLC ............................................................. 319 RAM size .................................................... 324
Polarity ....................................................... 319 Range ......................................................... 324
Port number ............................................... 319 Range control limits .................................. 324
Post-down delay ........................................ 319 Range max ................................................. 324
Primary contact ......................................... 319 Range mean ............................................... 325
Primary internet path................................. 319 Range min .................................................. 325
Print reports privilege ............................... 320 Real-time .................................................... 325
Printing a report to the screen .................. 263 Reason set ................................................. 325
Process and Production Monitoring ........ 202 Rebuilding the display .............................. 263
 vi SYSCON-PlantStar Help System

Recalling profiles ....................................... 263 Schedule selected job by due date .......... 329
Recording an announcement.................... 264 Scheduled idle time ................................... 330
Re-feed runners ......................................... 325 Scheduled jobs .......................................... 330
Re-feed scrap ............................................. 325 Scheduled machine usage........................ 330
Refreshing the display .............................. 264 Scheduled up time .................................... 330
Refreshing the lists ................................... 264 Scheduling jobs by due date .................... 268
Register number ........................................ 326 Scheduling jobs by earliest start date ..... 268
Reject count ............................................... 326 Scheduling selected jobs by due date ..... 269
Reject exception ........................................ 326 Search Product Standards........................ 269
Reject multiplier ......................................... 326 Searching for a job .................................... 270
Reject Pareto / Pie .......................................69 Searching material lots ............................. 271
Reject percent ............................................ 326 Selecting a machine state ......................... 271
Reject reason ............................................. 326 Selecting a period interval ........................ 272
Reject Reason Sets .....................................43 Selecting a time scale ............................... 272
Reject state colors ..................................... 326 Selecting a year ......................................... 272
Reject threshold ........................................ 326 Selecting criteria for a report .................... 273
Reject Update............................................. 138 Selecting current/queue jobs ................... 273
Reject_Pareto_Pie ..................................... 100 Selecting display groups from the schedule
Release Notes ............................................ 339 board ...................................................... 273
Removing child jobs from a product Selecting forecast intervals ...................... 274
standard .................................................. 264 Selecting product standards .................... 274
Removing child jobs from a work order ... 264 Selecting Report Criteria........................... 274
Removing machines from a display group Selecting specific machines ..................... 274
................................................................. 265 Selecting users .......................................... 275
Removing machines from a REU list........ 265 Selecting/viewing tote details ................... 275
Renaming a reason set ............................. 265 Sending a report to the printer ................. 275
Required by ................................................ 327 Set name .................................................... 330
Resizing columns ...................................... 265 Set report to display in HTML format ....... 275
Restore Session ..........................................36 Sets Menu .................................................... 41
Retrieve default product standard ............ 266 Setting down reason flags ........................ 275
REU ............................................................. 327 Setting report criteria ................................ 276
REU Setup ....................................................53 Setting up your System ............................ 206
RIO .............................................................. 327 Setup sheet ................................................ 330
Running state............................................. 327 Setup time .................................................. 330
Running state colors ................................. 327 Shift ............................................................ 332
Save Session ...............................................36 Shift count ................................................. 332
Saving Jobs as a Product Standard ......... 205 Shift history size........................................ 332
Saving process variables .......................... 266 Shift ID ....................................................... 332
Saving profile variables............................. 266 Shift idle period ......................................... 332
Saving reason sets .................................... 267 Shift length ................................................ 332
Saving your changes-Apply ...................... 268 Shift schedule ............................................ 332
Saving your changes-Update.................... 268 Shift Schedule ............................................. 88
Scale factor ................................................ 328 Shift Scheduling ........................................ 206
Schedule .................................................... 123 Shift-to-date ............................................... 332
Schedule Board Overview ......................... 190 Shop Floor Configuration ............. 25, 36, 210
Schedule factory ........................................ 328 Shop Floor Menu ......................................... 49
Schedule jobs and shifts privilege ........... 329 Shop Floor Monitor ............................... 25, 57
Schedule Menu ............................................80 Shop floor privilege ................................... 333
Schedule now ............................................ 329 Shot size .................................................... 333
Schedule reports privilege ........................ 329 Shuttle boot set ......................................... 333
 Index vii

Silence Mode.............................................. 117 Tote pieces ................................................ 337

Slow state ................................................... 333 Tote reject .................................................. 338
Software Configuration ............................. 161 Tote start tim ............................................. 338
Software Upgrades .................................... 177 Trigger delay .............................................. 338
Sorting columns ........................................ 276 Trigger event ............................................. 338
Source ........................................................ 333 Ty-Decimal ................................................. 338
SPC ............................................................. 333 Unassigned child jobs .............................. 338
SPC alarms ................................................ 333 Understanding Machine States ................ 214
SPC Graph Area ......................................... 334 Undoing your changes .............................. 277
SPC History ..................................................93 Units ........................................................... 338
SPC history size ........................................ 334 Up cycles ................................................... 339
SPC interval ............................................... 334 Up time ....................................................... 339
SPC Statistics Concepts ........................... 210 Updating a comm processor .................... 277
SPC subgroup............................................ 334 Updating a DCM......................................... 278
SPC subgroup size .................................... 334 Updating default Product Standard ......... 278
Specification limits .................................... 334 Updating existing standards .................... 278
SQC Sample ............................................... 150 Updating machines ................................... 278
Standard completion time ......................... 334 Updating schedules .................................. 279
Standard cycle ........................................... 335 Updating users .......................................... 279
Standard deviation .................................... 335 Upper spec................................................. 339
Standard multiplier .................................... 335 User Accounts ............................................. 39
Standard production time ......................... 335 User Defined Labels .................................... 40
Standard rate ............................................. 335 User Menu .................................................... 39
Standard rate factor................................... 335 User name .................................................. 339
Standard setup time .................................. 335 User Preference ........................................... 58
Standard shot weight ................................ 335 User Preferences ................................. 37, 217
Start date .................................................... 335 Using PlantStar Help ................................. 218
Start time .................................................... 336 Value .......................................................... 339
State Announcement ................................. 113 Variable long name ................................... 339
Storing profiles .......................................... 277 Variable short name .................................. 339
Suspend ..................................................... 336 View ............................................................ 122
Switch code................................................ 336 View and Print...................................... 26, 122
System Administration .............................. 161 View only privilege .................................... 339
System Architecture .................................. 214 Viewing job summary information ........... 280
System Features ..........................................28 Viewing machine detail ............................. 281
System icon ............................................... 336 Viewing machine exceptions .................... 281
System Overview .........................................27 Viewing machine status ............................ 281
System Parameters ................................... 112 Viewing min and max values .................... 281
Technical Support Contact ....................... 366 Viewing production hours ........................ 281
Toggling auto size and normal size.......... 277 Viewing the shift schedule........................ 282
Toggling Process and Profile view ........... 277 Voice file name .......................................... 339
Toggling tool change view ........................ 277 Voice Output ........................................ 25, 109
Tool ............................................................. 336 Weekly schedules list ............................... 339
Tool Change .................................................92 Weekly shift chart ...................................... 339
Total cycles ................................................ 337 Weight per part .......................................... 340
Total rejects ............................................... 337 Welcome to PlantStar.................................. 25
Tote box ..................................................... 337 What’s new in PlantStar 4.20 ...................... 33
Tote box size .............................................. 337 What's new in PlantStar 4.10 ...................... 34
Tote end time ............................................. 337 Window Menu .............................. 54, 105, 118
Tote history size ........................................ 337 Work center ............................................... 340
Tote ID ........................................................ 337 Work Center Setup ...................................... 45
 viii SYSCON-PlantStar Help System

Work order ................................................. 340 X-bar Control Limits .................................. 340

Work order privilege .................................. 340 X-bar Max ................................................... 341
Work Orders .................................................84 X-bar Mean ................................................. 341
Work Orders Import ................................... 179 X-bar Min .................................................... 341
X-axis .......................................................... 340 Y-axis ......................................................... 341
X-axis Value ............................................... 340 Zooming selected profiles ........................ 282
X-bar ........................................................... 340