COLOR PHARMACY 3.0Colorant, Resin, and Component Distribution

ORDERING AND ATTENDANT PHARMACY APPLICATION

ORDERING SCREEN

The pharmacy comes in two versions. The outside of the pharmacy runs on a touchscreen monitor and has a badge reader attached to it.

ATTENDANT SCREEN

The attendant screen is used inside the pharmacy. It is used to issue out all colorant, resin, components, etc. It needs a label printer and a Honeywell barcode scanner attached to it.

COLOR PHARMACY 3.0Ordering Process

ORDERING SCREEN

Located on the outside of the pharmacy.

OPERATOR LOG IN

Operator scans in using his or her badge or by typing in their employee ID number using the keypad.

OPERATOR INVALID

If a number is entered or a badge is scanned that is not recognized by the system a error toast window pops up. Valid users can be entered from the attendant’s screen (see slide xx).

NEW SCHEDULE DATAIf new production schedule data is detected it is loaded automatically. This detects both PASS and FQVT scheduled data. This will also interact with Hydra.

ORDER SCREEN MAIN

COLORANTIssued by the bucket

MOLD COMPONENTS

Components that are needed for press side assembly. These are issued by the standard pack.

RESINIssued by full containers.

ASSEMBLY COMPONENTSComponents used in assembly cells. These are also issued by the standard pack.

ALTERNATIVE PACKAGINGAlternative cardboard packaging.

PROCESS BOOKSBoth process and ODS books are issued at the same time. You must return the previous books to get the new ones.

PRODUCTION LABELSThese are preprinted labels stored in mail boxes. They are only issued once they are ordered.

PURGE COMPOUND

This is a set weight based on press tonnage. Issued in buckets.

NEW COLOR ORDER

COLOR/TOOL CHANGEWhen changing tools or colors select using the COLOR/TOOL CHANGE button.

PRESS SELECTION

Choose the press colorant is needed for. Each separate color represents a zone of presses within a facility. This is configurable within the system.

ORDER SELECTION

Operator chooses the correct operation from the production schedule. If a family tool is chosen (produces both left and right parts) the system automatically combines the orders so that the correct amount of colorant is requested.

SELECT AND PLACE ORDERChoose the job from the list and click the ‘SELECT’ button at the top.

COLOR ORDER PLACEDToast box confirm order has been placed.

OFF SCHEDULE ENTRY

If an order is not listed (emergency mold change) you can use the ‘Off Schedule Entry’ screens to place a manual order for colorant.

OFF SCHEDULE ORDERChoose a tool. The keyboard is ‘smart’ and only allows you type characters from existing known tools.

CHOOSE TOOL

CHOOSE PART NUMBERCascading combo boxes narrow the search fields

ENTER QUANTITYEnter the quantity needed for the operation

ORDER CONFIRMATIONIf a family tool is chosen (produces both left and right parts) the system automatically calculates the total weight needed.

COLOR ADDWhen an order requires more colorant than can be issued at once the ‘COLOR ADD’ process is used.

PRESS SELECTIONEmployee selects the press that more colorant is needed.

CURRENT ORDERThe currently running order information is presented. If correct, an order is simply placed.

ORDER DETAILThe remaining pounds of colorant is listed. The system keeps track of the total pounds needed and how much has already been issued.

NEW RESIN ORDER

PRESS SELECTIONChoose the press that needs resin.

ORDER SELECTIONChoose the job from the list and click the ‘SELECT’ button at the top.

ORDER CONFIRMATION

OFF SCHEDULE ENTRYIf an order is not listed on the order selection screen a manual order can be placed. Enter the tool, part number, and the quantity and submit the order.

MOLDING COMPONENTS

PRESS SELECTION

Choose the press that components are needed for.

OPERATION SELECTIONChoose the operation from the production schedule.

SELECT QUANTITIES

Based off of the Bill of Material a list of components for the selected order are presented. Select the quantities of each component needed.

PLACE ORDEROnce the quantities are selected click the ‘SELECT’ button at the top to place the order.

OFF SCHEDULE ORDER

OFF SCHEDULE ORDEREnter the tool, color, and quantity needed for the manual order.

COMPONENT SELECTIONComponents are issued by standard pack. Select the number of standard packs needed for each component. The system calculates the total number of components needed using the Bill of Material and rounds up to the next nearest standard pack. It limits the order to that value.

ASSEMBLY COMPONENTS

ASSEMBLY ORDER

CHOOSE ASSEMBLY UNITAn assembly unit is chosen to narrow down the tool and color search. An assembly unit is typically made up of several tools supplying the same customer.

CHOOSE TOOLSelect the correct tool number.

CHOOSE COLORChoose the color

ENTER QUANTITYEnter the total quantity needed. If a family tool is selected the correct components will be selected.

CHOOSE QUANTITIES

Components are issued by standard pack. Select the number of standard packs needed for each component. The system calculates the total number of components needed using the Bill of Material and rounds up to the next nearest standard pack. It limits the order to that value.

PROCESS BOOK ORDERProcess and ODS books.

OPERATION SELECTIONChoose the operation from the production schedule. Press the ‘SELECT’ button to place the order.

MANUAL ORDERA manual order can be placed using just the tool number.

PRODUCTION LABELS

ORDER SELECTION

Choose the operation from the production schedule. Press the ‘SELECT’ button to place the order.

PURGE COMPOUND

SELECT PRESSPurge compound is issued out by weight. This weight is static based off of the tonnage of the press. Once you select the press an order is placed. No need for an order selection.

COLOR PHARMACY 3.0Attendant Process

ATTENDANT SCREEN

BADGE INDICATORSThe badges on each button indicate how many orders are currently open for each category.

FLASHING INDICATORA red flashing badge indicates that the category has the oldest order still open.

COLORANT ORDERS

BLOWING AGENT ORDERSIf a tool requires blowing agent an automatic blowing agent order is placed with the colorant. This is a separate process and requires an different bucket.

RESIN ORDERS

RESIN RETURNSPartial containers of resin are checked back in to the pharmacy using this process.

COMPONENT ORDERS

FILL COMPONENT ORDERSOnce component order labels are printed the issuing process starts here.

RETURN PARTIAL COMPONENTSPartial components can be returned to the pharmacy using this process.

PURGE COMPOUND ORDERS

PROCESS AND ODS BOOK ORDERS

ALTERNATIVE PACKAGING ORDERS

PRODUCTION LABELS

FILL COLOR ORDERProcess to fill a color order.

BUCKET INFORMATIONEach press is assigned a specific bucket. Label on bucket must be present to get issued colorant. Barcode is used to identify the assigned press and the order/colorant currently associated to the press.

SCANNERA Honeywell 4820i scanner is used for all transactions within the pharmacy.

ORDER SELECTION

Attendant selects the order to fill from the list of currently open orders.

ORDER TYPESIn the order type column either a CC or a CA will be listed. CC indicates the order is a full color or tool change. A CA indicates that a color add has been requested.

BUCKET SCANAttendant scans the bucket to begin the color issuing process.

WRONG BUCKET/LABELIf a label is scanned that is not associated with the order/press selected a warning will pop up with an audible tone (buzzer) to alert the attendant.

CORRECT LABELIf the correct label is scanned the screen flashes green and an audible tone (ding) is heard to let the attendant know the information is correct.

BUCKET WEIGHTThe bucket is then placed on a scale to determine the amount of colorant that is being returned. This is to allow the return of unused colorant. If no colorant is being returned a ‘0’ is entered here.

RETURNING COLORANTA weight of 3.5 pounds was entered in the previous screen. The process to return colorant is started. The returning colorant is listed in the window and there is a hatching pattern used as a visual indicator to the attendant that this is the colorant return process.

BARREL SCANThe attended proceeds to the correct barrel corresponding to the returning colorant. The attendant scans the part number on the barrel of colorant. In this example the attendant has scanned the wrong barrel of colorant.

WRONG BARRELThe screen flashes red and an audible tone (buzz) is heard to indicate that the correct barrel of colorant was not scanned.

CORRECT BARREL

If the correct barrel is scanned the screen flashes green and an audible tone (ding) is heard. The attendant now knows that the correct barrel was scanned.

LOT NUMBER SCANThe lot number is then scanned to record the returning barrels information. Lot numbers have a 1T prefix. In this example the barrel weight barcode has been scanned.

WRONG LOT NUMBERThe screen flashes red with an audible tone (buzz) to indicate that the incorrect barcode has been scanned.

CORRECT LOT NUMBEROnce the correct lot number barcode has been entered the return process is completed by the attendant. The colorant in the bucket is dumped into the barrel and the bucket is cleaned out. The outgoing colorant process can now begin.

OUTGOING COLORANTThe attendant proceeds to the outgoing colorant barrel. The colorant number is shown on the screen and the hatching pattern is no longer on the screen as a visual indication that this is not a return process.

WRONG COLORANTThe attended proceeds to the correct barrel corresponding to the outgoing colorant. The attendant scans the part number on the barrel of colorant. In this example the attendant has scanned the wrong barrel of colorant.

WRONG COLORANTLike the colorant return, the screen flashes red and an audible tone (buzz) is heard to indicate that the correct barrel of colorant was not scanned.

CORRECT COLORANTIf the correct barrel is scanned the screen flashes green and an audible tone (ding) is heard. The attendant now knows that the correct barrel was scanned.

LOT NUMBER SCAN

The lot number is then scanned. This process has the same audible indicators as the return process.

ORDER WEIGHTA visual indicator is shown to let the attendant know approximately how much colorant is needed for the order. This is based on the calculated weight needed for the order using the Bill of Materials. The standard bucket can hold approximately 21 pounds of colorant. This visual indicator is divided into thirds with each representing 7 pounds. This is only to assist the attendant from having to make numerous trips to the same barrel. Since more than 21 total pounds was needed for this order a full bucket is issued.

SUMMARY SCREEN/WEIGHT ENTRYThe full bucket is the placed on a scale and the weight is entered into the system.

NEW LABELA new order label is printed. The old label is removed from the bucket and discarded. The order number on this label has a prefix to indicate the type of order (CC or CA). This new label is then placed on the bucket and the colorant is given to the material handler to take to the press. This concludes the color order fill process.

COLOR ADD PROCESSThe CA (Color Add) process is similar to the full color change with one exception. There is no process to return colorant. The systems assumes since it is a color add that a completely empty bucket is being returned. The system skips the color return process and goes immediately to the outgoing colorant process.

RESIN ORDERS

ORDER SELECTIONAttendant selects the resin order needed to be filled.

RESIN SCANThe container of resin is scanned.

WRONG RESINIf the wrong resin is scanned all the same audible/visual warnings are used.

LOT NUMBERThe lot number is scanned.

CONTAINER WEIGHT

The container is then weighed and the weight is then entered into the system.

RESIN LABELA resin order label is then printed and placed on the container.

RESIN RETURNS

RESIN RETURNUnused resin is returned to the pharmacy. The hatching pattern at the top is a visual indicator that this is a return process. The label that was printed in the outgoing process is scanned.

CONTAINER WEIGHTThe container is then weighed and that weight is entered into the system.

RESIN LABELA new resin container label is printed. This is used in the outgoing process. The attendant can now scan this label to enter the outgoing information – including the weight. This saves time when issuing partial containers. This completes the resin return process.

COMPONENT ORDERS

COMPONENT ORDER SELECTIONThe component order to be filled is selected and the ‘Print Order’ button is pressed.

COMPONENT LABELS

A label is printed for each component for the order. If multiple standard packs are needed a label for each box is printed. Meaning if an order will need a total of 3 standard packs to complete then 3 individual labels for that component are printed.

FILL COMPONENT ORDERS

SCAN LABEL

COMPONENT LABEL SCANThe process starts by scanning the label that was printed for the component.

SCAN COMPONENT PART NUMBERThe attendant is prompted to scan the part number on the container of the component.

PART NUMBER SCAN

The barcode on the box is scanned.

WRONG COMPONENTThe same audio and visual indicators are used in this process (buzz/red ding/green).

CORRECT COMPONENTIf the part number is correct the attendant is prompted to enter the quantity. This is done by a scan of the barcode on the container.

QUANTITY ENTEREDThis completes the transaction.

COMPONENT RETURNS

SCAN COMPONENT LABELAttendant scans the pharmacy label on the returning component. This is why it is important that every box of components gets a label. This label is needed for returns.

PART NUMBER SCANThe part number on the box is then scanned again to verify that it is the same as the label indicates.

SCAN PART NUMBERIf part numbers match the attendant is required to count the pieces and enter that number on the following screen.

ENTER QUANTITYThe total number of pieces being returned is entered.

NEW COMPONENT LABELA new label is then printed and placed on the box. This allows the attendant to quickly scan these barcodes when issuing out this partial box. This also speeds up inventory as these partial boxes already have the remaining quantity listed.

BLOWING AGENT

ORDER SELECTIONThe blowing agent order is selected.

SCAN BLOWING AGENTThe same process is followed as colorant. The same tones and color poke yokes are used. The bucket fill indicator is also used to indicate how much blowing agent should be issued.

WEIGHT ENTEREDTotal weight is entered.

BLOWING AGENT LABELA blowing agent label is printed and placed on the separate blowing agent bucket.

BOOK ORDERS

BOOK ORDER SELECTION

SCAN RETURNING BOOKSThe returning books are scanned back into the system.

OUTGOING BOOK SCANThe outgoing books are scanned out of the system.

PURGE ORDERS

PURGE COMPOUND ORDER SELECTION

PART NUMBER AND LOT NUMBER ARE SCANNEDBucket fill indicator is used to indicate total weight of purge compound needed.

PURGE LABELA purge label is printed and applied to the purge bucket.

ALTERNATIVE PACK

ADDITIONAL SCREENS

SCRAP MATERIALAllows attendant to enter scrap materials. Part number is entered followed by a total amount. This can be in pieces or pounds based on the commodity.

EMAIL MATERIALSAllows attendant to instantly notify the materials team of an issue in the pharmacy. Attendant can select from a number of predefined subjects. The body is comprised of detail letting the team know exactly what the issue is.

ADDITIONAL SCREENSSome maintenance screens for the attendant.

ORDER HISTORYCan list the last X amount of transactions.

TOOL INFOLists the combination of tools, part numbers, colorants, and resins that the system uses.

FILTERED INFORMATIONGrid allows filtering to easily search for specific strings. This makes troubleshooting much easier.

SUPPLIER LABEL REPRINTAllows the attendant to print a label that can be applied to a supplier component. On occasion a container will come in with a barcode that cannot be scanned. This option prints a scannable label for transactions within the pharmacy.

PHARMACY LOCATION LABELThe pharmacy uses a visual system for labeling in the racks. This allows you to print a new colorant location label if one is missing or colorants get moved.

LOCATION LABELThe colorants are stored 2 deep under the racks. This is a visual indication to the attendant of which colorant is located in front and which is in the back.

ADD USERIf a user is not found in the system they can be added here. Enter the employee’s name.

BADGE INFORMATIONEnter or scan their badge information. This will allow them to log in to the ordering system.

These indicators at the bottom of the screen let the attendant know how many of each order are open. These also flash based on FIFO. They are also shortcuts to allow the attendant to jump from screen to screen without returning to the main window.

SHORT CUTS

If an order is more than X minutes old a reminder on the attendant screen will pop up and remain for 5 seconds. It then fades out. They system can check every X seconds to see if any orders are overdue.

GROWL LIKE NOTIFICATIONS

It is just a reminder to the attendant that these orders have fallen outside of the predetermined window of filling orders. This is totally configurable.

GROWL CLOSE UP

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