MANUAL INOVEX SYSTEMS LIMITED 1 Windows Dispense and Checkweigh Systems INOVEX MANAGEMENT SYSTEMS IIN O V E X S Y S T E M S L IIM IIT E D INOVEX SYSTEMS LIMITED NOVEX SYSTEMS L M TED Windows User Manual Inovex Systems Limited Alexander Court Fleming Road Earlstrees Industrial Estate Corby Northants NN17 4SW United Kingdom T: +44 (0) 1536 400222 F: +44 (0) 1536 400133 sales@inovexsystems.com www.inovexsystems.com Inovex Systems Ltd. All rights reserved. No part of this manual, including interior design, cover design and icons may be reproduced or transmitted in any form, by any means (electronic, photocopying, recording or otherwise) without prior written permission of Inovex Systems Ltd. Copyright©2003 LIMIT OF LIABILITY.DISCLAIMER OF WARRANTY: THE AUTHOR AND PUBLISHER HAVE USED THEIR BEST EFFORTS IN PREPARING THIS MANUAL. INOVEX SYSTEMS AND INOVEX SOFTWARE AND AUTHORS MAKE NO REPRESENTATION OF WARRANTIES WITH RESPECT TO THE ACCURACY OR COMPLETENESS OF THE CONTENTS OF THS MANUAL AND ESPECIALLY DISCLAIM ANY IMPLIED WARRANTIES OF MECHANTABILITY OF FITNESS FOR A PARTICULAR PURPOSE. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTIONS CONTAINED IN THIS PARAGRAPH. NO WARANTY MAY BE CREATED OR EXTENDED BY SALES REPRESENTATIVES OR WRITTEN SALES MATERIALS. THE ACCURACY AND GUARANTEED OR WARRANTED TO PRODUCE ANY PARTICULAR RESULTS, AND THE ADVICE AND STRATEGIES CONTAINED HEREIN MAY NOT BE SUITABLE FOR EVERY INDICIDUAL. NEITHER INOVEX SYSTEMS AND INOVEX SOFTWARE NOR AUTHOR SHALL BE LIABLE FOR ANY LOSS OR PROFIT OR ANY COMMERCIAL DAMAGES, INCLUDING BUT NOT LIMITED TO SPECIAL, CONSEQUENTIAL OR OTHER DAMAGES. Trademarks: All brand names and product names used in this manual are trade names, service marks, trade marks or registered trademarks of their respective owners. Inovex Systems and Inovex Software is not associated with any product or vendor Table of Contents THIS SECTION APPLIES TO DISPENSE SYSTEMS ONLY 5 GENERAL OPERATION AND SAFETY GUIDELINES GENERAL OPERATION EMERGENCY STOP OPTIONS RESET AFTER EMERGENCY STOP GENERAL SAFETY HAZARDOUS AREA OPERATION STATIC ELECTRICITY WHY CARE ABOUT SAFETY? 5 5 6 6 7 7 7 8 MATERIAL ORDERS RECEIVED (COMPLETE) 28 MATERIAL ORDERS RECEIVED (COMPLETE BY SUPPLIER) 28 MATERIAL STOCK 28 MATERIAL PRINT OPTIONS 29 MATERIAL GRAPHS 30 THE FORMULATIONS MENU 31 MANAGEMENT SOFTWARE NAVIGATING THROUGH THE PROGRAM COMMON PROGRAM ELEMENTS 9 10 10 THE UTILITIES MENU INK CATEGORY COLOUR GROUPS CUSTOMERS DELETED FORMULATION LIST DELETED MATERIAL LIST DELIVERY ADDRESSES FORMULA TYPE DOWNTIME REASONS FORMULA TYPES JOB CATEGORY MATERIAL TYPE PACK SIZES PRESSES PRESS RETURN LOCATIONS PRINT PROCESS PROCEDURES RECIRCULATION TABLE STANDARD TEXT SOLVENT TYPES SUBSTRATES SUPPLIERS REPLACE MATERIAL PERCENTAGE PRICE CHANGE SETUP PASSWORDS 12 13 13 13 14 14 14 14 14 15 15 15 15 15 15 16 16 16 17 17 17 17 17 17 18 21 FORMULATIONS 31 FORMULATION LIST 33 FORMULATION LIST BY DATE CREATED 33 FORMULATION LIST BY DATE AMENDED 33 FORMULATION LIST BY SUBSTRATE 33 FORMULATION LIST BY INK TYPE 34 FORMULATION LIST BY COLOUR GROUP 34 FORMULATION LIST BY FORMULA TYPE 34 FORMULATION LIST BY COLOUR GROUP AND FORMULA TYPE 34 FORMULATION CODE WILD CARD SEARCH. 34 FORMULATION NAME WILD CARD SEARCH. 35 FORMULATION SEARCH BY L*A*B*. 35 FORMULATION PRINT OPTIONS 35 THE DESIGNS MENU DESIGNS DESIGN LIST BOX DESIGN LIST BY SELECTED CUSTOMER DESIGN WILD CARD SEARCH DESIGN PRINT OPTIONS 37 37 38 38 39 39 THE JOBS MENU JOBS CURRENT WORKS ORDERS FINISHED WORKS ORDERS ISSUE MATERIAL TO JOB JOB TO JOB TRANSFER ISSUE FORMULATION TO JOB DOWNTIME WORKS ORDER PRINT OPTIONS 40 40 41 42 42 42 42 42 43 THE DISPENSE LOG MENU DETAILED DISPENSE LOG BY MATERIAL SUMMARY DISPENSE LOG DISPENSE LOG PRINT OPTIONS 44 44 44 44 THE MATERIALS MENU 23 MATERIALS 23 MATERIAL ORDERS 26 MATERIAL ORDERS (INCOMPLETE) 27 MATERIAL ORDERS (COMPLETE) 27 MATERIAL ORDERS (COMPLETE BY SUPPLIER) 27 MATERIAL ORDERS RECEIVED 27 MATERIAL ORDERS RECEIVED (INCOMPLETE) 28 THE PRESS RETURNS MENU 46 FORMULATIONS AVAILABLE IN PRESS RETURNS 46 FORMULA SEARCH LIST 46 PRESS RETURNS SEARCH BY LOCATION 46 MATERIALS AVAILABLE IN PRESS RETURNS 46 RETURN FORMULATED INKS INTO PRESS RETURNS 47 RETURN MATERIALS INTO PRESS RETURNS 47 L*A*B* PRESS RETURNS SEARCH 47 PRESS RETURN PRINT OPTIONS 47 THE MANAGEMENT MENU THE MANAGEMENT MENU 49 49 THE ADDRESS BOOK THE ADDRESS BOOK 51 51 WEIGH/REMIX MANUAL WEIGH AND REMIX 52 52 DISPENSING DISPENSING DISPENSING BY WORKS ORDER FORMULA DISPENSE MATERIAL DISPENSE LOOK IN PRESS RETURNS RETURN INKS MANUAL DISPENSING THIS SECTION APPLIES TO CHECKWEIGH SYSTEMS ONLY 54 56 57 57 58 58 58 59 60 61 THIS SECTION APPLIES TO DISPENSE SYSTEMS ONLY SYSTEM MAINTENANCE ROUTINE MAINTENANCE DISPENSING VALVES 61 61 61 63 64 64 64 64 PUMPS REPLACING A PUMP HOSES STRAINERS (IF FITTED) RE-CIRCULATION SCALE 63 SOFTWARE MAINTENANCE BACKING UP DATA RESTORING DATA COMPACT BLANK REPAIR WHAT TO DO IN CASE OF PROBLEMS THE SYSTEM HANGS DISPLAY OF ERROR MESSAGES 65 65 66 66 66 66 66 66 67 CUSTOMER SUPPORT TECHNICAL SUPPORT BY MAIL BY PHONE/FAX BY EMAIL SPARES 68 68 68 68 68 68 INOVEX USER MANUAL A Section This section applies to dispense systems only General Operation Safety Guidelines Creating A Safe Working Environment and As with any equipment containing moving and hazardous parts there are certain safe working procedures and practises that must be adhered to achieve a safe working environment. Inovex dispense systems are approved for the application for which they were designed according to the specification stated at the time of order. General Operation The procedure detailed below should be followed systematically to place the system into operation for the first time or after it has been shut down. Two services are required to operate the system, the first being air which serves the pneumatic switches, dispensing valves, pumps and pneumatic logic control and secondly an electrical supply is required to drive the control system and the computer. 1. 2. 3. 4. 5. Switch on the dispense unit control via the isolator. Put the power on to the computer and allow the start-up software to run. Ensure all Emergency Stops are unlocked and the system is switched to automatic dispense mode on the key switch. Ensure the power lamp is on, if not press the reset button on the dispense console desk. Ensure that power is on to the scale. Ensure that there is a minimum air pressure of 80 psi (5.4 bar) indicated on the pressure gauge in the dispense console. The system is now ready to run. 5 INOVEX USER MANUAL RESPONSE OF THE DISPENSING VALVES. RENDER THESE VALVES INOPERATIVE. NOTE: AIR PRESSURE OF LESS THAN 80 PSI (5.4 BAR) WILL RESULT IN A SLUGGISH AIR PRESSURE OF LESS THAN 60 PSI MAY Emergency Stop Options In the unlikely event of an emergency and it is necessary to perform an emergency stop, there are a number of options that can be chosen. 1. Depress the Emergency Stop button on the dispensing stand. 2. Switch off the main isolator. 3. Isolate the Air supply Reset after Emergency Stop In the event of any of the emergency stops having been operated, to render the system operative again: 1. 2. Ensure that the stops are returned to the 'out' position. Press the system reset button on the dispense enclosure. There are indicator lamps to show the system status. If the lamps are not lit, press the Reset button on the control panel. You should now be able to continue dispensing. PLEASE NOTE THAT IF THE EMERGENCY OCCURRED DURING A DISPENSE AND COMPUTER WAS NOT SHUT DOWN DURING THE EMERGENCY, THE COMPUTER MAY CONTINUE DISPENSING WHEN RELEASING THE EMERGENCY STOP. 6 INOVEX USER MANUAL General Safety The following methods, procedures and practises must be adopted when operating the dispense system - · Do not operate the dispenser without all the panels and · · relevant safety items and guards in place, as there are moving parts under automatic control. Always wear the appropriate safety equipment when operating the system including safety spectacles. Before attempting to carry out any maintenance, repairs or modifications to the dispenser or its ancillary equipment: · Switch off the control system, isolate the electrical supply, isolate the air supply and vent any residual pressure. · Shut off and drain any ink, which may cause a health or safety risk from the supply and delivery lines and ensure you have permission to work on the system. Observe routine maintenance procedures as laid down in this manual. Ensure that the area around the dispenser and ancillary equipment is clear of personnel and or obstruction before operating the system. Check for correct container alignment before initiating a dispense procedure. Observe handling instructions and specific safety guidelines for the relevant inks being dispensed. · · · · Hazardous Area Operation 2 If your system is designed to operate in a hazardous area the dispenser may be handling highly combustible inks and as such all the appropriate Zone 1 safety procedures and working practises over and above those listed below MUST be implemented. Static Electricity Static electricity is a very common phenomenon caused whenever two dissimilar inks separate. This separation causes an imbalance of electrons which in turn creates a voltage which, when discharged, causes a current to flow. 7 INOVEX USER MANUAL If you experience static shocks from any of your equipment, first check that all the equipment is earthed correctly. If everything checks out OK, you can eliminate the risk by using some of the equipment mentioned in the paragraph below. In general, to avoid getting a static shock when handling pipes, working with computer equipment and dispense equipment etc. there are several products available on the market, which help eliminate the risk. These include wristbands, ground heels, ionisers and grounding kits. It is especially important to be aware of the dangers of static when working in a hazardous Zone 1 area and to ensure all barrels are connected to bonding clamps. Moreover, the dispense vessels should be made of conducting material and grounded using the earth clamp. Why care about safety? Should you hesitate whether or not to adhere to safety regulations, think about the possible hazards you may be exposed to when not observing the safety guidelines: · · EXPLOSION TRAPPING SYSTEM BY MOVING PARTS SUCH AS SCALE CARRIAGE AND HEADWASH · SPRAYING WITH FLUID WHEN DISCONNECTING A VALVE, PUMP, FILTER HOSE OR · SPILLAGE 8 INOVEX DISPENSE SYSTEM MANUAL B Section Management Software Starting and navigating through the Program To launch the Windows Management Software use the shortcut icon on your desktop or go though the Start menu. When the program is launched you will see the system entry screen. Entry Screen To gain access to the program, use the Operator Code and passwords that are supplied by Inovex Systems. If you do not have these, contact Inovex to help you through this screen: · In the Operator Code pull down box select the desired operator and press enter or Tab. · In the Password box type your personal password. Press Log On and you will now go to the main program menu screen. 9 INOVEX DISPENSE SYSTEM MANUAL Navigating Through the Program The best way to move around a screen in Windows is to use a mouse-pointing device. This manual assumes that a mouse/tracker ball is attached to the computer. Menu Bar The figure shows the Menu Bar from the Windows Management Software. Select the appropriate menu and a pull down will appear containing sub categories for that selection. Common Program Elements Command Buttons and Other Common Elements. Throughout all the screens in the software there are certain commands and elements which remain constant. For example, the picture shows a common Button Bar which appears in most of the screens with either the same configuration or one or two buttons added or removed. a) a) b) c) d) e) f) g) h) b) c) d) e) f) g) h) First record in set Previous record Next record Last record in set Add new record Exit the form Shortcut (e.g. From Materials to Formulations) Opens the report functions available for the current category 10 INOVEX DISPENSE SYSTEM MANUAL a) a) b) c) d) b) c) d) Delete a record Pull down box containing the list of records for the current category Edit current record Refresh current record (used to force screen update) a) b) c) a) Preview a report b) Print a report c) Export a report to file The actions of each Command button are described above and remain constant throughout most of the screens. When you request the program to complete or instigate a task, a pop up dialogue box may sometimes appear in the middle of the screen. This screen will ask to confirm tasks such as deleting records by instructing you to press either the 'y' key for yes, or the `n' key for no. The figure below shows a typical pop up dialogue box. Pop up Dialogue Box. 11 INOVEX DISPENSE SYSTEM MANUAL Chapter 1 The Utilities Menu In order to effectively use the program you must first build a database containing all your records. To do this you initially use the input menus in the Utilities Menu, Sub group. The database will allow you to keep an up to date list of all your customers, ink categories, press return locations, passwords and any other setup information relevant to the dispense operation. The common name for an area where you input information is a Form. Information entered on these Forms is stored in Tables. Tables allow the database to build up relationships between information, which may be contained in several different tables through preprogrammed links. This is known as a relational database. Most of the records you enter follow the same pattern, making use of the button bar described earlier and allowing the use of codes, descriptions etc. The following examples will guide you through entering your first records and describe briefly the different options available on the screens as you progress through the program. The best way to learn the program is to experiment with all the different options and routines. Once you have carried out a task several times you will see that most of the other tasks you perform will follow the same pattern. 12 INOVEX DISPENSE SYSTEM MANUAL Ink Category The first screen we will look at in the Utilities menu is the Category screen. This form is used to enter ink type; the table is already preprogrammed with solvent based, water based & UV inks. Should you wish to add a new record, click the add record button and enter a new ink type into the form. To save the information simply exit the form. Colour Groups The colour groups form contains a list of the most common colours used within printing. These are used throughout the software to assign a colour swatch to a particular Material of Formulation record. This will aid visual identification of the particular colour whilst dispensing. To add a new record click the add record button and enter a colour name into the form, simply select the desired colour from the palette and save the record. Tip. If the desired colour is not available within the palette simply select the nearest colour and nudge the Hue by clicking R, G or B. Customers To enter a new record into this part of the database follow the procedure below which will add the name and address of a new Customer to the table. ð When the form is initially opened the cursor will initiate within the Customer Code field. Enter a code to provide a shortcut to this record when the details of the Customer are needed in other parts of the program. Press Enter to continue. ð Enter the Name of the Customer in the Name text box and Contacts in the Contact box. Press enter to continue ð Enter the Customers address details in the Address text box. Press Enter. ð Enter the telephone numbers and email in the relevant fields. ð Exit the form to save the record. ð You may now continue to add your records by repeating the above procedure. Refer to the Button Bar paragraph earlier in this section to check the command button functions. 13 INOVEX DISPENSE SYSTEM MANUAL Deleted Formulation List Once a formulation has been deleted from the formulation record set it will be archived and stored should you wish to recover the deleted data. To undelete a formulation simply double click the deleted formulation you wish to recover, this will display a new form showing formulation details and an `Undelete this Formulation' button in the upper right hand side of the form. Click this button and the formulation will be undeleted. Deleted Material List Once a material has been deleted from the material record set it will be archived and stored should you wish to recover the deleted data. To undelete a material simply double click the deleted material you wish to recover, this will display a new form showing material details and an `Undelete Material' button in the upper right hand side of the form. Click this button and the material will be undeleted. Delivery Addresses This is required for the material order processing part of the software. Enter into this form details of the delivery addresses to which you may want materials to be delivered. You can have more than one delivery address if required. To add a new record click the add record button and enter a new location into the form. To save the information simply exit the form Formula Type This is required to identify the formula type or ink type in the formulation form. Enter into this form details of different formula types you are going to have on the system. Typically this might be `Water Based Ink', `Solvent Based Ink'. Downtime Reasons This is used in the press downtime monitoring functions of the software. Reason codes can be assigned to press downtime and these are set up in this module. The form contains three fields, a reason code and two description fields explaining the meaning of the reason code. 14 INOVEX DISPENSE SYSTEM MANUAL Formula Types This is required to identify the formula types in the formulation form and at the Checkweigh/Dispense screen. Enter into this form the names of different formula types you are going to have on the system. Job Category This is used to identify different job categories. The form contains two fields, the first is an automatically generated identification number, the second is the job category. Typically this might be `Flexo', `Gravure' etc. Material Type This is required to identify the Materials and Formulations type in the Material Form and the Formulation Form. Enter into this form details of different Material types you are going to have on the system. By default these are set to `Colour', `White', `Lacquer' and `Other'. Pack Sizes Pack Sizes are required by the material order processing system. Enter into this the different pack sizes that material would normally be delivered in. Typically this might be `Barrels', `Pails'. Any number of different pack sizes can be entered. Presses This is required to identify the press a design or job is going to be printed on. Enter into this form details of the printing presses. The form has three fields, Press Number, Press Name, and Startup Amount which is used by the ink estimation software to ensure that at least the minimum amount of ink required to start a press and maintain it running is estimated. Press Return Locations Press return locations are used to identify where a press return is stored once returned from the press. To add a new record click the add record button and enter a new location into the form. To save the information simply exit the form 15 INOVEX DISPENSE SYSTEM MANUAL Print Process This is required to identify the print process in the design file. The form has two fields, Print Process which might typically contain `Flexo', `Gravure' etc and a default GSM for the ink estimation. The default GSM can be overridden in the design file if required to do so for individual formulations as they are added to the design. Procedures Standard procedures are installed here, and can then be applied to certain production methods as a standard text addition. Recirculation Table The `Recirculation Table' controls when and for how long each group of ingredients are recirculated. Enter a time zone between which you want the ingredients to be recirculated (normally 24hours but some cases vary). Then set the start and end times of each group's time to be recirculated. On the table shown, group 1 will start at 00 minutes and finish two minutes later. Group two will then start and run for two minutes. Group three will then start and so on until group 6. 16 INOVEX DISPENSE SYSTEM MANUAL Standard Text Standard text's are accompanying comments which can be added to designs at the time of installing them. If the same comments or procedures are used over and over, they can be set up as standard text, and are then obtainable by a simple draw down in the designs screen. Solvent Types This is required to identify the different solvents that may be contained within the raw materials and is used when allocating a percentage of solvents to a material in the material file. The form has two fields, solvent code and solvent name. Substrates This is required to identify the substrate that a design is to be printed on in the design file. The form has four fields, Substrate Code, Substrate Name, Supplier and Cost per Square Meter. Suppliers This is required by the material order processing system. Enter in here details of your material suppliers. Any number of suppliers can be included. Replace Material This module can be used to make bulk replacement of a material with another in the formulation file. If a material is to be replaced then the replacement material must first be entered onto the material file. In order to use this feature first select the material to be replaced as indicated, then the material to replace it, and finally, if relevant the percentage of the original that the replacing material is to have. Percentage Price Change This module can be used to make bulk changes to the price of materials by a given percentage for a selected supplier. 17 INOVEX DISPENSE SYSTEM MANUAL Setup The setup form contains configuration settings for the dispenser and management system. Below are extracts from the form. The above check boxes should be set as to the type of system you are running. The colours of the software can be configured manually. Clicking the box to the right of the number will start a colour palette for colour selection. Press returns can be costed in different ways depending on the users requirements. The above settings will cost an ink returned at £2 per KG and issued at £2 per KG. Should you wish to cost returns at a percentage of the original value select the % option. Communications settings for the PLC or scale (in Checkweigh mode). These should not be altered. 18 INOVEX DISPENSE SYSTEM MANUAL Dispense accuracy settings can be configured from within setup or by individual material depending on selection. Time in seconds for the dispense screen to default to operator log on. Default setting for where stock is added on the system when using the stock control functions of the software. Wash time & Drain time in seconds for automatic head wash systems. Max weight, inclusive of bucket weight, to ensure dispenser does not overfill a bucket. Min weight should be slightly lower than the intended bucket weight to ensure the dispenser does not dispense without a bucket on the scale. 19 INOVEX DISPENSE SYSTEM MANUAL By checking the uppermost box the dispenser, following a dispense, will offer an option to print a dispense ticket. Depending on the above selection and font size will determine what is printed on the ticket. Default dispense amounts that operators will be offered at the Dispense screen. Enables or disables buttons on Dispense screen main menu. Should the dispenser see a loss in weight of the above value the dispense will be suspended, thus assuming the bucket has been removed. Enables or disables Works Order option on the dispense screen. Check this if you don't want to use Works Orders (Jobs). Is used to automatically check for 100 parts when formulations are added or entered. The second check box will produce a warning if a material is entered into a formula at a higher percentage than its preset maximum amount. 20 INOVEX DISPENSE SYSTEM MANUAL If `Warn if Stock on Dispenser is Low' is checked, the dispense screen will check to ensure there is enough stock of the relevant materials to fulfil the dispense requirement. All other options are not used in this version. Select from Language list whether the software is to run in Chinese or English (UK). The two options below are used by translators to convert the operating language. Do not select these. Passwords This form is used to set up the operators for logging on to the management system and the dispense screen. The form contains four fields, Operator Code, Operator Name, Operator Rights(Not used) and Password. For each operator, check the boxes below for each of the main menu areas the operator is to have access to. Also check the relevant edit check box if the operator is to be able to edit and not just view the information in that area of the system. 21 INOVEX DISPENSE SYSTEM MANUAL 22 INOVEX DISPENSE SYSTEM MANUAL Chapter The Materials Menu Entering Materials 2 Materials The Materials section contains all the relevant information about the inks used on your system. By assigning codes, you can easily call the ink required into other records such as formulas. Enter all the relevant information about the ink in the text boxes. Refer to the common toolbar as before to Add a record or Edit a record. v Materiiall Code : A code is assigned as a shortcut to the ink. This Mater a Code may be the actual product code or a shortened version of the product code, or any alphanumeric value. v Water : Check this box if the Material is Water. This will exclude Water the Material from any costings or reports. v Materiiall Name : Enter the material name. This field will be used Mater a Name by reports and dispense screen. 23 INOVEX DISPENSE SYSTEM MANUAL v Descriiptiion : A more detailed description of the ink. Descr pt on v Collour Group : Select the nearest colour to the material. (refer to Co our Group this section under Utilities for further info) v Materiiall Type : Select the type of material. Typically this will be Mater a Type `White', `Colour', `Lacquer' or `Other' as described in the Utilities section. v Materiiall Category : Select the Ink Range for the material. Refer Mater a Category to Ink Range in the Utilities section for more details. v Supplliier : Select the supplier for the material. Supp er v Supplliier Reference : The supplier may have a different reference Supp er Reference number for the material; you can enter this in this field. v Date Created : This is automatically assigned today's date when a Date Created material is created. v Batch Number : Materials can be backtracked as to which Batch Number Formulas they were used within, only works if field is completed. Leave blank if you do not wish to trace batch numbers. v Stock On Diispenser: This gives the stock levels in the storage Stock On D spenser: vessels on the dispense head. v Stock In Warehouse: This gives the stock levels of inks kept in Stock In Warehouse: storage not on the dispenser. v Priice Per KG : Current new ink cost per KG. Pr ce Per KG v Optiimum Stock Levell: This is the stock level of which is ideal. Opt mum Stock Leve v Miiniimum Stock Levell: This is the stock level below which new M n mum Stock Leve ink should be ordered. v Stock On Order : This shows the amount of this material that is Stock On Order on order and is automatically updated when material is ordered or received. v Delliivery Tiime (Days) : The number of days to allow for delivery De very T me (Days) of new ink stocks. v Materiiall Solliids Content (%) : Enter the material solid content. Mater a So ds Content (%) v Materiiall SG : Enter the material specific gravity. Mater a SG v Materiiall Tollerance (g) : The allowed amount of deviation of Mater a To erance (g) dispense weight before dispenser will warn of an over dispense in grams. v Materiiall Tollerance (%) : The allowed amount of deviation of Mater a To erance (%) dispense weight before dispenser will warn of an over dispense as a percentage of the overall material requirement. v Usage Thiis Week,, Month & Year: Amount in KG of total Usage Th s Week Month & Year: amount of material dispensed. You are given the option to zero this when the Week, Month, Year to date usage reports are printed. 24 INOVEX DISPENSE SYSTEM MANUAL v Vallue Used Thiis Week,, Month & Year: Amount in value of total Va ue Used Th s Week Month & Year: amount of material dispensed. You are given the option to zero this when the Week, Month, Year to date usage reports are printed. v Openiing Stock Week,, Month & Year : Not implemented on this Open ng Stock Week Month & Year system. v Delliivered Thiis Week,, Month & Year : Shows the amount of the De vered Th s Week Month & Year material delivered in the relevant time period. You are given the option to zero this when the Week, Month, Year to date usage reports are printed. v Materiiall Max Amount : If the material is to limited to a Mater a Max Amount maximum amount in a formulation, then set this to the maximum percentage allowed. v Materiiall Miin Amount : If the material is to be limited to a Mater a M n Amount minimum amount in a formulation, then set this to the minimum percentage allowed. v Materiiall Fiixed % : If a material is to be a fixed percentage in a Mater a F xed % formulation, then set this to the fixed percentage amount. v Resiistance & Speciifiicatiions : You can use these checkboxes to Res stance & Spec f cat ons identify the resistance and specifications of a material. If the management system iis beiing used wiith a diispenser,, If the management system s be ng used w th a d spenser then the follllowiing are rellevant: then the fo ow ng are re evant: v Product On Diispenser: Check this box if the Material is an Product On D spenser: automatically dispensed item. If it is left unchecked the software will assume the material is a manually added item (used for lower usage materials) v Reciirc Group: This is automatically assigned and should be left Rec rc Group: blank. v Vallve Number: Determines on which pump the material resides. Va ve Number: Starts from 1. v Fllow 2 To Fllow 1: This is the value in which the flowrate trips to F ow 2 To F ow 1: a lower flow. For example, if the trip value is set at 0.200, the valve will switch to a lower flow when the scale reads 0.200 before target weight. v Fllow 1 To Off: This is the value in which the flowrate trips the F ow 1 To Off: valve to stop dispensing, following this the valve will enter spit mode. 25 INOVEX DISPENSE SYSTEM MANUAL v Stutter Factor: This is normally set to 20. Increasing the Stutter Stutter Factor: Factor increases the amount of time the valve is open when spitting. If it is set too large then the valve will overshoot, if it set too small the valve will spit many times. v Miiniimum Spiit: This value will normally be set to 80 M n mum Sp t: (milliseconds). This controls the minimum length of time the valve is allowed to open for in spit mode. If it is set too low the valve will spit and no material will be dispensed, set too large and the valve will dispense too much per spit and will overshoot. Material Orders The system has a material order processing system that allows you to input and save material orders as well as print an order form. Once the order is received then using the material orders received module you can receive the material into stock. v Order Number : This is generated by the system as a series of Order Number sequential numbers. v Order Date : This is generated by the system and defaults to Order Date today's date. v Supplliier : Select from the pull down list the supplier for the order Supp er being placed on the system. Suppliers are setup in utilities by selecting suppliers form the menu. v Delliivery Address : Select from the pull down list the delivery De very Address address to which the order is to be shipped. Delivery addresses are set up in the utilities menu by selecting Delivery Addresses. v Delliivery Date : The delivery date is selected by use of the De very Date calendar control. v Materiiall Code : Select the material code for the material being Mater a Code ordered using the pull down list. Any number of materials can be ordered on one material order. The material name field is automatically updated according to the material code selected. v Amount : Select the amount of the material being ordered. Amount v Pack Siize : Select the pack size you expect the material to be Pack S ze delivered in i.e. Barrels, Pails.... Pack Sizes are set up in the utilities menu by selecting Pack Sizes. v Date Requiired : Separate dates required can be included for each Date Requ red material being ordered. The default is the delivery date selected by the calendar control on the main form. v Comment : Comments regarding each material being ordered can Comment be entered in this field. v Previiew Button : Click this to preview the order form. Prev ew Button 26 INOVEX DISPENSE SYSTEM MANUAL v Priint Button : Click this to print the order form. Pr nt Button Material Orders (Incomplete) This produces a list of all orders that have not been tagged in the material orders received as having been completed. Double click on a selected order to view that order details. Material Orders (Complete) This produces a list of all orders that have been tagged in the material orders received as having been completed. Double click on a selected order to view that order details. Material Orders (Complete by Supplier) This produces a list of all orders that have been tagged in the material orders received as having been completed for the selected supplier. Double click on a selected order to view that order details. Material Orders Received Material deliveries can be logged onto the system against the relevant material order. Using the order pull down list on the top of the form select the material order number for which material has been received. Details of the relevant order will then be displayed and by clicking on either the amount or date receive box for a material a dialogue box will appear into which you enter the details of the delivery. v Amount Receiived : Enter the amount received. If not all the Amount Rece ved amount has been received the system will keep a record of the outstanding. v Date Receiived : Enter the date received. Double click this to Date Rece ved enter today's date. v Batch Number : If required enter the batch number of the Batch Number material being delivered. v Save Button : Click the save button to save the information on Save Button the material orders database. 27 INOVEX DISPENSE SYSTEM MANUAL Material Orders Received (Incomplete) This produces a list of all orders that have not been tagged in the material orders received as having been completed. Double click on a selected order to view that order received form. Material Orders Received (Complete) This produces a list of all orders that have been tagged in the material orders received as having been completed. Double click on a selected order to view that order received form. Material Orders Received (Complete by Supplier) This produces a list of all orders that have been tagged in the material orders received as having been completed for the selected supplier. Double click on a selected order to view that order received form. Material Stock This form allows you to view or adjust the stock levels of each material on the system. From here you can adjust both the stock on dispenser, and the warehouse stock. 28 INOVEX DISPENSE SYSTEM MANUAL Material Print Options This form contains all reports relevant to the Materials section of the software from Usages to stock levels. Reports can be previewed, printed and exported to different file formats. Refer to the common toolbar section to see functionality for each of the buttons. v Materiialls Delliivered Between : By using the calendar control Mater a s De vered Between next to this option, select two dates that you wish to run the report from and to. By selecting the same dates the report will generate information for that selected day only. This will produce a listing of materials delivered between the selected dates. v Materiiall Usage Between (Sorted By Date): By using the Mater a Usage Between (Sorted By Date): calendar control next to this option, select two dates that you wish to run the report from and to. By selecting the same dates the report will generate information for that selected day only. This will produce a report of material usage between the selected dates. v Materiiall Usage Between (Sorted By Materiiall): As above, but Mater a Usage Between (Sorted By Mater a ): the report will be sorted by material as opposed to date. v Materiiall Detaiills For Materiiall: By selecting a material form the Mater a Deta s For Mater a pull down box a report will be generated showing all parameters relevant to that selected material. 29 INOVEX DISPENSE SYSTEM MANUAL v Materiiall Where Used : By selecting a material from the pull Mater a Where Used down box, a report will be generated showing all formula's which contain that material v Materiiall Batch Number Search No : This searches the detailed Mater a Batch Number Search No dispense log for a given batch number and produces a listing of all dispenses of a material with that batch number. v Materiialls On Order Report : This generates a report of all Mater a s On Order Report materials on order. v Week,, Month & Year To Date Usage Report : These reports Week Month & Year To Date Usage Report will generate usage based on the previous week, month or year to date. These will only work properly if they are zeroed on a week, month or year basis. By printing a hard copy of the usage, a `Zero' button will appear, this should be pressed to zero report contents. v Materiialls Bellow Optiimum & Miiniimum Stock Levell: Mater a s Be ow Opt mum & M n mum Stock Leve Generates reports of all materials that fall within these parameters. This is based upon data for each material that is entered into the Material Form. v Materiiall Liist : List of the whole material record set. Mater a L st v Run Stock Valluatiion Report : Generates a full value and Run Stock Va uat on Report volume-based report of stock levels. v Priint Overdue Order Liist : This will produce a listing of all Pr nt Overdue Order L st overdue orders. v Materiiall On Order Report Sorted By Overdue : This produces Mater a On Order Report Sorted By Overdue a listing of all materials on order, showing the overdue orders first. v Priint Stock Check Liist : This produces a listing of all materials Pr nt Stock Check L st allowing the user to manually check stock levels against the given stock levels for the materials. Material Graphs The system can produce a number of graphs, each displaying relevant information to the materials. Select this option to view the list of possible graphs. 30 INOVEX DISPENSE SYSTEM MANUAL Chapter 3 The Formulations Menu Entering Formulations Formulations By clicking on the `Add Record' button option you may begin adding all your formulas into the database. Again codes are assigned to help speed access to your formulas when completing other tasks in the program. The following is a step-by-step description on how to enter a new formula. v Formulla Code: Enter the formula code for the formulation. Formu a Code: This has to be a unique code for every formula. v Formulla Name: Enter the formula name for the formulation. Formu a Name: 31 INOVEX DISPENSE SYSTEM MANUAL v Materiiall Type: Select from the pull down list the Material Mater a Type: type. The Material types are entered in the `Material Type' option found in the `Utilities' menu and are generally `Colour', `Lacquer', `White' and `Other' v Formulla Type: Select the Formula Type for the formulation. Formu a Type: These are set up in `Formula Types' in the Utilities Menu. v Collour Group: You can use this to identify formulations by Co our Group: colour groups if you wish. This is useful when searching for a particular shade of a colour whereby a list can be generated of only those in a particular colour group. v Substrate: If a formulation is substrate specific you can Substrate: select this using the substrate pull down list. Substrates are set up in `Substrates' in the Utilities menu. v Priice Per KG: This is an automatically calculated value based Pr ce Per KG: on the price of each material as entered in the `Material' form found in the `Materials' menu. v Totall Amount: This is the sum of all of the amounts in the Tota Amount: formulation. v Date Last Diispensed: Shows the date that the formulation Date Last D spensed: was last weighed out. v Date Created: Shows the date when the formulation was Date Created: created. v Date Amended: Shows the date when the formulation was Date Amended: last amended. v Check Materiiall Max/Miin: Click this to check the materials in Check Mater a Max/M n: the formulations against the stored Maximum and Minimum values for the material. v Make 100: Click this to re-apportion the formulation to 100 Make 100: parts. v Addiitiive Lock Fiixed %: This should be checked if you are Add t ve Lock F xed %: using the `Lock fixed Amount' function found in materials. v Diisablle Fiixed %: This should be checked if you are not using D sab e F xed %: the `Lock fixed Amount' function found in materials. v Totall Number Of Formullatiions: This displays the total Tota Number Of Formu at ons: number of formulations stored in the system. v Materiiall Code: Use the pull down list to select each material Mater a Code: in the formulation. v Materiiall Name: This is updated automatically depending on Mater a Name: the material selected under `Material Code'. 32 INOVEX DISPENSE SYSTEM MANUAL v Amount: Enter the amount of each material required in the Amount: formulation. As you enter each material amount, the total amount field is updated. Use the make 100 button to reapportion to 100 parts when all materials and quantities have been entered. To remove a material from your formula, click `Edit'. Next to each material in the formulation is a `Delete Record' button (a red cross), click this. You will be asked to confirm the deletion through a dialog box. Press Y to delete the ink. To check the formulation has been stored correctly, move to the previous formula then move back to the formula just entered. If there is anything to be changed, you will have to click the edit button before any changes will be allowed. Formulation List `Formulation List' is found in the `Formulations' pull down menu. This produces a list box containing all the formulations. Use the scroll bars and double click the formulation for which you want to view. Formulation List by Date Created `Formulation List by Date Created' produces a list box containing all the formulations in order of date created. Use the scroll bars and double click the formulation you want to view. Formulation List by Date Amended `Formulation List by Date Amended' produces a list box containing all the formulations in order of date last amended. Use the scroll bars and double click the formulation you want to view. Formulation List by Substrate `Formulation List by Substrate' is found in the `Formulations' pull down menu. This is very similar to `Formulation List', except that the scroll selections box shows the formulations for the selected substrate. 33 INOVEX DISPENSE SYSTEM MANUAL Formulation List by Ink Type `Formulation List by Ink Type' is found in the `Formulations' pull down menu. This is very similar to `Formulation List', except that the scroll selections box groups the formulations by Ink type. Formulation List by Colour Group Formulation by Colour Group is found in the Formulations pull down menu. This produces a list box with all the formulations in for a specific colour group. Use the scroll bars and double click the formulation for which you want to view the formulation. The layout and use of this is very similar to that of `Formulation List by Ink Type', the only difference being the extra pull down box for the colour group selection. Formulation List by Formula Type `Formulation List by Formula Type' is very similar to `Formulation List', except that the scroll selections box limits the number of formulations displayed to just those of the selected formula types. Formulation List by Colour Group and Formula Type `Formulation List by Colour Group and Formula Type' is used in the same way as Formulation List by Formula Type, but allows the user to further limit the list to only show formulations which are of the selected formula type, and in the colour group. Formulation Code Wild Card Search. `Formulation Code Wild Card Search' is found in the `Formulations' pull down menu. By way of example, if you enter *103* then the list box will contain PMS103L and PMS103F as the * means any character before or after the 103. You can place a star either in front of the string or after or both. 34 INOVEX DISPENSE SYSTEM MANUAL