diff --git a/README.md b/README.md index deaa61f..9f912b2 100644 --- a/README.md +++ b/README.md @@ -68,8 +68,12 @@ The detail lives in dedicated documents: - [Worker safety](docs/worker-safety.md): safety training, galvanics clean rooms and decontamination, PPE - [Facility security and site systems](docs/facility-security.md): access - control, CCTV, archive and audio protection, fire and life safety, plant - monitoring, Thai compliance anchors + control, CCTV, whole-factory HVAC (temperature, humidity, PM), archive and + audio protection, fire and life safety, plant monitoring, Thai compliance + anchors +- [Process logging and traceability](docs/traceability.md): end-to-end + per-order traceability for customers, batch genealogy from audio file to + shipment, and the requirements this sets for the factory software ## Repository Layout @@ -82,8 +86,9 @@ docs/ │ └── pressing-line.md Press fleet strategy and equipment plan ├── finance/ Project cost overviews ├── suppliers/ Supplier contacts, vendor landscape, supplier map -├── facility-security.md Security, fire and life safety, compliance +├── facility-security.md Security, HVAC, fire and life safety, compliance ├── sustainability.md Energy, water, materials commitments +├── traceability.md Process logging and per-order traceability └── worker-safety.md Training, clean rooms, PPE ``` diff --git a/docs/facility-security.md b/docs/facility-security.md index 2ae1323..0bb5a4b 100644 --- a/docs/facility-security.md +++ b/docs/facility-security.md @@ -1,8 +1,37 @@ # Facility: Security and Site Systems -What the plant needs beyond the production machinery. Access control and -CCTV are set requirements; the rest of this list is what a plant of this -profile definitely needs, to be refined during site design. +What the plant needs beyond the production machinery. Access control, CCTV, +and whole-factory HVAC control are set requirements; the rest of this list +is what a plant of this profile definitely needs, to be refined during site +design. + +## Climate control: whole-factory HVAC + +The entire factory runs under continuous HVAC control, covering temperature, +humidity, and particulate matter (PM). This is a set requirement, not an +option per room. + +- **Temperature and humidity**: the process spec already demands 20-26 °C at + 35-60% relative humidity for pressing; the same conditioning extends to + the whole building so materials, masters, packaging stock, and electronics + never sit outside controlled conditions. PVC compound and paper packaging + are both humidity-sensitive. +- **Particulate matter**: filtration for the whole plant, with stricter + tiers by zone. Dust in a groove is an audible defect, so the cutting room + and galvanics clean room run at the tightest spec with positive pressure; + pressing and packaging run cleaner than ambient; offices and logistics at + a baseline tier. Northern Thailand's burning season (roughly February to + April) brings some of the world's worst PM2.5 episodes, so intake + filtration and building tightness must be designed for those peaks, not + for average days. +- **Continuous monitoring and alarms**: temperature, humidity, and PM + sensors logging in every zone, with alarms on excursions, tied into the + plant monitoring below. +- **Energy design**: conditioning a whole factory in a tropical climate is + a major electrical load on top of the 250 kW process cooling, and it must + be included in the solar PV and battery sizing from the start. Heat + recovery from the press hall (steam, hydraulics, and hot PVC all reject + heat) and from compressors should feed the design rather than fight it. ## Physical security @@ -58,9 +87,9 @@ profile definitely needs, to be refined during site design. - **Lightning protection and grounding**: northern Thailand has intense storm seasons; the PV array, steel structures, and electronics all need a proper LPS and earthing design. -- **Environmental monitoring**: temperature and humidity logging in - production (the process spec calls for 20-26 °C, 35-60% RH), the archive, - and the clean room. +- **Environmental monitoring**: the whole-factory HVAC monitoring above + (temperature, humidity, PM in every zone), with the archive and clean room + as the most tightly alarmed spaces. ## Compliance anchors (Thailand) diff --git a/docs/suppliers/equipment-suppliers.md b/docs/suppliers/equipment-suppliers.md index 507bbcf..e2b0659 100644 --- a/docs/suppliers/equipment-suppliers.md +++ b/docs/suppliers/equipment-suppliers.md @@ -160,6 +160,9 @@ Open: identify and qualify Thai/regional PVC compound producers. - Water treatment for boiler feed and closed-loop cooling - Compressed air generation - Hydraulic oil (~200 L, ISO VG 32/46 HLP per DIN 51524-2, per Newbilt spec) +- Whole-factory HVAC: continuous temperature (20-26 °C), humidity (35-60% + RH), and PM control with zoned filtration tiers, sized for northern + Thailand burning-season PM2.5 peaks; a major load for PV/battery sizing - Clean rooms, ventilation, decontamination infrastructure for galvanics - Fire protection, exhaust work benches, PPE stock diff --git a/docs/sustainability.md b/docs/sustainability.md index 6ba0dac..eb3707b 100644 --- a/docs/sustainability.md +++ b/docs/sustainability.md @@ -35,6 +35,10 @@ at 10 bar / 180 °C) and the 250 kW cooling system. abundant fuel), and solar-thermal pre-heating of boiler feedwater. No technology choice has been made yet; it will be driven by honest numbers on load profiles, storage, and grid backup, not by what sounds greenest. +- Whole-factory HVAC (continuous temperature, humidity, and PM control, see + [facility systems](facility-security.md)) adds a major tropical-climate + load on top of process cooling and must be part of the PV and battery + sizing. - System sizing (kWp, storage, grid-connection model) is open until the site is chosen. diff --git a/docs/traceability.md b/docs/traceability.md new file mode 100644 index 0000000..d193bc0 --- /dev/null +++ b/docs/traceability.md @@ -0,0 +1,60 @@ +# Process Logging and Traceability + +Every step of production is logged continuously, so that every record is +traceable end to end for the customer. This is a set requirement, and it is +the core specification for the factory software this repository will +eventually host. + +## What a customer can trace + +For any order, the customer can follow the full chain: + +1. **Audio intake**: file received, checksums, versions, who handled it, + approval trail +2. **Mastering**: session log, engineer, settings, customer approvals +3. **Cutting**: lacquer IDs, lathe parameters, stylus used, inspection + result +4. **Galvanics**: silvering and plating batch IDs, bath chemistry logs, + father/mother/stamper genealogy (which stamper came from which mother + from which father), or the external stamper supplier and batch if bridged +5. **Pressing**: press ID, operator, shift, mold and stamper IDs, cycle + parameters (temperatures, pressures, cycle times), PVC compound lot and + virgin/recycled mix, label lot +6. **Quality control**: test pressing approvals, inspection results, reject + counts and reasons +7. **Finishing and packaging**: trimming, sleeving, carton lot, packaging + partner batch +8. **Fulfillment**: warehouse location, shipment or dropshipping consignment, + carrier tracking per end customer + +## Principles + +- **Log at the source**: machine data comes from the machine (the presses + and the plating rectifiers expose PLC data; the AD12 supports remote + monitoring), not from manual transcription. Manual steps get simple + operator check-ins, not paperwork. +- **Batch and genealogy first**: every physical artifact (lacquer, father, + mother, stamper, press run, box) gets an ID, and every ID knows its + parents. A customer complaint about one record resolves to a specific + stamper, press, shift, and compound lot. +- **Environment attached**: the whole-factory HVAC monitoring (temperature, + humidity, PM per zone) is logged on the same timeline, so any production + window can be correlated with plant conditions. +- **Immutable and retained**: logs are append-only and retained for the + life of the customer relationship; stamper genealogy is retained as long + as the archive holds the metal parts. +- **Customer-facing view**: traceability is a product feature, not an + internal file. Customers get a per-order view (portal or report) covering + the chain above, without exposing other customers' data. + +## Open design work + +- Data model for batch genealogy across all eight steps +- Which PLC/machine interfaces each vendor exposes (ask Newbilt, Pheenix + Alpha, and Digital Matrix during procurement, before purchase) +- Retention, backup, and PDPA handling for operator-linked records +- Whether test-pressing approval workflows live in the same system from day + one + +This system should be specified alongside equipment procurement: machine +data access is a purchasing requirement, not an afterthought.