diff --git a/README.md b/README.md index 490672c..4672299 100644 --- a/README.md +++ b/README.md @@ -78,6 +78,9 @@ The detail lives in dedicated documents: (Keyence-class confocal, profiler, XRF), layered pressed-record QC (100% optical inspection, per-cycle press telemetry, sampled automated audio comparison), and how it feeds traceability +- [Process flow](docs/process-flow.md): the whole chain from audio file to + delivered record as a chart and stage table, with every check and the + three artist approval gates (printable diagram alongside) ## Repository Layout @@ -91,6 +94,7 @@ docs/ ├── finance/ Project cost overviews ├── suppliers/ Supplier contacts, vendor landscape, supplier map ├── facility-security.md Security, HVAC, fire and life safety, compliance +├── process-flow.md Audio file to delivered record, with all checks ├── quality-automation.md Stamper metrology and layered record QC ├── sustainability.md Energy, water, materials commitments ├── traceability.md Process logging and per-order traceability diff --git a/docs/equipment/pressing-line.md b/docs/equipment/pressing-line.md index ac205f2..5070b8f 100644 --- a/docs/equipment/pressing-line.md +++ b/docs/equipment/pressing-line.md @@ -40,5 +40,14 @@ electrical load, saturated steam at 10 bar, and compressed air and cooling water circuits, plus side rooms for materials, compressor, chiller, and finished goods. +**Floor loading is a building-selection criterion**: the slab must carry +multiple tons per m² in the machine areas. A Newbilt press weighs 1,350 kg +on a footprint under 1 m², and the boiler, chiller, hydraulic aggregate, +battery stack, and stacked material storage all concentrate weight the same +way. The floor must also be flat but not slippery (machine levelling pads +need grip) and resistant to the solvents used in production. Dynamic loads +from press cycles come on top of the static figures, so the structural +engineer gets the vendor data sheets, not just the totals. + Source documents live in [`newbilt/`](newbilt/): the budgetary offer, the Duplex site requirements, the process schematic, and the service rate card. diff --git a/docs/process-flow.drawio b/docs/process-flow.drawio new file mode 100644 index 0000000..a4fe05d --- /dev/null +++ b/docs/process-flow.drawio @@ -0,0 +1,238 @@ + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + diff --git a/docs/process-flow.md b/docs/process-flow.md new file mode 100644 index 0000000..274bef8 --- /dev/null +++ b/docs/process-flow.md @@ -0,0 +1,71 @@ +# Production Process Flow: Audio File to Delivered Record + +The complete chain with every check and approval gate. Three gates involve +the artist or label directly (marked as approval gates); everything else is +internal QC. Every step writes to the [traceability +database](traceability.md); the instruments behind the checks are specified +in [quality automation](quality-automation.md). + +A printable diagram of this flow lives alongside this document: +[process-flow.drawio](process-flow.drawio) (editable), +[process-flow.png](process-flow.png), and +[process-flow.pdf](process-flow.pdf). + +```mermaid +flowchart TD + A[1. Audio intake] --> G1{Artist gate:
master plan approved} + G1 --> B[2. Vinyl mastering] + B --> G2{Artist gate:
master approved} + G2 --> C[3. Lathe cutting
lacquer] + C --> D[4. Silvering and
electroforming
father, mother, stampers] + D --> E[5. Stamper prep
punch, back-finish, coin] + E --> F[6. Pressing] + PVC[PVC compound intake] --> LAB[Material lab gate] --> F + REG[Regrind stream] --> LAB + F --> G3{Artist gate:
test pressing approved} + G3 --> F2[Production run] + F2 --> H[7. Finishing
trim, label, shrink] + H --> I[8. Packaging
and assembly] + CART[Cartons and sleeves
from local partners] --> PQC[Packaging incoming QC] --> I + I --> J[9. Fulfillment
warehouse, bulk, dropshipping] + + A -.-> QA1[Checksums, format,
technical QA] + C -.-> QA3[Groove microscope,
test cut, dead-wax
scribe and fiducial] + D -.-> QA4[Bath logs, XRF thickness,
metrology on sampled zones,
mother listening check,
laser back marks] + E -.-> QA5[Concentricity,
dimensional, visual] + F2 -.-> QA6[Press telemetry per cycle,
100% optical inspection,
sampled audio comparison] + I -.-> QA8[Matrix code vs jacket
barcode scan, barcode
verification] +``` + +## Stage by stage + +| # | Stage | Internal checks | Approval gate | +|---|---|---|---| +| 1 | Audio intake | File checksums and format verification; technical QA (levels, clipping, side length vs format) | Artist/label confirms the master plan | +| 2 | Vinyl mastering | Engineer QA of the vinyl master | Artist/label approves the master | +| 3 | Lathe cutting | Groove inspection under microscope; test cut evaluation; dead-wax matrix scribe and angular fiducial applied (cold mechanical scribe, never laser) | | +| 4 | Silvering and electroforming | Bath chemistry logs per batch; XRF nickel thickness per part; confocal/profiler groove metrology on sampled radial zones; mother listening check (mothers are playable); laser Data Matrix marks on part backs | | +| 5 | Stamper prep | Concentricity and dimensional checks after punch, back-finish, and coining; visual inspection | | +| M | PVC intake (parallel input) | Material lab gate per lot: certificate of analysis, moisture, heat stability, color, density, granulate physicals; new lots released only by test pressing; regrind stream passes its own contamination gate before joining the 80/20 mix | | +| 6 | Pressing | Press telemetry logged every cycle; then per record: 100% inline optical inspection; sampled automated audio comparison against the source master | Artist/label approves the test pressing before the production run | +| 7 | Finishing | Trimming quality; label print inspection (labels pre-dried in the oven); shrink wrap on sampling basis | | +| 8 | Packaging | Incoming carton QC per delivery (dimensions, print Delta E against approved proof, seam strength, inner sleeve scuff check); assembly verification by scanning the runout matrix code against the jacket barcode; barcode verification on every unit | | +| 9 | Fulfillment | Consignment assembly against the order's bill of materials; carrier tracking recorded per shipment or per dropshipped end customer | | + +## Reading the chain + +- **The three artist gates** are the customer-facing milestones: master plan, + approved master, approved test pressing. Nothing proceeds past a gate + without a recorded approval, and the approvals live in the same + traceability record as the physical process data. +- **Identity travels with the product**: the dead-wax scribe from stage 3 + propagates through every metal generation and appears on every pressed + record, which is what lets stage 9 verify that the right record is in the + right jacket. +- **Materials join the chain with their own gates**: PVC lots and regrind + batches enter at pressing, cartons and sleeves at packaging, and their lot + IDs attach to every record and order they touch. +- **A complaint resolves backwards**: any single record traces to its + stamper, press, cycle, operator, compound lot, and packaging lot, and from + the stamper back through mother and father to the lacquer and the approved + master it came from. diff --git a/docs/process-flow.pdf b/docs/process-flow.pdf new file mode 100644 index 0000000..ee926df Binary files /dev/null and b/docs/process-flow.pdf differ diff --git a/docs/process-flow.png b/docs/process-flow.png new file mode 100644 index 0000000..1d94c68 Binary files /dev/null and b/docs/process-flow.png differ