Plant page: mature fleet at real cycle times

Rebuild docs/plant-operation.html from the single P1 press into the mature
plant: Newbilt Duplex (two HRP 12 on a VEX 50, EX 35 for splatter), two
Newbilt Classic automatic presses with edge trimmers, label punch and
Granulator 400; Pheenix Alpha PASU, PPPU, two PDPU and PMPB; Sibert VSF,
VSP and VSC in that order; father and mother archive and the stamper rack.

Time runs at 1x real time with speeds up to 3600x. Press cycles are
Newbilt's (Classic 28 s, Duplex ~30 s), plating follows Faraday's law at
the PDPU current, and the operator steps use the galvanics.md table, with
unpublished times marked as estimates. Titles flow through the three artist
gates in days; test pressings unmount and the presses run approved work
meanwhile; worn stampers and represses come from the archived mothers.
Two shifts, unplanned press stops sized to scale.md's 60 to 70 %
effectiveness, and demos for a steam dip, a new PVC lot and a repress.

The boiler and chiller are shown at 800 kg/h and 500 kW (estimates) and
the detail panels flag that scale.md's 400 kg/h and 250 kW are Duplex
figures; scale.md itself is unchanged.

Also commits the galvanics.md cycle-time table the page runs on (one PDPU
covers demand, the second is redundancy) and updates the README and the
test-site descriptions.

README.md

@@ -131,12 +131,14 @@ The detail lives in dedicated documents:
   fan-funded campaign that the plant presses and ships to each fan once
   enough have pre-ordered, with refunds if not
 - [Plant operation page](docs/plant-operation.html): a single static page
-  animating the whole plant as a simulated SCADA overview, from PVC intake
-  and the material lab through extruder, press, trim, optical inspection,
-  finishing, packaging and fulfillment, with the metal path, utilities and
-  energy alongside; open it in a browser, every station is clickable;
-  on phones and tablets held sideways it pinch-zooms and opens station
-  details in a side sheet
+  animating the mature plant as a simulated SCADA overview at real cycle
+  times: the Newbilt Duplex and two Classic presses, the Pheenix Alpha
+  electroforming line and Sibert stamper prep, from PVC intake and the
+  material lab through pressing, inspection, packaging and fulfillment,
+  with the three artist gates, the mother archive, utilities and energy;
+  1× is real time, up to 3600× (a day in 24 s); every station is
+  clickable and names the source of its figures; on phones and tablets
+  held sideways it pinch-zooms and opens station details in a side sheet
 - [Test site](site/README.md): `site/` builds https://cnxvinyl.lol/, the
   internal test site with demo pages from `docs/` (the plant operation
   page first) and any static site we want to share by link; Gitea Actions

docs/equipment/galvanics.md

@@ -102,10 +102,24 @@ What this changes in the plan:
   no vendor cloud. The maintenance alerts are the bath events the
   galvanics record in [traceability](../traceability.md) needs anyway.
 
-### How many cells (estimate)
+### Cycle times and cell count
 
-The cell count is the number that sizes the line, and no vendor has stated
-a cycle time. A rough count from this repo's own figures:
+Pheenix publishes no cycle times. Published practice from other plating
+rooms agrees with Faraday's law at the PDPU's 200 A ceiling (1.095 g of
+nickel per ampere-hour), and these are the times the
+[plant operation page](../plant-operation.html) runs on:
+
+| Step | Time | Source |
+|---|---|---|
+| Silvering (clean, sensitise, spray, rinse) | ~15 min | estimate; no published figure |
+| Pre-plate | 15 to 30 min at 10 to 20 A | ~15 min at 35 °C (flight 13 duplication, Freiburg, in Leuze Verlag's Galvanotechnik report "Of fathers, mothers and sons"); ~20 min at ~20 A (Welcome to 1979, Nashville, on a Digital Matrix line, in Finishing and Coating); 30 min at 10 to 20 A (US patent 4,363,705) |
+| Father | ~1 h 15 min | ~0.2 mm and ~200 g at 150 A and 11 V (flight 13); 1¼ h with the current raised from 20 to 200 A (US 4,363,705) |
+| Mother | ~1 to 1¼ h | 1¼ h at 200 A (US 4,363,705); "as little as one hour" (Wikipedia, Production of phonograph records) |
+| Stamper | ~45 min | a 145 g stamper in 45 min (Wikipedia, same article) |
+| Separation, passivation, cleaning and drying (PMPB) | ~10 to 15 min | estimate |
+| Back-finish (VSF), centre punch (VSP), coin (VSC) | ~5 to 10, 3 to 5 and 1 to 2 min | estimate; Sibert publishes none |
+
+The count, from this repo's own demand figures:
 
 - At full capacity the [revenue model](../finance/revenue-model.md) assumes
   300 to 600 titles a year across 1.0 to 1.5 million records, so 2,500 to
@@ -114,18 +128,18 @@ a cycle time. A rough count from this repo's own figures:
   (at 1,000 to 2,000 pressings per stamper): 8 to 10 electroformed parts per
   title, **~2,400 to 6,000 parts a year**, 8 to 20 per working day at 300
   days, before remakes.
-- A 12" part of ~0.25 mm nickel is roughly 150 to 200 g. At the PDPU's
-  200 A ceiling (1.095 g of nickel per ampere-hour) that is under an hour of
-  deposition; with the current ramp, loading, rinsing and separation,
-  **~2 to 3 hours per part per cell** (estimate).
-- Two shifts give 5 to 8 parts per cell per day, 10 to 16 per PDPU.
+- With ~15 minutes of loading, rinsing and unloading on top of 45 to 75
+  minutes of deposition, a cell turns a part in ~1 to 1.5 hours: 10 to 16
+  parts per cell per two-shift day, **20 to 32 per PDPU**.
 
-So **one PDPU covers the low end and the high end needs two** (or a third
-shift). One PASU, one PPPU (pre-plate is for the masters, 2 to 4 a day at
-full capacity, and the unit takes four at once) and one PMPB cover the
-rest. Thicker fathers and mothers scale the time up in proportion. Ask
-Pheenix for the measured cycle per part at the plant's thickness before
-this goes into a budget.
+So **one PDPU covers full-capacity demand** with headroom for remakes, and
+a second PDPU buys redundancy rather than capacity, which is how Pheenix
+itself sells it ("more capacity as well as enhanced redundancy"). The
+first version of this page assumed 2 to 3 hours per part and concluded
+that the high end needed two. One PASU, one PPPU (pre-plate is for the
+masters, 2 to 4 a day at full capacity, and the unit takes four at once)
+and one PMPB cover the rest. Ask Pheenix for measured cycles at the
+plant's thickness before this goes into a budget.
 
 ## Stamper prep: the Sibert VS line
 
@@ -149,10 +163,13 @@ What this changes in the plan:
   the air network has to reach the stamper prep room.
 - **Weights 200, 250 and 600 kg**, on castors: pallet-truck moves, not
   crane lifts ([crane table](../crane-workshop-tours.md) updated).
-- **Order of operations.** The VSC locates on the punched centre hole, so
-  the punch comes before the coiner. The
-  [process flow](../process-flow.md) already lists punch, back-finish,
-  coin.
+- **Order of operations: finish, punch, coin.** Gotta Groove's
+  Electromastering Lab in Cleveland, which runs a Sibert VSF and VSP,
+  back-sands first, then centres and punches on the VSP, then trims and
+  coins the edge and forms the centre hole for the press type
+  (recordplating.com). The VSC locates on the punched hole, which fits the
+  same order. The [process flow](../process-flow.md)'s "punch, back-finish,
+  coin" names the operations, not their sequence.
 - **Centring is manual.** The VSP pre-centres pneumatically, then the
   operator centres the lead-out groove under ×100 optics against the
   graticule. Concentricity depends on the operator, so the stage 5 check
@@ -163,7 +180,9 @@ What this changes in the plan:
   them: the answer decides whether stamper prep stays a manual check-in
   station in the [digital factory](../digital-factory.md).
 - **Mould fit.** The standard punch is Ø25.4 mm, other sizes on request,
-  and the VSC claims tooling for every vinyl mould. Which centre hole and
+  and the VSC claims tooling for every vinyl mould. Gotta Groove keeps nine
+  centre-hole forming tools to fit the presses its customers run, which
+  shows the scale of the question. Which centre hole and
   edge form each mould needs (Newbilt book mould, Pheenix/Toolex, M-Tech)
   has to come from the press vendors, and the tooling sets per mould type
   are a quote line. Whether the VSC duplicates anything a press vendor

site/public/index.html

@@ -54,11 +54,13 @@
     <li>
       <a href="demos/plant-operation/">
         <strong>Plant overview (simulated SCADA)</strong>
-        <span>The whole plant animated, from PVC intake and the material lab
-        through extruder, press, trim, optical inspection, finishing,
-        packaging and fulfillment, with the metal path, utilities and energy
-        alongside. Every station is clickable; on a phone, turn it sideways
-        and pinch to zoom.</span>
+        <span>The mature plant animated at real cycle times: Newbilt Duplex
+        and Classic presses, Pheenix Alpha electroforming and Sibert stamper
+        prep, from PVC intake and the material lab through pressing,
+        inspection, packaging and fulfillment, with the artist gates,
+        utilities and energy alongside. Real time up to a day in 24 s;
+        every station is clickable; on a phone, turn it sideways and pinch
+        to zoom.</span>
       </a>
     </li>
   </ul>