face699a284ac81718537026ee0a7207bc92ee70
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Commits
| Author | SHA1 | Message | Date | |
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 grabowski
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face699a28 |
Optical QC: EtherCAT control plan with geizhals.de prices
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User, 19 Oct 2026: plan the current EtherCAT setup, keep the 100 W servo, check prices on geizhals.de. - New docs/equipment/inline-qc-control-plan.md: decisions, bus layout (drives at the end of the line because the A6-200EC takes control power from the main supply), I/O list for EL1809/EL2809/EL3152/EL5101 and the drive touch probe, PDO and DC notes from the A6-EC manual, geizhals.de price table (EUR 1,891.60 to 2,104.39 + USD 246.58 for the servo kits, THB 80k to 88k), NixOS/EtherCrab software, safety circuit (PNOZ s3, two contactors, dump valve), bench test with pass marks (parts about THB 64k, all reused), build order, spares, open points. - EL3102 replaced by EL3152: the optoNCDT 1420 output is 4 to 20 mA. - Spindle encoder index goes to an EL5101 instead of the drive touch probe; encoder 2,000 to 2,500 pulses. - BOM: control lines split per part with geizhals.de prices (+30% high end for shipping and Thai duty/VAT, estimate); total USD 16,912 to 33,061 (THB 0.56M to 1.09M). Doc, render caption and fleet calculator text now say USD 17k to 33k. - README links the plan. |
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grabowski
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e8674795f5 |
Inline QC station: real 40x40 profiles, labelled investor render
User, 18 Oct 2026: use real 40x40 profiles, make a render with text pointing out the parts to show the investor; the ring lights looked like they were floating. - build_station.py: frame drawn from the real 8-slot 40 series section (profile_shape: slots, centre bore, corner cavities; 40x80 with centre cavity) and 24 cast angle brackets; top beams now butt between the uprights; label-camera posts moved beside the cameras so both ring lights clamp straight to them; top line-scan on a side post with visible camera plate and light hangers; slide strips on carrier angles, pulley axles, end-stop posts, presence-sensor brackets, backlight post, cabinet on base crosses, chute on two supports and clear of the rail, pneumatics rail, stack light on the back upright, touch screen on the front end upright. A connectivity check at the end lists any part that does not reach the floor through touching parts: none. - render_annotated.py (FreeCAD): front three-quarter view, camera backed off so nothing is clipped, no navigation cube or preselection, label positions projected from the camera and checked with marker renders. - annotate_render.py (Pillow): title, 16 labels in two columns, leaders assigned so none cross -> inline-qc-station-annotated.png. - render_station.py: same camera and preselection fixes; all six views re-rendered. - BOM: 32 m of 40x40 in 45 pieces; total still USD 16k to 33k. - inline-optical-qc.md and README updated; .gitignore for the render intermediates. |
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grabowski
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609424b598 |
Inline QC station: concept setup on an aluminium profile frame
User, 18 Oct 2026: create a setup for the inline optical QC, an aluminium extrusion frame with all sensors and a conveyor mounted to it. - docs/equipment/inline-qc-station/: FreeCAD script (build_station.py) and model (.FCStd) of one station, 1.9 x 0.65 x 1.5 m on 27 m of 40x40 and 3.8 m of 40x80 profile: rim-belt conveyor (two 6 mm PU round belts under the unrecorded rim, open centre), label gate with top and bottom colour cameras on the fly, inspection position with a lift and rotate chuck (75 mm lift, expanding mandrel, belt-driven servo), top and bottom 4k line-scans on opposite radii with coaxial, dark-field and backlights, two warp lasers, optional thermal camera, light-tight black tunnel with door switch, rodless-cylinder reject pusher with chute and bin, outfeed stop, cabinet, PLC, NixOS edge PC, HMI, stack light. - render_station.py renders six views (open and closed iso, front, plan, inspection detail and elevation via clipped temporary documents). - inline-qc-station-bom.csv: 32 lines with sources; USD 16k to 33k per station without the thermal camera. - inline-optical-qc.md: new section "The station setup" (flow table, inspection zone, cycle ~5 to 6 s, control, BOM by group, open points); cost table updated (two launch stations ~USD 50k to 105k, still inside the metrology launch tier); Duplex/Classic flow now via the conveyor. - README bullet and tree. |
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grabowski
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5207808b57 |
Inline optical QC: devices for the record inspection station
User, 17 Oct 2026: research on the inline QC equipment, which devices can be used for the optical check. - New docs/equipment/inline-optical-qc.md: defect-by-defect table with the optical signature, device and limit (IEC 98 / DIN 45547 hole and eccentricity, Stamper Discs targets, Mobineko warp limits), precedents (no vinyl product; Dr. Schenk ISM CD scanner as template; Basler/Xiris; PRP AQA 2023; CTU thesis), a station design (centring turntable, 4k line-scan per side with dark-field, bright-field and transmitted light, colour label camera, two laser warp sensors or a line profiler, optional thermal camera) with sourced price signals, resolution and eccentricity math, throughput, placement at the Duplex cell and the Classic, smart-camera vs open GenICam/Aravis/OpenCV/anomalib on NixOS, specials, Thai channels, next steps. - Estimate USD 12k-30k hardware per station, ~USD 40k-100k for the two launch stations; inside the existing metrology launch tier, no plan price change. - Backlinks: quality-automation.md layer 1, digital-factory.md QC integration row, README bullet and tree. |
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grabowski
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984ced2485 |
Biomass steam in both plans, PV on the factory roof only
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User, 17 Oct 2026: "only put solar on the factory, prepare the other buildings for solar, option a and b should operate on biomass". - Steam: two 500 kg/h biomass modules (Getabec class, 6M to 10M THB) plus a fuel store and handling block (1M to 2M, estimate) in both plans; the electric bank becomes the alternative. ~0.67M THB of fuel a year against ~4.9M for electric steam; grid demand ~264 kW instead of ~980 kW. - Solar: ~520 kWp on the factory roof (the biomass-case optimum is ~500 to 550 kWp, hourly sketch in sustainability.md "PV size with biomass steam"); office roof and parking canopies built PV-ready (~120 kWp later). ~87 % used on site, ~61 % of the plant's electricity. - Calculator: biomass default, bFuel row, pvKWp 520, pvSelf 87, iso fills the factory roof first and shows the other roofs as PV-ready. - Numbers: launch plant ~168M / 232M / 296M with contingency; Plan A ~182M (~2M above 180M: the Chinese-route lever priced only electric boilers; a Chinese biomass quote is the way back), Plan B ~217M (label ~215M), ~35M more. Calculator EBITDA A 2.17M, B 2.23M USD. - CSV, total-investment, revenue-model, sustainability, scale, biomass, site-candidates, boi, steam-cooling, construction RFQ (canopies PV-ready), README, roadmap; business plan draft 0.3 rebuilt (A and B 63 pages) with new renders. |
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grabowski
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9ff5feef11 |
Solar on every roof, BOI solar correction, open source section
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Solar (user, 17 Oct 2026: "use as much roof space as possible") - PV on every roof and canopy: ~640 kWp on the Payap scenario plot (factory roof ~523, canopies ~54, flat office roof ~65 kWp around the AC units); ~300 kWp on the Mueang Chi hall. Calculator: pvKWp 640, new pvSelf 85 % (zero export, hourly sketch), PV cost per kWp times the array, office-roof PV in the iso view, roofs drawn full. - 12.8M to 16.6M THB at 20 to 26 THB/W; CSV baseline 34.37M to 56.34M; launch plant ~168M / 231M / 294M THB with contingency; Plan B ~216M (label ~215M), ~39M above Plan A; Plan A unchanged (it leases the array), its solar lever ~17.5M. PV payback ~4.2 to 5.9 years. - Permits (rooftop solar no factory licence since 28 Dec 2024, ERC exemption under 1,000 kVA, PEA zero export) and PPA discounts sourced in sustainability.md. BOI correction - Announcement 3/2568 (in force 1 July 2025) ended BOI promotion for solar installations; only the battery may qualify (12M THB per MW cap). Removed the "BOI solar measure" from boi.md, total-investment, revenue-model, sustainability, site-candidates and both plan versions; Plan B's case for owning the array is the PPA bill it avoids (~0.07M USD a year). Open source (user, 17 Oct 2026) - digital-factory.md "Open source throughout, and working with other plants": everything we run and build is open source on NixOS, our code published (licence to decide), vendor firmware the stated exception; later the stack and factory-automation services for other pressing plants, not in the revenue. - Business plan section 5.6 plus an executive-summary bullet, reading guide and not-modelled mentions; draft 0.3 rebuilt (A 60, B 61 pages), renders re-made with the roofs full. |
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grabowski
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ab303618d8 |
Solar and battery re-priced from Thai market data (October 2026)
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- Rooftop PV, 300 kWp (size still illustrative): 20 to 26 THB/W installed with the Deye hybrid inverters, 6.0M to 7.8M THB (was 25 to 35 THB/W, 7.5M to 10.5M). Sources in the utilities CSV: DEDE Thailand PV Status report (Mahidol survey: 22 to 25 THB/W for factory systems of 10 kW to 1 MW, 2023), CapSolar 2026 (20 to 25 under 1 MWp), Saimai Solar's list (300 kW for 5.4M THB), Deye hybrid inverter retail (160,500 THB per 50 kW). - Battery 271 kWh, now installed: 2.0M to 3.5M THB (was the bare Gobel list price, 1.4M to 2.0M, which matches DEDE's 5,000 to 7,000 THB/kWh for LiFePO4); adds enclosure, fire protection, controls and installation, below CapSolar's 12,000 to 15,000 THB/kWh for a fully installed factory BESS because the hybrid inverters do the conversion (estimate). - Utilities baseline 27.57M to 47.50M THB; launch plant ~160M / 222M / 283M THB with contingency; Plan B ~208M (~149M to 266M), ~31M more than Plan A; Plan A's total unchanged, its solar lever ~9.7M. PV payback ~3.8 to 5.4 years (sustainability.md). Calculator, README, roadmap, revenue model and both business plan versions (renders included) updated. |
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grabowski
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3f33babdaa |
Plan B re-defined: the launch plant with everything in (~210M THB); front view on the cover
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- Plan B now starts like Plan A with one Duplex system and one Classic, but takes none of the six levers: owned solar and battery (with the BOI solar measure), the full metrology stack, the visitor corridor, cassette and CD-R, the bought crane and Thai-supplied utilities (user, 17 October 2026). ~193.8M THB before the reserve, ~209M with it (~150M to 268M), ~32M (~18 %) more than Plan A; the second Duplex is a growth step from revenue in both (~15.4M THB, estimate). - total-investment.md "Two plans" re-based (heading and anchor now "B at ~210M THB", README and roadmap links updated); revenue-model.md operating pictures: same volume and EBITDA as Plan A, depreciation on Plan B's capital (operating profit 1.26M USD central, payback ~3.7 yr); the extra earns nothing in the modelled table, which the docs say. - Calculator: Plan B preset = the launch plant with contingency kept out (EBITDA 2.07M USD, cash payback year ~4.3, IRR ~21 %); budget card marks 180M and 180M plus 25 %; preset label "Plan B (~210M, all in)". - Business plan draft 0.3, both versions rebuilt: every Plan B branch of the three content files rewritten; renders regenerated with the isometric view turned to the front of the site (road, car park, office, corridor facade) for the cover and Figures 8 to 10. |
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grabowski
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ffc6cedbca |
Business plan: isometric calculator views instead of FreeCAD, software section with screenshots
- Cover and section 6.2 now use the isometric plant view of the plant and business plan calculator, drawn with each version's own preset: the cover (roofs, no labels), Figure 8 the site from above, Figure 9 the ground floor cut open, Figure 10 the press hall close up. The FreeCAD aerial render, the Mueang Chi site plan and the hall layout sketch are no longer in the plan; the captions say the calculator draws the Payap scenario model while the 6.2 text and zone table are the Mueang Chi hall. - New section 5.5 "The software: plant overview, factory console and artist platform" with six screenshots of the demos: the plant overview (simulated SCADA), the factory console press floor and its ERPNext link, the artist ordering offer, fan funding and the record passport. Simulated data is marked as such; the platform name stays undecided. - Figures renumbered (budget card 11, cash 12) and named in the section 15 source table. Renders in docs/renders/calculator/ and docs/renders/demos/; README bullet updated. |
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grabowski
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bd357ab03f |
Business plan draft 0.3 in two versions: Plan A ~180M and Plan B ~225M THB
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- One build makes both documents: plan_variant.py switches the plan-specific text (pick / is_a / label); build_plan.py writes CNX-Vinyl-Business-Plan-A and -B (docx), export_pdf.py exports both PDFs with the table of contents filled in. Draft 0.2 (single launch-plant plan with contingency) is removed; it stays in the history. - Plan A: the launch plant with every machine and six cost levers, ~177M THB with the ramp-up reserve, no contingency. Plan B: the second Duplex at launch, five presses, ~224M THB on the same basis. Each version reads as a complete plan with one table comparing it with the other; the 216M investor-question text is gone, Pheenix is priced at OMS's reference plus 20 %. - Calculator renders in both documents, each from its own preset: the plant at a glance (Figure 4), the budget check (Figure 5) and ten years of cash (Figure 6), in docs/renders/calculator/. - Calculator budget card: the verdict and third KPI now name the tightest budget the midpoint fits (Plan A: 3.3M to spare under 180M; Plan B: 0.8M under 225M) instead of always 225M. - Fixes: CD replication cross-references point to section 4.10; the blended price in section 3.3 and roadmap item 1 is 3.76 to 5.27 USD at 60 % specials (3.50 to 4.60 at a standard-heavy mix). |
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grabowski
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f2ff1eac1f |
Two plans for the investor: Plan A ~180M, Plan B ~225M THB; Pheenix at OMS +20 %
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User (October 2026): price the Pheenix galvanics line at OMS's reference plus 20 %, and work on a new business plan in two versions, one at roughly 180M THB and one at +25 %; the plans do not include contingency; Plan A keeps every machine and uses cost levers only. - total-investment.md: Pheenix block 324k to 445k USD (OMS 4-cell wet room with know-how transfer, EUR 234k to 321k, plus 20 %; was 320k to 650k estimate); launch plant now ~161M to 285M THB with contingency, midpoint ~223M. New section "Two plans": Plan A = launch plant with solar PPA, metrology launch tier, corridor later, cassette and CD-R later, rented crane, Chinese boilers and compressor: subtotal ~161.7M + ramp-up reserve 10 to 20M = ~177M THB (127M to 226M). Plan B = second Duplex at launch (five presses), everything in: subtotal ~209.2M + reserve = ~224M THB (162M to 286M). Contingency listed as not in either price (~24M / ~31M at 15 %). The 180M / 216M answer marked superseded. - revenue-model.md: operating pictures of both plans at 60 % specials. Plan A central EBITDA 1.73M USD, operating profit 1.34M, payback ~3.1 yr on the plan price; adverse loses money. Plan B (1.0 / 1.25 / 1.5M records) central EBITDA 3.14M, operating profit 2.63M, payback ~2.2 yr; adverse just covers depreciation; needs ~1.25M records sold. - Calculator: Pheenix price basis "OMS +20 %" and "OMS directly"; new contingency switch (in the total / shown separately); presets Plan A and Plan B (replace "investor levers" and "five-press"); budget card against 180M and 225M. - galvanics.md price note, README, roadmap. Checks: calculator regression updated and passing (0 fails, no page errors), node --check on all scripts, site build (no dead links), no em dashes added. |
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grabowski
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f7e20e1015 |
Make a record: USD / THB / EUR selector and English / Thai language switch
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User (October 2026): currency selector on the first page (USD / THB /
EUR) and a language selector for Thai on the make-a-record demo.
- Top bar: one currency control (replaces the THB/USD switch on the
price step) and an EN / Thai control, visible from step 1; both persist
(localStorage, #cur= / #lang= in the URL, hash wins). Prices stay
computed in THB: USD = THB / 33, EUR = THB / 38.115 (1 EUR = 1.155
USD); the fan price is entered in the chosen currency and stored in
THB, the campaign rule max(100, break-even) unchanged.
- Thai: every visible string, tooltip, aria label, file check, quote
line, production update, passport, investor note and tour caption
(dictionary T = {en, th}, t(key, vars), data-i18n attributes; 636
keys), system Thai fonts, Thai dates with Gregorian years, and a footer
note that the Thai is a draft translation for review. Template PDFs
stay English (Helvetica has no Thai glyphs).
- Top bar wraps to two rows below 1000 px (steps were cut off between 761
and 990 px before).
- README and landing entries mention the currencies and Thai.
Checks (headless Edge): doc example unchanged in THB (37,836 per title,
232 per copy at 100, break-even 41, goal 100, ~548 kept, 640 hint);
conversions exact; 390 / 768 / 1024 / 1440 px, light and dark, EN and
TH, all currencies, steps 1 to 5: no page errors, overflow or untranslated
leftovers; tour in Thai; node --check; no em dashes.
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grabowski
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3f1e4452b8 |
Press hall: five Duplex bays and four Classic positions (balanced at 60 % specials)
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User (October 2026): "change the hall layout" after the finding that the 60/40 floor split leaves the Classics about half loaded at 60 %+ specials (specials run only on the Duplex systems). - Press hall now keeps five Duplex bays (four along the visitor corridor, the fifth at the head of the second row) and four Classic positions: 550 + 200 = ~750 m2 of ~870 m2, ~73/27 by floor, 10 to 4 by presses; launch plant fills one of each, growth adds Duplex first. - Full hall: ~2.9 to 4.4M records a year at 60 % specials, Classics ~80 to 100 % loaded (60/40 gave ~2.3 to 3.6M); ~3.2 to 4.4M at ~20 %; fourteen presses as before: ~2.1 to 2.5 t/h steam, up to ~1.8 MW cooling, a utility phase of its own. - pressing-line.md, scale.md, site-candidates.md, crane-workshop-tours.md, roadmap.md, README (FreeCAD model still the earlier layout, not redrawn); calculator preset "Full hall (5 D + 4 C)" and ladder; plant view reserves 5 Duplex bays and 4 Classic positions; business plan draft 0.2 rebuilt. Checks: renderer 720 checks and functional checks pass, calculator regression 0 fails, level checks clean; PDF 47 pages, TOC filled. |
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grabowski
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b3e8e4272b |
Specials share 60 %+: revenue model, calculator and business plan re-based
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User (October 2026): "lets say 60+% special prints" (the plant focuses on special prints, not mono colours). - Specials (splatter, marble, colour effects) run only on the Duplex systems, so at 60 % the Duplex sets the launch plant's output: ~0.58 / 0.74 / 0.90M records a year (was 0.71 / 0.84 / 0.97 at ~20 %), the Classic at about two thirds load. Full 60/40 hall: ~2.3 to 3.6M (Duplex -limited, Classics about half loaded); five-press fleet unchanged. A hall balanced by output at 60 % would give Duplex ~70 to 75 % of the floor (estimate; noted, not applied). - Blended price 3.76 / 4.49 / 5.27 USD (standard 3.40 / 3.80 / 4.25 plus the 0.60 / 1.15 / 1.70 specials premium on 60 %). Launch operating picture: revenue 2.28 / 3.65 / 5.41M USD, EBITDA 0.23 / 1.73 / 3.79M, operating profit -0.66 / 1.21 / 3.46M, payback ~3.8 yr central, break-even ~0.25M records; adverse needs ~1.1M records to cover depreciation. Specials' extra direct cost (coloured compound, purge, trim only into black) is not in the cost table yet: flagged as an upper bound until compound quotes. - Calculator default specials share 20 -> 60 % (planning rates keep the launch plant balanced at 850k: revenue 4.14M, EBITDA 2.07M, payback 3.3 yr, cash payback year ~4.8, IRR ~18 %). - revenue-model.md, scale.md, pressing-line.md, README; business plan draft 0.2 rebuilt (sections 1, 4, 9, risks). Checks: calculator regression 0 fails, no page errors, node --check on all scripts; PDF 47 pages, table of contents filled; no em dashes added. |
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grabowski
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d8b2c1e2db |
Press hall laid out 60/40 for Duplex systems (special pressings first)
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User (October 2026): "the factory should have more space for duplex setups than classic, we will mainly focus on special prints and not mono colours plan it to be 60/40 duplex classic". - Press hall (~870 m2) planned 60/40 by floor: four Duplex bays along the visitor corridor and six Classic positions in the second row (440 + 300 = ~740 m2 at 110 / 50 m2), the rest open for mould carts and staging; the launch plant fills one of each, growth adds Duplex systems first. Replaces "room for ten more Classics". - Full hall: 8 semi-automatic presses + 6 Classics, 57/43 by press count, ~1,250 to 1,410 records/h gross, ~3.6 to 4.7M a year on the scale.md basis (was 4.7 to 5.8M for 2 Duplex + 11 Classics); ~2.1 to 2.5 t/h steam and up to ~1.8 MW cooling, still a utility phase of its own. By hourly output the six automatic Classics still press more than the eight semi-automatic presses (estimate). - pressing-line.md, scale.md (capacity table, utilities), site-candidates .md, crane-workshop-tours.md, roadmap.md, README (the FreeCAD Payap model still draws the earlier layout; noted, not redrawn). - Calculator: preset "Full hall 60/40 (4 D + 6 C)", fleet ladder Duplex first (1+1, 2+1, 3+2, 4+3, 4+6) plus the same floor Classic-led (2+11) and Duplex-only (7+0) for comparison; plant view reserves 4 Duplex bays and 6 Classic positions. - Business plan draft 0.2 rebuilt (capacity table row, plot fit, layout). Checks: renderer 720 checks pass (node budget 2,700 for the Duplex-heavy stress preset, 60 fps), calculator regression 0 fails, level selector and page checks clean at 390 / 1024 / 1440 px dark and light; PDF 47 pages with a filled table of contents. |
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grabowski
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d7380919e4 |
Steam and cooling, plant operation: show the launch plant (1 Duplex + 1 Classic)
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User (October 2026): "launch plant should be 1x duplex system and 1x classic". The calculator already did; these two pages did not. - steam-cooling.html: default case is now "Launch plant" (D1-A, D1-B, Classic; B-1 and B-2; CH-1 and CH-2: 450 to 540 kg/h on 1,000 kg/h, 391.5 kW on 500 kW). Other cases: Duplex first (commissioning), Second Duplex (growth option, five presses), One module down (launch plant with B-2 and CH-2 out). Idle boxes say "reserved position" / "growth option". Phasing table: launch plant, second Duplex, options; galvanics cooling is launch scope. Five-press figures labelled as the growth case or backbone sizing; chiller cost per the CSV 2-module row. - plant-operation.html: the launch plant: Classic C2 removed everywhere (press, trimmer, routes, conveyor, lamps, texts), Classic re-centred; one PDPU (2 cells) as in total-investment; boilers 2 x 500 kg/h, chillers 2 x 250 kW; title arrivals scaled to three presses; phone legend in one column. - Landing entries and README bullets for both pages. Verified headless (Edge): skill checks pw_sc_check and pw_plant_check with launch-plant expectations, 90-day runs, perf unchanged; 390 / 1024 / 1440 px dark and light without page errors or overflow. |
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grabowski
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485b3b630a |
Plant and business plan calculator: configuration, investment, budget, ten-year cash
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User request (October 2026): an interactive business plan calculator where the plant configuration is chosen and everything follows. Built into the fleet calculator (same page and URL, one model): - Plant configuration card: galvanics in-house or bought stampers (and Pheenix estimate vs OMS reference), mastering and cutting in-house or outsourced, metrology full or launch tier, cassette and CD-R, solar buy / PPA / none, electric or biomass steam, Thai or Chinese utilities, crane buy or rent, visitor corridor now or later, ramp-up reserve; stamper supply to other plants; disabled-not-hidden controls. - Investment built from the total-investment blocks (low / mid / high, sources and kind badges); boiler and chiller modules sized from the fleet and flagged past the four positions; phase 2 building past the 870 m2 press hall. Default reproduces 160.9 / 226.7 / 292.5M THB. - Budget card against 180M and 216M THB; "Investor levers" preset gives 193.6M mid, 203.6 to 213.6M with the reserve. - Money follows the configuration: outsourced title steps passed through at cost (fee split 51.1 / 37.0 / 11.9 %), electric steam energy and demand charge, PPA power price, optional cassette/CD-R revenue. - Ten-year cash view: editable ramp and discount rate, payback, NPV, IRR, chart and table; pre-tax, pre-financing sketch. - Presets: launch plant, investor levers, lean, five-press, full hall. - Verified headless on Edge: 62 checks, 390 / 1024 / 1440 px, dark and light, no overflow, no page errors. Business plan 9.4 cross-check updated to the calculator's figures (EBITDA 1.68M, payback 4.1 yr; cash payback year ~5.7, IRR ~13 %); docx and pdf rebuilt. README and landing entry renamed. |
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grabowski
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d42e99389b |
Business plan draft 0.2: re-based on the launch plant
The investor business plan (docx + pdf) rebuilt for the launch plant decided in October 2026: one Duplex system and one Classic, Pheenix galvanics with zero discharge, the Sibert line, a Sillitoe cutting room, modular steam and cooling (rooms for four), cassette and CD-R; no bridge stampers, no outsourced cutting; second Duplex as a growth option. - Part A: executive summary (what changed since 0.1, the numbers, the 180M / 216M answer, first release marked open), reading guide, two price points (ResurRec and Record Industry), anatomy rewritten for Sillitoe, Pheenix, Sibert, Duplex + Classic, lead times without bridge stampers, new 4.8 artist platform, cassette 4.9, CD 4.10. - Part B: traceability with ERPNext as system of record, metrology launch tier as the investor's choice, QC, efficiency (PEA tariff, utility modules, fuel open, Chinese boilers and DIW rules), site (Mueang Chi, Payap zoning result), building blocks, safety, BOI and licences with galvanics in the first factory licence. - Part C: launch-plant investment table, the investor's question and levers, tranches, currency, operating picture of the launch plant, timeline with the metal path on the critical path, commissioning sequence and why the whole chain at launch, team, 22 risks, 17 phase 0 actions, the ask. - plan_lib: grid column widths so LibreOffice keeps table widths. - export_pdf.py: LibreOffice UNO export that fills the table of contents (47 pages). - README: total investment, revenue model and business plan bullets. |
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grabowski
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7344f12dc8 |
Chinese suppliers for boilers, compressed air and hydraulics
Checked October 2026 on the investor's budget question. New docs/suppliers/china-utilities.md: boiler makers (ZOZEN, Sitong, Fangkuai, Taiguo, Yuanda, Yongxing, Taishan, Nobeth) with fit for 500 kg/h at 1.25 MPa, claimed certificates, Thai references and listing prices; the Thai rules for an imported boiler (MR and MOI notification B.E. 2549: ASME/JIS/EN or equivalent, certification-body verification, once-through relief does not reach 10.5 bar, licensed controller, annual inspection); compressor makers with Thai offices (Kaishan, Denair) and sizing; hydraulic pump sets and accumulators (Huade, Yuci, Hengli, WMD, Renowell, Inovance, NXQ makers), the shared-ring-main risks and Thai HPU builders; duty and freight; open RFQs. Result: about 2M THB at the midpoint (~2.5M with contingency), ~1 % of the 216M target, mostly the boilers; Newbilt aggregates stay Newbilt's. total-investment notes it and lists the uncosted central hydraulic plant; utilities CSV gets the Chinese candidates and route estimates; backlinks from equipment-suppliers, pressing-line, README. |
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grabowski
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553b4a93d1 |
Launch plant roll-up and the investor's 180M THB question
Decided (user, October 2026): the plant launches with everything in one capital round, commissioned in sequence: one Newbilt Duplex system, one Classic, a Pheenix galvanics line with ZLD water, the Sibert line, a Sillitoe cutting room, and the modular steam and cooling plant (2 x 500 kg/h boilers, 2 x 250 kW chillers, rooms for four each). No bridge stampers, no outsourced cutting; cassette and CD-R stay; the second Duplex and further Classics are growth options, not in the investment. total-investment.md: new 'Launch plant' roll-up, 4.9M to 8.9M USD, 161M to 292M THB incl. 15 % contingency (midpoint ~227M), with what is left out (ramp-up reserve ~10-20M THB, CD replication, financing, FX, archive shelving) and the BOI assumption. The investor's question (180M THB, maybe +20 % = 216M): fits at the low end only; at the midpoint four levers that keep every machine (solar via PPA, metrology launch tier, galvanics near OMS's reference, visitor corridor later) give ~193M, plus reserve ~203-213M, inside 216M; 180M needs low quotes. The quotes that decide it: Newbilt (Duplex, Classic), Pheenix galvanics, building with soil test, metrology. Old full vision and phased entry marked superseded until the mirrors are re-based. Utilities CSV: chiller bank two modules (4.9-7.9M THB), boiler note for B-1 and B-2 at launch, ZLD and DI rows now launch scope (carried with galvanics); baseline 28.47M-48.73M THB. README project status. |
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grabowski
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07ef9c0b9a |
Order demos: spine choice, artwork templates, PDF and AI uploads
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User request (October 2026): the order tool needs a thin / thick spine selection, templates for the jacket and label upload, and must accept AI and PDF files. Both artist demos (artist-order, make-a-record): - Spine: thin 3 mm (one record) or thick 5 mm (two records, or a thick insert); a double album in a single jacket takes 5 mm, thin is then disabled; 7", gatefold (7 or 9 mm) and own jacket disable the row with the reason. Quote line 'Thick 5 mm spine' (R.spine 12 / 10 THB per copy, estimate from QRP 0.90 vs 0.55 USD and Kudos 137.50 GBP/order). Mock-up draws the spine edge to scale; caption names it. - Templates: vector PDFs written in the browser for the current choice: jacket spread (back, spine, front; 633/635 x 315 mm for 12" from Mighty Media Discs), gatefold with an inside page, labels with a page per side and the dinked hole; trim and bleed boxes set, 3 mm bleed, 5 mm safe area, folds, crop marks, guidance notes. - Uploads accept PDF, AI (PDF-compatible) and images. PDFs are read in the browser (object streams inflated with DecompressionStream): page boxes, pages, PDF/X, creator, colour spaces, font embedding; checks against the chosen spine (a 5 mm spread on a 3 mm order is flagged), bleed, CMYK, fonts; old PostScript-only AI files are refused with the fix. Image spreads are measured the same way. Preview via pdf.js (jsDelivr, loaded only when a PDF arrives); the front panel goes into the mock-up. artist-platform.md: new section 'Artwork templates and files' with the sources; preflight step links it; RI 'left out' list updated. README demo bullet. Checked headless on Edge: fixtures (3/5 mm spreads, no bleed, AI, legacy AI, front only, labels, 150 dpi PNG), downloaded templates parsed with PyMuPDF, 390/1024/1280 px no overflow, dark and light, no page errors; pw_mr_check --tour and pw_ri unchanged (37,836 / 232). |
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grabowski
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5c303dfc61 |
ERPNext is the only system of record; we build tools on it
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User (October 2026): we only build tools and interfaces that interact with ERPNext; invoices, stock and the rest are kept there, except telemetry and other machine data. digital-factory.md: standing decision, decisions 2, 3, 6, 7 and 10 rewritten (ERPNext holds every record of the business and of production, including artist gates, metal-part genealogy as serial numbers with parents, and quality inspections; the machine-data store keeps only cycle and record rows, the hash chain and time series, keyed to ERPNext names; ERPNext first, then custom fields or document types in cnx_erp, then a tool, never a second business database). Systems table, architecture labels, factory application section (modules as a table: records in ERPNext, what we build, machine data outside; our only tables are the machine-data ones), ownership table, integration rules 4 and 8, phasing and estimates (cnx_erp app 2 to 3 person-months; total 3.5 to 6). artist-platform.md: campaigns are an ERPNext document from launch, pledges post as advance payment entries; traceability, README, facility security (archive location on the serial number), production timeline (sets per mother on the mother's serial number), crane-workshop spares store, total-investment. Factory console: KPI row no longer touches the postings card (user screenshot); ERPNext page, order card, sidenote and ledger say every record lives in ERPNext and only machine data stays outside; new postings for artist gates, stamper metrology inspections, stamper set serial numbers (grown, retired with play count). Checked headless: Edge dark and light, 1440/1024/390, no overflow or page errors, rows aligned, pw_fc, pw_wo, pw_feed and pw_erp pass. |
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grabowski
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e12ad2ed7b |
ERPNext runs the whole plant; every tool we build integrates with it
Decided by the user (October 2026): the whole plant runs ERPNext, and all tooling we develop has to interact with it. digital-factory.md: standing decision in the summary; decision 10 (ERPNext owns the business documents, the factory application owns the floor; ERPNext names are the shared keys); new section 'ERPNext: the plant's ERP' with the ownership table (customers, prices, sales orders, items and BOMs, work orders and job cards per station, batches and quality inspections per compound lot, serial numbers for metal parts, downtime entries, delivery notes, assets, accounting, payroll vs. cycles, per-record inspection, genealogy and the hash-chained log staying in the factory application), the integration rules (one typed Frappe REST client in cnx-factory, an integration user per tool, webhooks in, transactional outbox with idempotent postings so the floor never waits on the ERP, business-sized postings, customisation as a Frappe app in Gitea, nightly reconciliation, no public ERPNext endpoint, new tools use the same client), hosting on NixOS (no nixpkgs module, NixOS/nixpkgs #241921; Avunu frappe-nix as the start, frappe_docker as oci-containers fallback; MariaDB + Redis; vinyl-erp on site behind the gateway proxy; OIDC sign-on; upgrades on a restored copy), Thai localisation (Ecosoft erpnext_thailand: VAT, WHT, PND, billing notes; Ecosoft as partner to quote; payroll and BOI reporting to check), phasing (dev ERPNext now; accounting and assets from the first capex invoice; manufacturing at commissioning) and estimates. ERPNext added to the architecture diagram, services, machines (vinyl-erp), module list, backup, cost, build order and open decisions; the old 'ERP out of scope, decide after launch' line replaced. artist-platform.md: price list, customers, sales orders, campaign pledges as payment entries, through the plant's outbox. traceability.md: one ERP, one set of keys. README summary. total-investment.md added scope: ERPNext (to quote, not in the sum, no licence fee). |
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grabowski
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f9b8407561 |
Factory console: work orders for the operators
Deploy test site / deploy (push) Successful in 51s
New "Work orders" section in the factory console (#work), derived from the same simulated records as the rest of the page, one work order per station and job: - order stages: mastering, lacquer cutting, electroforming, stamper prep, test pressings, press run, packing, dispatch - stamper changes (planned when a set nears its life, in progress during the change), fault clearing on a stopped press (maintenance) - material lab: lab gate per compound lot, release test pressing, and the held lot's re-dry and retest (button starts it) - audio QC: each sampled copy's listening check Board: In progress (press floor first) / Next up (planned press runs and stamper changes with time and press, jobs arriving at the next station) / Done today, filter per station, KPIs. Each work order opens a kiosk view: the steps an operator follows (badge in, scan what the step asks for, with the IDs to scan, confirm), confirmation times and who did it, the order, lot or press it belongs to, and what it writes to the log. Order detail lists the order's work orders by station. Mastering and cutting are booked to the engineers, the lab, QC and maintenance to technicians, the rest to numbered operators; jobs finishing at night are booked to the late shift. README, digital-factory.md demo paragraph and the landing page mention the work orders. |
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grabowski
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9ed51f4b22 |
Factory console and customer order status: investor demo
Deploy test site / deploy (push) Successful in 51s
New page docs/factory-console.html (site /demos/factory/): the factory application of digital-factory.md on a simulated plant day, with a switch to the customer portal of the same orders. Factory console (sidebar: Floor, Orders, Quality, Lab, Metal, Ledger): - floor: five presses of the launch fleet (two Newbilt Duplex systems, one Classic) with the mounted order, live good / rejected counters, stamper plays against life, cycle time and steam; KPIs for the day; live optical inspection stream with record keys; alerts (stops, lab holds, stampers near end of life, listening reviews, long gate waits); stations (cutting, galvanics, stamper prep, lab, packing); orders by stage; good records per day - orders list with stage filters and search; order detail with stage track, approvals, metal genealogy and stamper metrology, press run telemetry, compound lot certificate, rejects by reason, audio samples, packing and shipping, and the order's events - press detail with telemetry sparklines; quality (rejects by reason, yield per press, audio comparison); lab (compound lots with results against illustrative limits, one lot on hold with re-dry and retest, regrind batches, hoppers); metal (baths, mounted stampers, metrology, archive); hash-chained event log Customer portal (four demo customers: pressing now, waiting to approve the test pressing, in plating, delivered): progress through every step and the three gates, copies pressed so far with the latest copies and their record keys, approving the test pressing books the press slot (greedy plan of the queue gives the start time and press), and a quality report that fills in step by step: files, lacquers, metal parts with metrology, test pressings, the compound lot's lab results, pressing and inspection, listening checks, packing. Simulation: 60 days warmed up at load (about 0.7 s), then 1x to 3600x. Stages and durations from the production timeline, Newbilt cycle times, two shifts 06:00 to 22:00, unplanned stops, stamper life 1,000 to 2,000 plays, audio sampling first-off plus about 1 in 50 (1 in 25 near end of life), compound lots through the lab gate and release test pressing. All orders, values and IDs are simulated; limits are illustrative. Linked from digital-factory.md (the factory application), traceability.md (customer-facing view), the README and the landing page. |
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grabowski
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607f6631a7 |
Make a record: investor demo of the artist platform, end-user flow
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New static page docs/make-a-record.html (test site /demos/make-a-record/): the artist platform as a customer would see it, polished for presenting. - five steps (design, music and art, price, fan funding, track) with a sticky stage: to-scale mock-up (record spins at 33 1/3 or 45 rpm on hover), spec chips, price per copy, ship month and the next action - design as option cards and swatches; options that do not apply stay visible and disabled (weight and gatefold off 12", colour pickers for black vinyl) - masters and artwork read in the browser as in the detailed demo, side bars per side, checks in plain words, approval 1 of 3 - price with the curve, itemised lines folded under one summary, lead time as two bars (approvals, then the 7 to 9 week quote) - fan funding: goal, break-even and what the artist keeps, money rules; the campaign on a phone with a pre-order ticker, funded or missed ends, production timeline with the artist's approvals, updates feed - record passport for one delivered copy (stamper, press, cycle time and side; stage dates; optical inspection and sampled audio), per traceability.md and quality-automation.md, IDs simulated; repress card - "Investor notes" switch with the business case per step (market research, vault, short-run economics and the Thai price gap, plant-owned vs broker and the Qrates lesson, traceability and represses); guided tour of about a minute (#tour, #notes in the URL) - light/dark theme shared with the other pages; phone layout with a bottom bar Same price list (demo-0.1) and stage table as artist-order.html, so the defaults reproduce the artist platform example: 37,836 THB per title, 232 THB per copy at 100, break-even 41, goal 100, 548 THB kept a copy. artist-platform.md: investor demo paragraph. traceability.md: the record passport as the per-copy customer view. README bullet and layout line, site DEMOS line and landing-page entry. |
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grabowski
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7688d03be6 |
Payap scenario: Part/Draft model with roof, rooftop PV and PV parking canopies
New FreeCAD model docs/cnx_vinyl_parametric_payap_parts.FCStd: the Payap scenario rebuilt from plain Part solids and Draft (arrays, labels, dimensions) on the same Params sheet, no BIM objects, plus: - monopitch roof 10 deg, low eave 7.0 m south, high side 11.4 m north (phase 1 RFQ geometry); gables and the fire wall follow the roof - rooftop PV: 901 x 580 W placeholder modules, ~523 kWp, 17 rows in blocks of four with walkways, 1 m edge strip, 2.5 m clear over the fire wall (estimate) - car canopy (10 bays, 72 modules) and scooter canopy (30 spaces, 22 modules), ~54 kWp, RFQ footprints and heights - module counts and kWp as sheet expressions; ~577 kWp in all FreeCAD 26.3 RC1 does not propagate spreadsheet edits: CNX_apply_Params macro touches the dependents and recomputes; parametric test (factory length, pitch, car bays, walkway) matches the sheet counts. site-candidates.md: roof/PV/canopy section with the export, battery and BOI questions a 577 kWp array raises; mirrors in sustainability.md and scale.md; README layout lines. |
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grabowski
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a07faf6ef0 |
Artist ordering demo: configure, check, offer, fan-funded campaign
Deploy test site / deploy (push) Successful in 53s
New static page docs/artist-order.html (test site /demos/artist-order/) walking the artist platform flow end to end: - record configurator (format, speed, discs, weight, colour, packaging, extras, mastering, test pressings) with a live mock-up - track list or dropped masters read in the browser (WAV/FLAC/AIFF headers, sample peak and clipping), side length against the format, jacket and label preflight (size, dpi, CMYK), rights and gate 1 - itemised offer (per title / per copy, pass-through jacket), price per copy against quantity, lead time from the production timeline - direct order or fan-funded campaign: goal = max(minimum run, break-even), what the artist keeps, the money rules, a simulated campaign (sells out / just makes it / falls short) with refund or go-ahead-at-minimum, and the production tracker with the three gates and the fan update feed Price list demo-0.1 splits the doc's 38,000 THB per title and 132 THB per copy into lines (estimates, each listed with its basis); defaults reproduce the artist platform example (break-even 41, goal 100, ~548 THB kept per copy at 100). artist-platform.md: demo paragraph, side length per format table with sources, VAT note on the campaign example. README bullet and layout line, site DEMOS line and landing-page entry. |
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grabowski
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3984d0c93b |
Payap: the point given fails zoning (DPT, checked 14 October 2026)
Point 18.797678 N, 99.038272 E, queried on the DPT land-use plan map: Chiang Mai comprehensive city plan in force from 25 May 2026, zone ย.7-1, very high density residential. The zone prohibits every factory under the Factory Act except the types in the plan's annex, and prohibits warehouse and silo businesses. Annex for this zone: type 107 (CD production, whose definition names gramophone records and recorded tapes) is not permitted here, only in the low density residential, special industrial, agricultural land reform and rural and agricultural zones; type 72 (sound recording, record players, gramophone records) only for modification or repair; plastics products and metal plating are not on the list. A record pressing plant cannot get a factory licence at that point. Caveats recorded: point, not parcel; DPT data is preliminary, the provincial office confirms; the pharmaceutical neighbour may be in another zone or type. Since type 107 is permitted in the plan's low density residential and rural zones, other Payap land is worth checking before the lead is dropped. - docs/land-listings/payap/: source record (zone rules, annex rows, the 51 types permitted in the zone) and the Thai panel text. - site-candidates.md: plot point, zoning row, status, the result with caveats, check 1 marked failed for this point. - README: project status line, layout line for land-listings/. |
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grabowski
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7af5d89dd0 |
Steam and cooling plant for the five-press fleet; utilities re-based
Deploy test site / deploy (push) Successful in 44s
New page docs/steam-cooling.html (site /demos/steam-cooling/): the utility plant as a clickable process diagram. Steam side: raw water, softener and dosing, feed tank with heat-pump feedwater recovery, feed pumps, a bank of two 500 kg/h boilers (third for N+1 as an option), separator and metering, optional accumulator, blowdown, the 10 bar header with a valved, metered branch and trap per press, drip legs and condensate return. Cooling side: Newbilt's press outlets are open (max. 2 bar), so returns drain to a warm tank, pass the heat pump, an optional dry cooler and a plate heat exchanger to a cold buffer tank, and VFD pumps feed the 20 to 25 C header at ~10 bar to every press, the extruders and the central hydraulic oil cooler; the chiller loop (three 250 kW air-cooled modules at 40 C ambient, fourth as option) stays closed and clean. Galvanics cooling (12 to 20 C) is a separate circuit. Operating cases (launch, Duplex system 1, five presses, one module down) show demand against installed capacity; design basis with sources, equipment schedule, RFQ questions. Static SVG, no per-frame work. Design basis at Newbilt's per-machine figures: steam 750 to 900 kg/h, cooling 652.5 kW (625 presses, 15 extruders, 12.5 hydraulics), 305 to 540 l/min circulating. Also found: Newbilt's 53 l/min at ~60 C out is ~140 kW, above its 125 kW peak; listed as a re-quote question. Re-based in the same commit: - scale.md: electrical table (chiller bank ~210 to 325 kW electrical, plant peak ~430 to 700 kW, ~950 to 1,330 kW with electric steam), grid 800 to 1,000 kVA (1,250 to 1,600 with electric steam, Schedule 4 past 1,000 kW), tariff 4.5M to 6.8M THB/yr, battery ~1 h of chiller peak, boiler and chiller banks, biomass up to ~550 t/yr at 1.5 M records, utilities money line. - sustainability.md, biomass.md: same figures; electric steam 5.2M to 6.0M THB/yr mature, 1.6M to 1.8M early; fuel saving 4.0M to 5.4M. - utilities CSV: boiler bank, chiller bank with HX and tanks, softener and loop treatment re-sized; baseline 23.98M-41.63M -> 30.07M-51.33M. - total-investment.md: re-size as an added-scope row (+185k / +294k USD); headline 4.7M to 8.9M unchanged until the investment re-base. - pressing-line, equipment-suppliers, facility-security, fleet calculator (boiler 1000 kg/h, chiller 750 kW), plant page detail texts; README, landing page, build.sh. |
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grabowski
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8032e0ea47 |
BOI: machinery import duty and import VAT, PVC duty relief
Deploy test site / deploy (push) Successful in 35s
User, October 2026: take the BOI duty-free import and VAT exemption into consideration. - boi.md: import VAT goes with the BOI duty exemption (Revenue Department answer on the BOI OSOS FAQ, checked October 2026); what it is worth: ~2.75M USD of imported machinery at the start fleet (block midpoints) would otherwise carry ~5 % duty (Thai MFN averages 4.1 % on HS 8477, 0 to 10 % across HS 84; estimate until the HS codes are set), ~0.14M USD, and 7 % import VAT, ~0.2M paid at the border and recovered later as input tax, mostly as a refund claim since exports are zero-rated. - total-investment.md: the blocks are vendor prices without duty or import VAT, so the headline already assumes promotion. - Fleet calculator: BOI promoted / not promoted switch and export share. Not promoted adds the machinery duty to capex and depreciation, shows the import VAT as cash at the border, and charges duty on imported PVC compound; promoted exempts both, with no compound duty on exported records and 90 % off for domestic sales (sections 36(1) and 30). A note under the KPIs shows what promotion saves either way. Defaults: payback 3.1 years with BOI, 3.2 without; adverse case operating result -31k with BOI, -68k without. CIT and BOI CIT exemptions still not modelled. |
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grabowski
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1a368287f8 |
Labour from base salaries; health care with check-ups for all staff
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User, October 2026: option to enter base salaries; the company should provide proper extra health care with check-ups for all staff. - worker-safety.md: new "Health care for all staff" policy (decided October 2026): group health insurance (inpatient and outpatient) and a yearly check-up for everyone, office included, on top of social security; the occupational checks Thai law requires for risk-factor work (Ministerial Regulation B.E. 2547: within 30 days, then yearly, by an occupational physician, records kept 2 years after the job ends) for the press floor, galvanics and maintenance; planning costs with sources checked October 2026 (group insurance ~8,000 to 18,006 THB a head a year, plan ~15,000; Rajavej Chiang Mai check-ups 1,290 to 5,990 THB, plan ~2,500 plus ~1,500 risk-factor tests, estimates); social security 5 % up to the 17,500 THB ceiling since 1 January 2026. - revenue-model.md: cutting engineer 50,000 THB is base salary; health care on top of the x1.3 (~0.35M THB a year at the start fleet); what the x1.3 is made of. - Fleet calculator: base salaries per role (the revenue model loaded rates / 1.3; cutting engineer 50,000), employer social security 5 % capped at 17,500, 25 % overtime, bonus and PPE, health insurance and check-ups for all staff incl. 4 office staff (scale.md 3 to 5), risk- factor tests for the press floor, galvanics and maintenance; all as editable assumptions; people table gains office and all-staff rows. Defaults: labour 5.25M THB (was 4.67M loaded), direct cost 1.90 USD a record, EBITDA 2.19M USD. |
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grabowski
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ce1d71e0b5 |
Fleet calculator: material, energy and labour cost, revenue and P&L
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User, October 2026: add calculation for material cost, PVC, carton, chemicals, labour etc. and revenue from sales. New "Money a year" card (and a "Prices and money" input card): - revenue: standard records at the standard price, specials with the premium, title services per title (revenue-model.md 3.50 to 4.60 blended, +0.60 to 1.70, 580 to 1,730 USD a title); - materials and packaging: PVC from the compound tonnage (rejects in, trim back as regrind), labels per pressed record, inner sleeves, printed jackets, shrink wrap, shipping cartons (estimate), maintenance; - stamper making: lacquer blanks and styli per side (estimate), nickel, silver and chemistry per electroformed part (revenue model: 60 to 150 USD a three-generation set); - energy from the fleet: machines, chiller and compressors at the hours run plus an estimated base load, roof PV off, PEA 3.2.2 blended rate and demand charge; steam from the presses running time at the biomass heat price (biomass.md); the start fleet lands in scale.md 4.3 to 6.4M THB; - loaded labour per role (revenue-model.md wages; cutting engineer an estimate), headcount now also counts QC, maintenance and cutting; - overheads, EBITDA, depreciation of capex (total-investment.md start fleet plan plus or minus each Duplex system and Classic), operating profit, payback; per-record cost bar; - Adverse / Central / Favourable presets from the revenue model ranges, USD / THB / EUR display; ladder gains revenue and EBITDA columns. At the defaults (1 M records, 20 % specials): revenue 4.42M USD, direct cost 1.86 USD a record (revenue model central 1.94), EBITDA 2.23M. README bullet; revenue-model.md links the calculator from its operating picture. |
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grabowski
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7d7a378c8b |
Fleet calculator: machine park schematic with the stamper line feeding it
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User, October 2026: add a visualization of the machine park and the connected stamper production to the tool. - New card "Machine park and stamper production": one live SVG that follows every input. Top: the stamper line, lathe, Pheenix PASU, PPPU, PDPU (2 cells), PMPB, Sibert VSF, VSP, VSC, each with its count, flow a day and how busy it is. Middle: the press hall, each Duplex cell drawn as in the cell sketch (presses either side of the operator, EX 50 and EX 35 behind, trimmer in front) and each Classic with its built-in extruder, wrapping into rows and scaling down for big fleets; compound in on the left, stamper rack in and finishing out on the right. Bottom: central hydraulics, boiler, cooling, air and electrical piped up into the hall, amber where they exceed the plant as planned today. - Stamper production is now counted per station from the cycle times in galvanics.md (silvering, pre-plate four at a time, father, mother, stamper plus handling per PDPU cell, PMPB, Sibert steps; usable share of the hours 80 %, estimate) instead of a flat 20 to 32 parts per PDPU. At the defaults: 1 PDPU at ~43 % busy, as galvanics.md concludes. New assumptions with sources; the lathe rate (8 sides a day) is an estimate. - Requirements table: per-station counts and load; the URL hash now also reloads in an open tab (hashchange). Checked headless in Edge, both themes: no JS errors, no text overlap or overflow in the schematic at the default, 8 M and 30 M records, no horizontal overflow at 390 px. |
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grabowski
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c6bec71442 |
Press fleet calculator: target output and specials share to fleet mix and needs
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User, October 2026: calculations for the later business plan, starting from 2 Duplex + 1 Classic at 3 records a minute per Duplex and 2 per Classic, as an interactive tool on the website: pick the yearly output and the share of splatter/specials, get the machine mix and all the requirements (people, hydraulics, power, ...). docs/fleet-calculator.html (single static page, no dependencies): - target mode sizes the fleet (specials only on Duplex with its EX 35; grow with Classics or with Duplex systems; start fleet as the floor); fleet mode takes a fleet and gives its output at the specials share; - output, capacity, utilisation and the mix bar per machine type; - needs: people per shift and in total, galvanics operators, machines, connected kVA and average kW, MWh/yr, central hydraulics (flow, motor, oil, accumulator), steam, cooling and cooling water, compressed air, press floor, room climate, compound, trim, titles, electroformed parts and plating units; checks against the 400 kg/h boiler, 250 kW chiller and the 870 m2 Payap press hall; - ladder from the start fleet to a full Payap press hall, click to load; - every assumption editable with its source (Newbilt Duplex site requirements V14 and offer 240620-04, scale.md, galvanics.md, revenue model, Payap model; estimates labelled), shareable link via the hash. The Classic counts as one HRP 12 press plus one extruder until Newbilt states figures (Toolex Alpha leaflet as a cross-check). Site: DEMOS entry (/demos/fleet-calculator/) and landing-page entry. README bullet and layout line; backlinks from scale.md (capacity) and pressing-line.md (current plan). |
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grabowski
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7da64088ce |
Duplex cell layout: one operator, presses turned towards him
User sketch, October 2026 (filed as docs/equipment/ duplex-cell-layout-sketch.png; arrangement only, the user notes it is not to scale): operator in the middle, the two presses either side turned 45 degrees towards him, EX 50 and EX 35 side by side behind him, one trimmer per cell in front on the left. Sized from the Newbilt site requirements p. 10 (press ~0.9 m2, extruder ~0.5 m2, hydraulic aggregate ~1.0 m2, walk-around space, >= 60 cm to walls, room height >= 2.5 m): cell ~5 x 3 m, 0.6 to 0.8 m between machines; EX 35 and trimmer footprints are estimates. The layout drawing the site requirements refer to on p. 11 is missing from our copy: ask for it with the re-quote. README layout line for the sketch. |
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grabowski
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83840d45dc |
Payap model v4: colour store, silos, two-storey finishing and print block
User, October 2026: ground-floor colour store plus outdoor silos; a two-storey block at the east end with packaging below and printing plus print and packaging stock above; in-house printing not decided, so the print room is reserved only. Model (rebuilt live in FreeCAD 26.3 after checking a copy of the saved file for user edits; parametric check plot 150->160 m and upper floor 3.8->4.2 m passed): - factory 128 x 25 m, plot 150 m (14.1 rai), corridor 98 m, fire wall at 106 m, new params crane_x (runway end = press hall end, 92 m) and mezz_z (+3.8 m); - galvanics open to stamper prep (wall kept only on the material area and electrical side); - colour store 10 m bay (~180 m2): two racking rows, ~100 pallet positions on 4 levels (estimate), weighing and mixing, vacuum conveying station; indoor silos replaced by regrind bins; - 4 outdoor PVC silos (2 black, 2 standard colours, ~50 m3 each, estimate), big-bag filling station, buried conveying lines; - finishing and print block 14 x 25 m: ground floor trim, optical inspection, QC, packaging (tables, shrink wrap, pallet wrapper), stair (Arch Stairs) and goods lift; upper floor print room (reserved), print stock, packaging materials. New docs/cnx_vinyl_parametric_payap-block.png with both block levels. Docs: site-candidates Payap section rewritten (areas ~3,800 m2 under roof, ~4,630 m2 of floor), crane doc (98 m corridor, runway ends at the press hall), README bullet and layout line. |
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Payap model: two-storey office building with canteen, changing and showers
User, October 2026: the office building also houses several showers, a changing room, toilets and a canteen; the office area itself about 150 m2; the building can be multi-storey. Model (office rebuilt live in FreeCAD 26.3; factory and site untouched): - 32 x 15 m on two storeys (off_storey 3.6 m), ~960 m2 of floor, Arch Stairs plus a lift, first floor slab with the stair and lift void; - ground floor: reception and lobby (entrance and link door), canteen ~40 seats with kitchen and servery, changing rooms women and men with 4 showers each and lockers, toilets, mastering and cutting (acoustic lining), listening room, archive; - first floor: offices 147 m2 (16 desks), training room (Payap programmes), meeting room, IT and server, toilets, pantry, flexible room; - factory staff entry relabelled "PPE, WC" (changing is in the office). New docs/cnx_vinyl_parametric_payap-office.png with both floor plans. Docs: site-candidates Payap section (office bullet, staff entry, area ~3,400 m2 footprint / ~3,880 m2 floor), README bullet and layout line. |
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Payap model v2: bigger factory, shared plant room, separate water treatment
User, October 2026: the factory is too small and needs room to grow (possibly ten more Classics), one shared hydraulic and air supply, water treatment perhaps in a separate building connected to the galvanics lab, and a fully equipped workshop (maintenance tools, 3D printers, maybe a lathe and a small CNC mill). Model (rebuilt live in FreeCAD 26.3, BIM objects, Params-driven, parametric check plot 135->145 m and factory 112->120 m passed): - plot 135 m (11.4 rai) with a reserve; factory 112 x 25 m, 16 bays, 82 m visitor corridor, fire wall at 90 m; - press hall ~870 m2: two Duplex systems (EX 50 + EX 35), the Classic, ten future Classic positions in two rows on a service trench; - central hydraulics and compressed-air plant room (~62 m2); - water treatment building 12 x 10 m behind galvanics: buried duct (gravity from the +1.2 m floor), covered crossing 6 m clear; - workshop ~200 m2 with benches, tool cabinets, 3D printers, lathe, small CNC mill, drill, saw, welding bay, press, washer, measuring table. Docs: galvanics (water treatment building, proposed), crane doc (workshop fit-out; lathe and CNC mill not yet priced; corridor now 82 m), site-candidates Payap section rewritten, README bullet. |
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Payap scenario: parametric BIM model of the whole plant on a square plot
A separate FreeCAD 26.3 model (the Mueang Chi model is untouched) sites the plant on a 110 m square placeholder plot of Payap land, built from BIM objects (Arch Site, Buildings and Levels, walls, slabs, columns, beams, a ramp, Spaces with computed areas, Equipment). Every object sits on an expression-driven base, so the Params sheet drives plot, setbacks, floor level, building sizes, fire wall line and office gap (checked: plot 110 to 120 m and factory 84 to 90 m, everything followed). - Factory 84 x 25 m, production only, in process order along a 54 m glazed corridor; press hall 465 m2 with the October fleet (two Duplex systems, each EX 50 + EX 35, and the Classic); crane to the fire wall; machine door and 12 m ramp at the north-west corner. - Office building 24 x 15 m, 12 m away on its own slab with a covered link: reception, offices, meeting/training, mastering and cutting, listening, IT, archive. Resolves the crane-zone conflict of the old sketch. - Utility yard behind the press hall (boiler and chiller flagged for re-sizing), gate, truck apron, car park, service road. - site-candidates: new section and plot-fit note; crane doc: conflict resolved, 54 m corridor; README bullet and layout lines; the old sketch is labelled as Mueang Chi with the earlier fleet. |
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Fleet: each Duplex has an EX 50 main and an EX 35 colour extruder
Correction from the user: the two Duplex systems are not in the two-extruder configuration. Each runs two HRP 12 presses from an EX 50 main extruder with an EX 35 auxiliary extruder beside it for a second colour; the Classic stays. Fleet still five presses. Updated in pressing-line (table, phasing, re-quote: EX 50 vs the VEX 50 of the 2024 quote, and whether one EX 50 keeps both presses at full rate), scale, total investment (wording; estimates unchanged), roadmap item 4, README. |
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Press fleet: two Newbilt Duplex systems with an extruder per press, plus a Classic
The current plan (user decision, October 2026) replaces the 50/50 target (two semi-automatic presses and two Pheenix AD12s) with an all-Newbilt fleet of five presses: two Duplex systems in Newbilt's two-extruder configuration (two HRP 12 presses, an extruder each, one hydraulic unit) and one Classic fully automatic press. - pressing-line.md: new "Current plan" section (fleet table, what it means, phasing from the Single 2.1 as the first half of system 1, re-quote questions); site requirements per Duplex system. - scale.md: capacity table and basis (368 to 448 records/h, ~1.06 to 1.5M a year on two shifts, same range as before); pressing electrical row; steam and cooling flagged, not re-based: five presses draw ~750 to 900 kg/h of steam and up to ~625 kW of cooling at Newbilt's per-press figures, against the 400 kg/h / 250 kW sized for one Duplex. - total-investment.md: fleet change as an added-scope row (system 2 ~230k-300k and the Classic ~290k-460k, estimates; -60k / -160k against the two blocks it replaces); headline unchanged until the re-base. - roadmap items 4, 5 and 24, revenue model mature row, crane doc (the Classic's weight now decides 5 t or 3.2 t), vendor landscape (AD12 is the comparison for the Classic), README. The business plan docx is not regenerated. |
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OMS introduction letter and links, Sibert's answer (9 October 2026)
OMS (Lou Wullms) sent its introduction letter, filed in docs/equipment/oms/: wet-room units with reference prices, two 4-cell configurations (EUR 224,000 basic with two EFS2-200, EUR 311,000 advanced with one AEFS4-250 and PLC; installation days extra), capacities of 24 and 32 shells in an 8-hour day, utilities, rooms, staffing, used equipment, and five contacts for buying a cutting lathe. Recorded in galvanics.md (tables, our reading: the advanced units add up to EUR 314,000, know-how transfer is left out of both totals although CNX has no plating know-how, the basic set has no passivation unit), the exhibitor follow-ups, vendor landscape (new section on used lathes and cutting-room contacts, plus Lou's three websites), supplier map, roadmap items 6 and 13, total investment (basis note only, block unchanged) and the scale people estimate. Open: forward the letter to Simona, as Lou asked. Sibert (Ian Locke, 9 October): footprints and formal quotations when we are ready; settle the pressing side first, hopefully with Pheenix, and mention his recommendation if we do; impressed by the green-factory plans (supplier feedback). Open: pass on the recommendation if Pheenix is chosen. CNX-01 in proplan: OMS basic and advanced added as options to D-002 with their reference prices in THB; budget line 3 notes the OMS range. |
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Record the replies to Sibert and OMS
- Sibert: back in Thailand, investor meeting in preparation, his OMS/Pheenix advice noted; itemised quotation not yet requested. - OMS: met in Haarlem; role split given to Lou (Simona management and audio, Alexander technical); waiting for his calculation material. - README: team roles, investor meeting in the status list. |
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Biomass: reported northern fuel prices (October 2026)
No public price index exists; DEDE lists buyers, not prices. Reported market prices: fresh chips 1,350-1,800 THB/t (LH Bank, Mar 2026), rubberwood firewood >1 THB/kg farm gate (OIE RIU 2026, doubled since late 2025), corn residue 2 THB/kg (Sunsweet, Mae Chaem), rice husk ~1.5 THB/kg, pellets 3,000-5,000 THB/t. Planning price 1.35-2 THB/kg delivered, so the mature fuel bill is ~0.6M-1.2M THB/yr (was 0.35M-0.8M): still a quarter to a tenth of electric steam. Prices follow diesel; Ratch Pathana's Pa Sak (Lamphun) buying centre is the local price-setter. Sources filed under docs/finance/biomass/; sustainability.md and README follow. |
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Energy: PEA tariff, electric vs biomass steam, PV vs solar thermal
PEA tariff schedule (May 2023 onward, still current) filed under docs/finance/pea/; Ft 0.1623 THB/kWh for Sep-Dec 2026 from the PEA Ft page. The plant falls under Schedule 3.2.2 (Medium General Service, TOU, 22 kV). New section in sustainability.md: blended ~3.81 THB/kWh for two-shift production plus 132.93 THB/kW demand charge; electric steam ~4.7M-5.5M THB/yr at maturity against ~0.35M-0.8M of biomass fuel; self-consumed PV worth ~3.7 THB/kWh (~4.5-7 yr payback); solar thermal not recommended; the battery earns little from TOU arbitrage or peak shaving. biomass.md, scale.md, the utilities CSV note and the README follow. |
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Production hall: rough BIM layout sketch
FreeCAD BIM (Arch) sketch of the 60 x 25 m phase 1 hall: Building > Ground floor with Spaces for every zone (areas computed), room-in-room partitions, the fire wall at 48 m, the 5 t crane runway, and the main equipment as BIM Equipment (Pheenix line, Sibert row, Newbilt Duplex and two Classic presses, silos, racking). Zones run in process order along the visitor corridor. Top-view PNG alongside. Linked from the README and from the crane doc, with the one conflict it shows: reception and cutting room under the crane travel. |
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Add the Poy Records logo
docs/brand/poyrecord-logo-1536x1536.png (1536 px PNG), shown at the top of the README and listed in the repository layout. |
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Sibert follow-up: USD 250k budget, current VS specs, OMS as galvanics option
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Ian Locke's email of 5 October 2026 after Making Vinyl Europe: - Budget of USD 250k for VSP, VSF and VSC confirmed; his time, spares, shipping and travel extra; itemised quotation on request. The total-investment block keeps its estimate until the re-base, the difference (+190k low case / +80k high case) goes into the not-yet-rolled-up table. - Current specifications filed (VSF and VSC 2022, VSP 2023) plus the VSF/VSP/VSC line-up drawing (4958 x 833 mm); the 2021 issues move to sibert/specs-2021/. VSC is now 1000 kg with split OD hydraulic / ID pneumatic forming; VSF 0-30 psi, 4-station head. Crane table, supplier map, vendor landscape and the plant page details updated. - Fully automatic VSPa exists; Sibert offers to move features to the VSP. - Electroforming: OMS (Optical Media Services, Lou Wullms) named next to Pheenix; added as a third galvanics candidate with open questions. - Sequencing advice (presses, boilers, operators and live feedback loops first) recorded in the exhibitor briefing, roadmap item 23, and as digital-factory design decision 9 (operators see the data first). |
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Plant page: mature fleet at real cycle times
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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. |