grabowski
808e3e34b8
- Keyence-class instrument stack for father/mother/stamper analysis (VK-X confocal sampled zones, VR-6000 wide-area, XRF thickness) with genealogy integration via middleware - Three-layer pressed-record QC: 100% inline optical inspection, per-cycle press telemetry, sampled automated audio comparison - Honest limits documented: no turnkey products exist for the optical and audio layers; 100% audio QC impossible at press speed
62 lines
3.0 KiB
Markdown
62 lines
3.0 KiB
Markdown
# Process Logging and Traceability
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Every step of production is logged continuously, so that every record is
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traceable end to end for the customer. This is a set requirement, and it is
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the core specification for the factory software this repository will
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eventually host.
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## What a customer can trace
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For any order, the customer can follow the full chain:
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1. **Audio intake**: file received, checksums, versions, who handled it,
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approval trail
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2. **Mastering**: session log, engineer, settings, customer approvals
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3. **Cutting**: lacquer IDs, lathe parameters, stylus used, inspection
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result
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4. **Galvanics**: silvering and plating batch IDs, bath chemistry logs,
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father/mother/stamper genealogy (which stamper came from which mother
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from which father), or the external stamper supplier and batch if bridged
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5. **Pressing**: press ID, operator, shift, mold and stamper IDs, cycle
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parameters (temperatures, pressures, cycle times), PVC compound lot and
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virgin/recycled mix, label lot
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6. **Quality control**: test pressing approvals, inspection results, reject
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counts and reasons (the automated instrument layers feeding this are
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specified in [quality automation](quality-automation.md))
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7. **Finishing and packaging**: trimming, sleeving, carton lot, packaging
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partner batch
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8. **Fulfillment**: warehouse location, shipment or dropshipping consignment,
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carrier tracking per end customer
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## Principles
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- **Log at the source**: machine data comes from the machine (the presses
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and the plating rectifiers expose PLC data; the AD12 supports remote
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monitoring), not from manual transcription. Manual steps get simple
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operator check-ins, not paperwork.
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- **Batch and genealogy first**: every physical artifact (lacquer, father,
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mother, stamper, press run, box) gets an ID, and every ID knows its
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parents. A customer complaint about one record resolves to a specific
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stamper, press, shift, and compound lot.
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- **Environment attached**: the whole-factory HVAC monitoring (temperature,
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humidity, PM per zone) is logged on the same timeline, so any production
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window can be correlated with plant conditions.
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- **Immutable and retained**: logs are append-only and retained for the
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life of the customer relationship; stamper genealogy is retained as long
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as the archive holds the metal parts.
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- **Customer-facing view**: traceability is a product feature, not an
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internal file. Customers get a per-order view (portal or report) covering
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the chain above, without exposing other customers' data.
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## Open design work
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- Data model for batch genealogy across all eight steps
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- Which PLC/machine interfaces each vendor exposes (ask Newbilt, Pheenix
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Alpha, and Digital Matrix during procurement, before purchase)
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- Retention, backup, and PDPA handling for operator-linked records
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- Whether test-pressing approval workflows live in the same system from day
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one
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This system should be specified alongside equipment procurement: machine
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data access is a purchasing requirement, not an afterthought.
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