Load Splitting

Using Control It, you can process multiple work orders each with a different coating thickness requirement in the same run. To allow your operators to use this feature, load splitting must be enabled. Access the ‘Settings’ tab, select the System icon, select the ‘Allow load splitting’ option and click ‘OK’. Selecting this option will allow load splitting on all your rectifiers.

  • When load splitting is enabled, the operator will be able to adjust the load size when a program is resumed from a pause. Load splitting is allowed when you are running a load with multiple work orders.

The operator will have the opportunity to adjust the process area in the bath when a program resumes from a paused condition regardless of what initiated the pause condition (the operator clicking the pause button, a program pause, etc.)

As an example of how to change the load size, assume you are running a mixed load with 3 work orders, each one containing varying amounts of process area. Work order #1 has 10 square feet, work order #2 has 20 square feet and work order #3 has 30 square feet. The operator puts the entire load (total 60 sqft) into the process tank and runs a program to ramp to 18 ASF and hold there for 60 minutes. After running 30 minutes, the operator pauses the process and removes all the parts that constituted work order #2 (20 square feet). When the operator clicks the Resume button he will be asked if the load size has changed. Clicking Yes will allow the operator to adjust the load size in the process bath. If the load size has not changed, the operator should click No. Clicking Cancel will cancel the Resume operation and the process will remain paused.

If the operator chooses to change the load size the Change Load Size window will appear with all the work orders listed. The operator can then either select the work order(s) to remove.  For our example, the operator removed the material for work order #2, so he would click work order #2 and remove it. If the operator clicks the cancel button, the load size will not change and the process will remain paused.

As long as there are at least 2 work order running, you can load split during a process, and you can run as many work orders with different coating requirements as you need.

Load splitting is also recorded on the process report and in the process data files. When the process report is created, it will state when a load split occurred and how much area was removed. The report will also state when a particular work order was pulled from the process bath.

Using the Mickabooh Control & Tracking System, you can process multiple work orders each with a different coating thickness requirement in the same run. To allow your operators to use this feature, the Allow load size changes options must be set for each rectifier. Open the rectifier settings by clicking Rectifier > Settings menu item. When the Rectifier Settings window opens, make sure to select the Allow load size changes option. This is a rectifier specific option and must be set for each rectifier that load size changes will occur.

When load size changes are enabled, the operator will be able to adjust the load size when a program is resumed from a pause. Load size changing is allowed when one of the following are true,

 

  • The process is running either a Current Density Control program or a Voltage Control program (see Creating Programs for information about Current Density programs)
  • OR
  • The program is associated with a part (see Working with Parts) for information about Parts)

 

As mentioned above, when the allow-load-size-changes setting for a rectifier is enabled, the operator will have the opportunity to adjust the process area in the bath when a program resumes from a paused condition. It doesn’t matter what initiated the pause condition (either by the operator clicking the pause button, program pause, etc).

As an example of how to change the load size, assume you are running a mixed load with 3 work orders; each with a varying amount of process area. Work order #1 has 10 square feet, work order #2 has 20 square feet and work order #3 has 30 square feet. The operator puts the entire load (total 60 sqft) into the process tank and runs a program to ramp to 18 ASF and hold there for 60 minutes. After running 30 minutes, the operator pauses the process and removes all of the parts that constitute work order #2 (20 square feet). When the operator clicks the Resume button he will be asked if the load size has changed. Clicking Yes will allow the operator to adjust the load size in the process bath. If the load size has not changed, the operator should click No. Clicking Cancel will cancel the Resume operation and the process will remain paused.

If the operator chooses to change the load size the Change Load Size window will appear with all of the work orders listed. The operator can then either select the work order(s) to remove, or he can select the amount of process area that has been removed. For our example, the operator removed the material for work order #2, so he would click work order #2. The operator cannot remove a work order AND specify the area. He must either select a work order OR enter the amount of area removed. If the operator clicks the cancel button, the load size will not be changed and the process will remain paused.

If the operator selects area to remove and clicks OK, a confirmation box will be shown and the user can either accept the change or not. If the operator clicks No, the load size will not be changed and the process will remain paused. If the operator clicks Yes, the process load size will be changed and the rectifier’s current output will be adjusted to maintain the correct current density. The rectifier will then begin its pre-process count down and the program will resume in the normal fashion.

There is no limit to the number of times you can adjust the load size during a process. You can run as many work orders with different coating requirement as you need.

Load size changes are also recorded on the process report and in the process data files. When the process report is created, it will state when a load size change occurred and how much area was removed. The report will also state when a particular work order was pulled from the process bath.