Stencil Room

 

Capabilities Required: Stencil Room

 

Area

Capabilities

Functionality

Priority

Identify Stencil Requirements

Ability to see stencil requirements by various criteria

  • Earliest Process Date Needed

  • Required Shift

  • Print process / description

  • Manufacture status

    • Require manufacture

    • Require retrieval

    • Require checking [there are various check states]

    • Number of stencils required  in set / actual number

  • screen set number

  • current location

  • last washed date

  • machine

  • priority

  • checked over status

  • combination of above

Exists

Essential

Ability to filter stencil requirements by various criteria

  • Required Date

  • Awaiting Artwork

  • Can be Made
  • Being Made
  • Final Check Status
  • Ready for Print Usage
  • In use
  • Being washed
  • In pre-check
  • Flagged for Pre-Check
  • Possible Re-checks ???
  • Replace
  • Possible Reclaims
  • Flagged for Reclaim

 

Exists

All Essential ?

Ability to set priority for stencil requirements

Exists

Essential

Ability to view & print detail labels  for stencil set requirements

 - stencil type / mesh count

 - position identifier for each stencil

- design identifier for the images that make up the set

 -total qty of stencils that make up the set

 - the barcode for each member in set

Exists

Essential

Ability to locate existing filed stencil sets

by location

by status

by design identifier

 

Exists

Essential

Satisfy Stencil Requirements - new manufacture

Ability to call up art separation data files for member stencils

ability to print / expose image onto stencil emulsion

Exists

Essential

Ability to record stencil set as  being manufactured

 = status updates for stencil set and stencil members

Exists

Essential

Ability to record stencil set as  manufactured

 = status updates for stencil set and stencil members (final checking etc)

 - update inventory information - in use

- record location information

 -

Exists

Essential

Satisfy Stencil Requirements - filed sets

Ability to locate stencil set

Ability to process drawing down filed sets

 - update location and status

Exists

Essential

Satisfy Stencil Requirements - missing or defective stencils

Ability to process one or more stencils in a set as not existing

 - if member missing processed as reclaimed (DR in use; CR available to coat)

 - if member stencil damaged process as split

 - update member stencil status

 - update set status

 - update set location information

Exists

Essential

Process manufacture of missing set members

 - ability to call up details / labels for specific stencils

 - account for new manufacture (CR in use; DR coated)

 - reunite with rest of set

 - update set status

update location

Exists

Essential

Satisfy Stencil Requirements - Checking

Ability to update stencil set  status as fully checked

Exists

Essential

Ability to record location

Exists

Essential

Inventory Management - control dashboard

Ability view stencils types (mesh count, frame size) by following classifications

 

  1. Flagged for Reclaim
  2. Expected
  3. Available
  4. Coated
  5. Required
  6. Coated - Required
  7. In Use

 

See  Manage_Screen_Inventory for definitions of the above classifications in current system

Exists

Essential
 

Ability to on demand recalculate screen classifications

Screens Required

Screens in use

 

 

Exists

Essential

Ability to on demand recalculate screen classifications

Screens Required

Screens in use

by stencil type

by whole inventory

It would be good to be able to run these recalculations on a scheduler / overnight batch

Additionally, it would be helpful to expose the last calculation timestamps to the user

 

Enhancement

TBC

Ability to adjust dashboard figures via adjustment functions

 

  1. Coated - [DR available ; CR Coated]
  2. Split from Coated [DR Coated; CR Split pool]
  3. Split from available [DR available; CR Split pool]

 

 

Exists

Essential

Ability to raise PO for Stencils from dashboard

Exists

Essential

Track Screen Statuses

Support tracking of statuses throughout screen workflow

 

Stencil Sets:-

 Colour

Status

Meaning

Red

Does not exist

No member stencils in the set exist..  (see note 1 below)

Amber

In Progress

One or more member stencils in the set is in the process of being manufactured. (see note 1 below)

Navy Blue

Final Check

All the member stencils in the set have been constructed, and are placed in the final check area awaiting a final check before usage.

(see note 1 below)

Green

Out to Print

All  member stencils have been manufactured, and are currently employed (or just about to be used) on a production screen print job.

Yellow

In Wash

The stencil-set is being washed. (post usage)

Sky Blue

Filed - Full Set

The stencil set has been washed and is filed as a full set (that is, all member stencils in the set are present.)
The set will either be filed in:-

  • the warehouse's stencil archiving area  - in which case the location field will be populated with its whereabouts.

  • the pre-check area (i.e. the stencil  set is required again)  - in which case, the check-over  flag will be enabled as black

Pink

Filed - Partial Set

The stencil  set has been washed and is filed as a partial set (that is, one or more member stencils in the set are missing / damaged and will require construction before the set can be used again.)

 

The partial set will either be filed in:-

  • the warehouse's stencil  archiving area  - in which case the location field will be populated with its whereabouts.

  • the pre-check area (i.e. the  set is required again)  - in which case, the check-over  flag will be set as black

Dark Pink

Partial  - Part Check

Following on from the partial set status, above, when one more member stencil in a set are missing, and the whole set is required on a another job, the missing stencil(s) will need to be constructed before the job can be done..

Whilst, this re-manufacture occurs, the partial set is placed in the part check area to await the replacement(s) to be made, and then the whole set is reconciled and subject to a final check before being used again..

The dark pink status indicates the partial set is in part check awaiting the manufacture of the missing screens.

Note: Currently - if a split occurs on 1 or more stencils whilst in use - the urgency of this is notified via flashing icon- a future state will need to support some form of highlighting

 

Stencil Set Members are also tracked status wise -Note how stencil set status is derived in part  by these

 Colour

Status / Meaning

Red

The screen stencil does not exist.

Amber

The screen stencil is in the process of being manufactured.

Green

The screen stencil has been constructed.

 

 

Exists

Essential

Process Screen Post Usage

Ability to automatically identify how to process screen-set post wash

Support use cases

 

  1. Stencils required on future (un-started) print run - Users physically place stencils in Pre-checkl
    1.  Location> Pre-check
    2. Status Wash > Full set filed & Checkover flag
  2. Stencils likely to be used in future (Screens Filed)
    1. Status Wash>Full set file
    2. Location > Location ID
    3. Available space DR by Stencil QTY
  3. Stencils not be used in future (Reclaim)
    1. Reclaim
    2. Set Status Wash > Not exist
    3. member Status > Not exist
    4. DR In use; CR available to coat

 

These scenarios are fully outlined in Wash_and_file_screen-sets_after_production_usage.

Exist

Essential

Inventory Management - Reclaims

Ability to identify stencils sets that are eligible for reclaim

Ability to update stencil sets as "flagged for reclaim (CR the flagged for reclaim)

Ability to process set as reclaimed

 - adjust status of set and members -  both statuses are not exists

 - account for location changes ;  

- account for change of status (DR flagged for reclaim; DR In Use; CR available to coat)

Exists

Essential

 

Is there appetite to enhance this

 

 - We know from stencils coated the Coated - Required figures

 - assume a trigger level for these that could be derived recorded

 - is it worth creating a function that once that trigger level is hit

 - searches for filed screen sets that contain the screen type

 - sorts those sets by last usage

 - returns that list to user as possible reclaims ?

maybe this is what possible reclaims is

 

 

 

Enhancement

TBC

Support Split Screen scenarios

There are several scenarios when stencil(s) can split

# Scenario Comments

1

During Preparation

either coated or available

split from the corresponding type

DR [Type} CR splits

2

Pre a Print Run

Pos id > reprint label

Obtain coated ; Make replacement - no entries done yet

Once made  - entries passed in dashboard

Split from coated
DR Coated ; CR Splits

 

3

During a Print Run

Run paused; remove screen; get pod id / label to stencil room

stencil set > stencil member > marked as split

DR in Use; CR Split

stencil set (indicates split)

Make replacement - DR Coated ; CR in Use
replacement > print press

split frame > repair

4

During Wash

stencil set > stencil member > marked as split
DR in use; CR Split
Stencil Set Filed
Wash > Filed (Part set)

split frame > repair

5

Pre-Check

Stencil set is in use classification

stencil set > stencil member > marked as split
DR in use; CR Split

stencil set status should remain pre-check

member stencil > not exist

Manufacture replacement
DR coated; CR In use

 

These are outlined in more detail in the working practices section

 

Exists

Essential

 

 

Inputs

From

Details

Art Dept

Stencil Set requirements on Technical Specifications

Print Department

Notification of in usage split screen(s)  - Requires priority replacement

Stencil Departments

Notification of Missing / Not FFP stencils in screen set(s) that are required on forthcoming processes

Suppliers

Repaired / Re-stretched stencils

 

Outputs

To

Details

Print Department

Stencil Sets ready for usage

Suppliers

Screen Orders

Consumables for stencils

Stencil Library

Stencil Sets for rPost-usage Filing

Suppliers

Purchase Orders for repair / re-stretch of split stencils