Faults

Faults can be registered on a product when a defect is observed.
Every fault is assigned a Fault Code, which is used by the operator when registering a fault.

If the current operation could not be completed and the operator wishes to register a fault

If the current operation can be completed and the operator wishes to register a fault

There are terminal commands to directly register a fault without entering the fault registration menu

There are some limitations on how faults are allowed to be registered depending on what operation type is currently being performed. See diagram.

	Loading	General	Inspect	Unloading
Reject	99 100	99 100	99 100	99 100
Partial Reject	99 100	99 100	99 100	99 100
Repair	99 100	99 100	99 100	99 100
Second Quality	99 100	99 100	99 100	99 100

If the flag Deduct is set on the fault, the operator that performed the blamed operation will recieve a SMV deduction. If the fault is set up as "Repair" with "Operator" destination, the system will attempt to send that product back to the same operator for repair when possible. The operator will then have the chance to re-earn the SMV for that product.

Faults are categorized in one of the following types

Second Quality

A second quality fault will continue on the production route as usual, but the product is marked as second quality.

Second quality faults will automatically increase the target quantity of an orderline if the system setting Allow Replacement Loading is activated.

Reject

A reject is a fault on the product which cannot be repaired, and the product has to be discarded. When a reject fault is registered, the operator is expected to have removed any materials from the carrier, which will then continue on the Return Empty Carrier route as an empty carrier.

System Reject

System reject is a sub-type of reject, the difference is that these rejects are not registered by an operator but instead by the system itself as a by-product of another function. These are not truly part of the quality handling, but required for statistical consistency.

Loading Reject (-1)

This occurs when an operator on a loading station loads an already loaded carrier with a new product. The previous product will then automatically be rejected with fault code -1.

It also occurs when the operator at the loading station has completed the loading operation by pressing the operator switch, but the carrier is never sent (likely due to some sort of routing error). If the operator in this case does not wait for the routing to succeed and instead logs out, the product is automatically rejected.

Reset Reject (-2)

This is automatically registered on a product attached to a carrier which is reset by a mechanic. Fault code will be -2.

Repair

If the fault can be fixed, it should be set up as Repair type.
You will then have to configure how the repair should be performed

Operator

The system will attempt to send the product back to the same operator that made the fault in the first place. If this is not possible because the operator has logged out, or does not have a reachable station, the product will go to any station that can perform the operation.

Operation

The product will be sent to any station that can perform the blamed operation, using the default adressing strategy for that operation.

Operation + Succeeding

Same as above, but will also repeat any performed operations following the blamed operation.

Free

Used when we potentially want to assign different operations for the repair and the blamed operation.
This can for example be if we need to go back in the route to repeat previous steps due to a fault that occurred later in the route.

When this is selected you will have to assign both the blame and repair operations when registering the fault.

Free + Succeeding

Same as above, but will also repeat any performed operations following the repair operation.

Multiple Free

Several repair operations will be re-made to repair the fault. The operator registering the fault will select what operations needs to be performed.

Route

The carrier will go on a set Repair Route. This can also contain buffer operations to help with capacity.

Repair Operation

Select a repair operation. This will be added as an ad hoc operation.

Partial Quantity Faults

Starting from version 1.14, it's possible to register a fault on a partial quantity. This is primarily for bundle tracking, but can also be used when there are multiple products in the same carrier.

To start a partial fault registration on a carrier use one of the following commands

There are some special rules that apply when registering partial faults.

Partial Reject

With a normal reject, the carrier will return as an empty carrier, however when you are rejecting only a part quantity, the remaining items in the carrier will continue on with the normal route. This means that the operation should not be aborted when doing a partial reject.

Partial Second Quality

This acts quite similar to a normal second quality in that the carrier will still continue on with the route. It's recommended to have some sort of stickers/labels to clearly indicate which pieces are second quality so that they are not mixed up during the unloading.

Partial Repair

A partial repair works in the same way as a repair on the full quantity, with the exception of that the produce count (and thus earned SMV) for the repair will be equal to the number of faulty pieces.

Combining Faults

There is some special logic that applies when you are registering a combination of partial faults. If there is a mix of first and second quality items in the bundle, it must be specified exactly which the fault will apply to.

In case the operator is registering multiple faults at the same time, reject faults should be registered first. Then the system will not have to make any guesses when adjusting fault quantities.

Scenario 1.

• Bundle has 2 pieces.
• A partial second quality fault is registered on 1 piece.
• On a later operation, a partial reject is registered on 1 piece. The operator registering the fault will in this case have to specify if they are rejecting the 2nd quality item or the 1st quality item so that the order line statistics will be correct.

Scenario 2.

• Bundle has 2 pieces
• At the same time, the operator registers a second quality fault on both items, then a reject on 1 item.
• The faults are now converted so that the second quality fault only applies to 1 item, and that we are rejecting 1 first quality item.

Scenario 3.

• Bundle has 2 pieces. There are two different second quality faults in the system.
• Operator registers the first second quality fault on one of the items.
• Later an operator registers the second quality fault on one of the items. This operator will be asked if they are registering the fault on the item that is already 2nd quality or on the item that is 1st quality. This is to keep the counters correct.