09/08/19 Updated 17/10/19

Innova release 5.8.2

The Innova 5.8.2 release provides Innova RoboBatcher generation 2 and the following improvements.

In the Innova 5.8.2 release, we made the following changes.

  • We improved our Quality Control (QC) module by allowing for configurations of the default view for QC scheduler improvements, and you can now close inspections with finishing them and still save the progress.
  • We improved our Recipe Manager module with the following changes:
    • The Recipe Manager module now allows for batch creation during the draft status while still allowing edits
    • You can now create batches from the Orders form
    • Introduced the creation of sub recipes
    • Improved the recipe editor
    • You can now start batches automatically on IPC
  • We improved our Overall Equipment Effectiveness (OEE) module by showing the alarm owner on the Top X alarm reports. You can now edit running events to add performance or quality to them.
  • We improved our FlexiTrim module by adding the following:
    • Improvements to the employee heatmap so that values set for minimum and maximum point size and intensity are respected as initial filtering values
    • All data shown on the heatmap is now filtered for the current process period
    • It is now possible to start and stop the infeed in the Operations screen in PreTrim web terminals
    • The system now automatically updates the PreTrim web terminals when inspections are completed

RoboBatcher generation 2

The Innova for RoboBatcher Flex generation 2 module is now available.

RoboBatcher_Flex_-_4-cell_standard_-_fillets.png

We specially designed this module to provide better control and monitoring of our RoboBatcher Flex equipment. Innova for RoboBatcher Flex helps effectively use incoming raw material and plan production to fulfill orders with the lowest possible giveaway and the highest efficiency rate. Using the information gathered by Innova, you can view data in real-time or historical information to view trends in production before making adjustments to:

  • Minimize giveaway of raw material
  • Maximize revenues of raw material
  • Optimize throughout (balance giveaway and throughput)

Production control

Using Innova, you can remotely adjust the RoboBatcher Flex or the whole line from a central office with a single click, allowing operators to make changes remotely to save time and maintain a saferdistance from machinery. Innova clearly indicates deviations from targets so you can respond quickly to gain the most value from raw material.

With Innova for RoboBatcher Flex you can:

  • Define and manage robot programs
  • Import and export programs and recipes
  • Create, edit and delete recipes
  • Import tray patterns

Reports

The following reports are available in Innova for RoboBatcher Flex:

  • Giveaway
  • Giveaway trend
  • Weight distribution
  • Reject rate history
  • Throughput

The Giveaway and Giveaway trend reports help minimize giveaway, enabling increased production profitability. The reports indicate target weight, recipe, and lot changes enabling you to adjust settings to minimize giveaway.

Giveaway trend report.png


The Reject rate history report shows the reject rate and milestones for lot and recipe activities, enabling you to respond quickly to minimize rejections and increase profitability.

Giveaway trend report 2.png


The Weight distribution report shows the weight distribution of the incoming graded material, enabling you to monitor weight distribution from different suppliers and providing valuable input regarding production planning and product allocation.

Weight Distribution.png


The Throughput report displays the device’s throughput on a chart, and the report can be shown as pieces per minute, weight per hour, or combined.

Throughput.png

Dashboards

The live dashboard components provide a real-time production overview, enabling operators to react quickly to improve line efficiency. For easy line monitoring, combine the most important components on a single dashboard.

Knowing how many fillets are used in each tray helps maximize raw material use and select the right bird size. The Batch count histogram component shows the number of batches produced with each item count.

Batch Count Histogram 1.png

The Batch item histogram shows the number of batches produced in each weight class, which is important for optimizing production planning and product allocation.

Batch Count Histogram 2.png

The Reject rate history shows a history of the reject rate per lane with percentages. The graph shows data from the current process period. A trip counter shows the percentage of rejected pieces since last reset.

Reject rate history.png

The Product monitor shows live product and batch data for all lanes/bulk bins in the main RoboBatcher program. A trip counter shows the data since last reset.

Product monitor.png

The Distribution monitor lets you to select:

  • Which recipes to run on RoboBatcher Flex lanes and bulk bins
  • Start recipes
  • Adjust some settings for running recipes

Once the recipes are running, it displays the data for the running recipes.

The Infeed monitor shows the number of infeed pieces grouped by lane. A trip counter shows the number of infeed pieces since last reset.

Infeed monitor.png


The Reject monitor shows the number of rejected pieces grouped by reject reason. A trip counter shows the number of rejected pieces since the last reset.

QC improvements

QC scheduler improvements

We added a new configuration parameter to the scheduler configuration. DefaultSchedulerViewType makes it possible to configure which view is the default view. Initially, the day view was the default one.

We also fixed an error in the Scheduler where the initial view defaulted to the day view, and upon opening, a reference error occurred.

Save QC inspection for later

We added a button to the inspection on the IPC to save and close inspections without finishing them.

Recipe Manager improvements

New master recipe status introduced

We added a new master recipe status, Reviewed. Master recipes can go from Draft to Reviewed instead of to Approved, allowing for batch creation during the Draft status while still being editable. Note that master recipes with a Reviewed status cannot be displayed in some reports because the control recipe cannot be compared to the master recipe while it is still editable.

The possible flows of master recipe statuses are now:

  • Draft to Approved, Reviewed, or Withdrawn
  • Reviewed to Approved or Withdrawn
  • Approved to Released, Withdrawn, or Released to Withdrawn
  • Withdrawn to nothing
master recipe statuses 2.png

When editing and saving a Reviewed master recipe, you must cancel any unfinished batches for that master recipe. The Recipe editor will prompt this.

cancel_batches_reviewed_master_recipe 3.png

Create batches from Orders form

You can now create batches directly from the Orders form. You must first have the CreateBatchesFromOrders view extension added to the Orders form. Once this is configured, the Create batch option is available from the Operations button menu in the Orders form.

use_createbatchfromorder.png


When selecting one or more orders to create a batch in the Orders form with, and select Create batch, a dialog box appears allowing you to configure the batch for each individual order.

createbatchfromorder.PNG

Ability to create subrecipes added

We added subrecipes, they are recipes used in a main recipe. You can create master recipes with subrecipes using the recipe step in the recipe editor. Subrecipe batches are created and seamlessly integrated into the execution of a recipe batch containing a subrecipe step. The product produced in the subrecipe is used as an input in the main recipe.

Example:

For a guacamole recipe we use avocados, tomatoes, onions, and a spice mix. In the spice mix there is black pepper, garlic powder, salt, and paprika. Since this spice combination is generic, it can be used in other recipes as well. So instead of adding each spice separately, we create a “Spice mix” subrecipe to use in other recipes.

First, we create the spice mix recipe that will be used within main recipes later using the Recipe step.

subrecipe_recipe.png


Input the Spice mix as a Product input in the guacamole recipe, and mark it as a Subrecipe output.

subrecipe_in_recipe.png


The guacamole batch is created, and you can find the Spice mix recipe in the Subrecipes detail tab.

subrecipe_in_batch.png

On the IPC, the subrecipe steps look like normal steps within the main recipe.

subrecipe_on_ipc.png


After completing the subrecipe batch steps, a pack is produced by the subrecipe. This pack can be scanned in the main recipe.

subrecipe_scanned_in.png

Recipe editor improved

We added the Code column to the Recipe editor Explorer view as a default and the ability to hide inactive recipes to the Operations button in the toolbar.

Recipe editor 1a.png


You can also now deactivate released recipes.

Recipe editor 2a.png


Finally, the two filters at the top of the Recipe editor, Status and Search, have been made independent of each other. Previously, if you used both filters and wanted to clear one using the X, both filters were cleared. Now you can clear one without affecting the other. When cloning a recipe, the selected filter is kept and the focus is on the clone.

Recipe editor 3a.png

Improvements to Recipe IPC functionality

The BatchManagerCE has a configuration option to start batches automatically on the IPC.

Recipe IPC Functionality 1.png


If AutomaticStartBatchWhenCreated is true, it puts the batch in progress as soon as the batch is created from the BatchManagerCE. Batches created from WinUI must be started on the IPC.

We added an Undo button to the recipe production screen, which deletes the last created pack record.

Recipe IPC Functionality 2.png

OEE improvements

Top X alarm report shows alarm owner

The Top X alarm report now shows the alarm owner if alarm forwarding is used. You can select the option in the report configuration to Show the alarm owner, making it visible in the owner column. Alarm owner and alarm forwarding are relevant for lines where OEE measurement is done on one device but is dependent upon other devices.

OEE Improvements.png

Edit performance and quality reasons on the IPC

As part of the running performance and quality monitoring, it is now possible to edit the running event to add performance or quality to the event. When selecting a Running event the Performance and Quality reasons buttons are shown.

The OEE status is still shown in case the operator wants to change that if allowed. Note that the running event now also may require input. The Performance reason button shows the red triangle if the selected event requires performance input and the same applies to the quality reasons button.

OEE Improvements 2.png

FlexiTrim improvements

Improvement made to employee heatmap

We improved the employee heatmap so that the values set for minimum and maximum point size and intensity are respected as initial filtering values. However, you can filter on higher values than those specified as the default values. If you are on the line using this filtering, a pop-up will be shown with a numeric keypad to make adjustment easier.

Heatmap improvements

We made improvements to the heatmap so that all data shown on heatmap is filtered for the current process period. Previously, all bones displayed on the heatmap were for the current day. Using the current process period on the main process unit for the trimming line gives better data quality for the customer.

Control infeed in pre-trim web terminals

It is now possible to stop and start the infeed in the Operations screen in PreTrim web terminals.

Pre-trim terminals updated on completion

We implemented a change to update PreTrim terminals automatically when inspections are completed. After this, the terminal navigates automatically to the previous screen.

Additional improvements

  • We added a Greek keyboard layout for the M6000.
greek keyboard layout.png
  • We added Portioning reports in Russian for versions 5.7.2 and up.
  • We added the ability to add a column summary field to master and data forms. This adds a summary field at the bottom of the grid which sums up column values and displays them at the bottom.