Barcode option details & costing February 2008

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1 Barcode Option 1a & 1b BTU International Barcode option details & costing February 2008 Option 1a: 1D SICK IT3800 Handheld Barcode Scanner: BTU Sell Price: $2600 Option 1b: 2D LYNX D432 Handheld Barcode Scanner: BTU Sell Price: $2600 Note: Only 1 Handheld scanner can be used. Barcode Option 2a & 2b The handheld scanner is used to manually scan product before placing it on the BTU Equipment. The scanner can also be used to create Lots (batches of work) where typically the user would scan paperwork associated with the lot. Option 2a: 1D SICK CLV422 Fixed Position Barcode Scanner: Option 2b: 2D Matrix 2021 Fixed Position Barcode Scanner: BTU Sell Price: $5200 / lane BTU Sell Price: $6800 / lane Number of Product Lanes SICK CLV422 Data Logic Matrix 2021 Single Lane $5,200 $6,800 Dual Lane $10,400 $13,600 Triple Lane $15,600 $20,400 Four Lane $20,800 $27,200 The Fixed scanner is typically used in an automated line, 1 scanner would be used for each product lane. As a product is scanned the BTU Equipment recipe is verified to be correct before the product is loaded onto the equipment. To support this the Scanner must be mounted upstream on the loading equipment. 3/13/2008 Barcode Costing Feb 2008 R1.doc Page 1 of 13

2 Barcode Option 1 & 2 can be purchased together Note: Must specify which models customer requires, SICK or Data Logic scanners. Handheld & Fixed Barcode Scanner: Number of Product Lanes SICK CLV422 Data Logic Matrix 2021 Single Lane $7,800 $9,400 Dual Lane $13,000 $18,800 Triple Lane $18,200 $28,200 Four Lane $23,400 $37,600 Both scanners can be used together; in this case the handheld scanner is used only to scan paperwork (Lot Data) to set up batches of work on the tool. The fixed scanner is used to verify each product is correct per the defined lot. Additional Options: Product Tracking and SMEMA With Fixed Barcode Scanners in an automated line, Product Tracking and SMEMA must be used. With Lot Control if you want to keep track of lot quantity processed the Product tracking is required. GEM Host Barcode is fully supported in GEM, additionally the Host can remotely setup a lot (Batch) of work defining: Lot ID, Recipe to run, Lot Quantity and Lot Description. Wincon 4.0d and Intellimax Barcode is only supported with Wincon 4.0e and higher, which uses Intellimax. PC requirement for Wincon 4.0 is Windows XP SP2 or higher. 3/13/2008 Barcode Costing Feb 2008 R1.doc Page 2 of 13

3 BARCODE Overview Wincon now supports Barcode, both handheld and fixed scanners for 1D linear barcodes and 2D Data Matrix barcodes. For automated lines fixed barcode scanners can be used to read the products barcode and verify the correct recipe is running on the equipment. If the recipe is incorrect an alarm will be raised, alternatively if the equipment is empty the correct recipe can be loaded, when the recipe is ready the product will be loaded on to the tool. For manually loaded product a handheld scanner can be used to scan each product barcode before loading to verify the recipe is correct. Barcode Formats: 1D & 2D Supports popular barcode formats such as Data Matrix (2D) code 39 Normal & Full ASCII, code 93, code 128, UPC-A, UPC-E, EAN-8, EAN-13, Interleaved 2 of 5, CodaBar & EAN/UCC128 (50 Character Limit). 3/13/2008 Barcode Costing Feb 2008 R1.doc Page 3 of 13

4 Barcode Recipe Lookup Table BTU International The Barcode Recipe Lookup Table is used to associate a Wincon recipe with a product id range. With barcode recipe validation enabled, the product id scanned is looked up in the table to confirm the correct recipe is running. The Recipe Lookup Table supports up to 1000 Recipe to Product ID definitions. The Product ID supports up to 50 characters. Overlapping Product ID ranges are not valid. The Same Recipe can be used for multiple different product id ranges. Barcode with Lot control With Lot Control you define a batch of work to run on the equipment and the number of products to run, every time a product is scanned the product will only be verified if it can be run with the recipe defined in the active Lot. Barcode without Lot Control Without Lot Control every attempt is made to automate product changeover, so when a product is scanned that requires a different recipe to be run the recipe will change immediately if no product is in the equipment. If there is product in the equipment then a Recipe Run Delay will automatically be created which will run the required recipe when the equipment empties. If the equipment is in an automated line SMEMA is used to prevent product being loaded onto the equipment until the correct recipe is running and process parameters are all ready. If the equipment is not in an automated line (Stand alone) and products are manually loaded then typically a handheld barcode scanner would be used and after scanning a product, messages are displayed to the user to notify them the result of the scan. 3/13/2008 Barcode Costing Feb 2008 R1.doc Page 4 of 13

5 Lot Control The Lot Control feature allows operators to create a lot (batch) of work to be run on the BTU equipment; a handheld scanner can be used to simplify this process so the operator can simply scan paperwork associated with the job lot. Alternatively the user can manually type in the data required to start a lot and if GEM Host option is used a lot can be setup remotely by the Host. To create a lot the user would typically use the handheld scanner to scan paperwork, which would then automatically open the Lot Create / Edit Dialog as shown below. The user could then continue to scan paperwork and have the scanned data fill in the lot dialog. LOT Data: Lot ID Recipe for the product ID range Lot Quantity Description (Optional) Lot Data Collection o Data Set o Data Collection Event The Lot Create / Edit Dialog can be configured to allow the recipe to be automatically selected based on the product ID (as shown above) or the recipe can be manually selected (as shown below). Only a single lot can be active at a time. Additional Lots can only be setup when the current lot has been completed. 3/13/2008 Barcode Costing Feb 2008 R1.doc Page 5 of 13

6 Lot Control from the Host BTU International With GEM Host installed the Host can create the Lots remotely. One option is to have the local user send a Lot ID to the host, the user would use the handheld scanner and scan a lot id and the Lot ID Confirmation dialog would be displayed. Clicking OK button would send an event to the host notifying them a LOT ID has been read. The host could then create the appropriate lot using a remote command Lot Create. The Host can setup a Lot to either start automatically or to have the local user start the lot as shown below (an optional operator sign-on can be configured). When the lot is created and the recipe needs to be changed and the equipment is empty the Lot Recipe will be run straight away. If the equipment has product a recipe run delay will be setup to run the lot recipe when the equipment empties, the SMEMA state goes to Wait Recipe to prevent product in an automated line from being loaded onto the equipment. With the correct recipe running the lot state will be waiting for start and the SMEMA interface will be Wait Lot. Once the user starts the lot the lot will be active and SMEMA state will be ready allowing product to be loaded. The Host can create the lot to close automatically based on lot quantity processed, or have the local user close the lot, or require the host to close the lot, in this case the local user could scan a lot close barcode, or select lot close from the menu and send a request lot close event to the host. The host would then issue a Lot Close command. The lot state would be closing until the oven was empty at which point it would be closed (inactive). When the lot is closed you can configure lot control to prompt the user to run another recipe, such as Cooldown. 3/13/2008 Barcode Costing Feb 2008 R1.doc Page 6 of 13

7 Fixed barcode scanner in an automated line. The Fixed scanner is typically used in an automated line, to support this, the Scanner must be mounted upstream on the loading equipment as shown below and Product Tracking and SMEMA are both used. SMEMA In an automated line the barcode and product tracking setup ideally is like that shown above. Normal operation is that a product id is scanned and product verification occurs before the board gets loaded onto the BTU equipment and if verification fails a barcode alarm occurs and the SMEMA interface state goes busy preventing the board from loading without user interaction. Ready = BTU equipment ready to accept new product. Busy = BTU equipment busy, unable to accept new product. Board Available = BTU Equipment has product ready for Offloading. Board Not Available = BTU Equipment does not have product available for Offloading. Wait Lot = only applicable with barcode option, active when lot is waiting start or closing. Wait Recipe = only applicable with barcode option, active when recipe change is required. 3/13/2008 Barcode Costing Feb 2008 R1.doc Page 7 of 13

8 Scanning Product using the handheld scanner A handheld barcode scanner is typically used on equipment where product is manually loaded. Scanning each product before manually placing the product on the equipment allows the active recipe to be verified. If the Handheld scanner is used for manually loading product, messages can be configured to display to notify the operator the result of the scan. Each of those messages are shown below: 3/13/2008 Barcode Costing Feb 2008 R1.doc Page 8 of 13

9 Barcode Alarm Unlisted Product The Unlisted Product Alarm occurs when a product is scanned but the Product ID read is not found in the Barcode Recipe Lookup Table. An Unlisted Product Alarm can occur with either the Fixed Lane or Handheld Barcode Scanners. Barcode Alarm Product Mismatch The Product Mismatch Alarm occurs when a product is scanned and the recipe is found in the Barcode Recipe Lookup Table but it does not match the Active Lot Recipe. A Product Mismatch Alarm can occur with either the Fixed Lane or Handheld Barcode Scanners. to run the recipe when the equipment is empty. The Product Mismatch alarm only occurs if a Lot is Active, if Lot Control is Inactive or Disabled and a product is scanned which requires a different recipe to be active then the recipe will be changed automatically to the new recipe if the equipment is empty, or it will automatically create a Recipe Run Delay 3/13/2008 Barcode Costing Feb 2008 R1.doc Page 9 of 13

10 Barcode Alarm Bad Read The barcode Bad Read Alarm occurs for the fixed scanner only (the handheld scanner does not report a bad read). With the fixed scanner a photo-sensor is used to trigger the barcode laser to turn on ready for a barcode read. If a read is not completed successfully while the product is under this photo sensor then a Bad Read alarm is reported as shown below: Data Collection A data set can be created to collect Lot ID and Barcode scanner data, an example of a data set and data report is shown below: 3/13/2008 Barcode Costing Feb 2008 R1.doc Page 10 of 13

11 Monitor Graphic and Monitor Table barcode views. Barcode Configuration. Showing some of the different configurable options. 3/13/2008 Barcode Costing Feb 2008 R1.doc Page 11 of 13

12 Typical Scanner Models Typically the Handheld scanner is triggered to read only when the button on the scanner is pressed. For the Fixed Position scanner a photo sensor is installed to trigger the scanner and turn on the laser ready for barcode read. The laser remains on until the barcode is read. Barcode Communication & Power Requirements The barcode communication for either scanner is RS232 and a direct link with the Wincon PC serial ports. The Handheld scanner comes with a DC power adaptor for V AC supply voltage, while the fixed scanner works from 24V DC power. 3/13/2008 Barcode Costing Feb 2008 R1.doc Page 12 of 13

13 Fixed Scanner Reading Distance Important considerations to make sure you can get a good barcode read are: Belt Speed (typically not greater than 60 inches per minute) Light (location where barcode is read needs to have good lighting) Reflections of shiny surfaces. (Location of barcode on the product should not be too close to reflective or shiny objects, this makes it much harder for successful reads) Size of barcode (typically not smaller than 3mm) The SICK CLV 422 scanner is just a 1D scanner and has a larger field of view (can scan larger barcodes) than the Data Logic 1/2D scanner. The SICK CLV Field of View data is shown in the picture on the left. The Data Logic Matrix /2D scanner has a field of view of 25mm x 19mm (0.98 x 0.75 ). 3/13/2008 Barcode Costing Feb 2008 R1.doc Page 13 of 13

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