Sheets, blanks and packs should not become interchangeable numbers. Know what each job produced and where changeover time went.
The order unit and machine counter may differ. A machine counts sheets while planning needs finished cartons and the next station counts packs. The selected count point and unit are therefore central to a useful MES record.
If the number of pieces per sheet changes with the product design, a raw sheet count is not finished output. Keep the product, counter meaning and agreed conversion with the job. Record rejects at the stage where they are actually observed.
Planning and production can then explain a difference through the count point, conversion rule or rejected quantity. They do not need to argue over two totals that describe different stages of the line.
A series of short interruptions can consume more time than one long fault. Reasons the operator can distinguish—feeding, adjustment, material and equipment—help reveal the cumulative loss.
Review format changes by product. Two changes to the same format often provide a more useful comparison than two whole shifts with a different product mix. A focused SCADA view can help investigate equipment states around repeated interruptions.
A job records 5,000 sheets, with four packaging pieces planned per sheet.
| Information | How to read it |
|---|---|
| 5,000 sheets | The quantity directly counted by the machine |
| Four pieces per sheet | The conversion for this product |
| Rejects after cutting | A separate record affecting accepted output |
Multiplying 5,000 sheets by four gives 20,000 expected pieces. Check the actual pieces after cutting and the rejected quantity before reporting accepted output.
Show us the report you use today and the part of production it does not explain. We can demonstrate the relevant screens and discuss the machine connections and modules for your setup.