A colorant, resin, component distribution system for an injection molding facility. Poke Yokes used to prevent contamination and wrong material being issued.

1. COLOR PHARMACY 3.0
Colorant, Resin, and Component Distribution

2. ORDERING AND ATTENDANT
PHARMACY APPLICATION

3. ORDERING SCREEN
The pharmacy comes in two
versions. The outside of the
pharmacy runs on a touchscreen
monitor and has a badge reader
attached to it.

4. ATTENDANT SCREEN
The attendant screen is used inside
the pharmacy. It is used to issue
out all colorant, resin, components,
etc. It needs a label printer and a
Honeywell barcode scanner
attached to it.

5. COLOR PHARMACY 3.0
Ordering Process

6. ORDERING SCREEN
Located on the outside of the
pharmacy.

7. OPERATOR LOG IN
Operator scans in using his or her
badge or by typing in their
employee ID number using the
keypad.

8. OPERATOR INVALID
If a number is entered or a badge
is scanned that is not recognized
by the system a error toast window
pops up. Valid users can be
entered from the attendant’s
screen (see slide xx).

9. NEW SCHEDULE DATA
If new production schedule data is
detected it is loaded
automatically. This detects both
PASS and FQVT scheduled data.
This will also interact with Hydra.

10. ORDER SCREEN MAIN

11. COLORANT
Issued by the bucket

12. MOLD COMPONENTS
Components that are needed for
press side assembly. These are
issued by the standard pack.

13. RESIN
Issued by full containers.

14. ASSEMBLY
COMPONENTS
Components used in assembly
cells. These are also issued by the
standard pack.

15. ALTERNATIVE
PACKAGING
Alternative cardboard packaging.

16. PROCESS BOOKS
Both process and ODS books are
issued at the same time. You must
return the previous books to get
the new ones.

17. PRODUCTION LABELS
These are preprinted labels stored
in mail boxes. They are only issued
once they are ordered.

18. PURGE COMPOUND
This is a set weight based on press
tonnage. Issued in buckets.

19. NEW COLOR ORDER

20. COLOR/TOOL CHANGE
When changing tools or colors
select using the COLOR/TOOL
CHANGE button.

21. PRESS SELECTION
Choose the press colorant is
needed for. Each separate color
represents a zone of presses within
a facility. This is configurable within
the system.

22. ORDER SELECTION
Operator chooses the correct
operation from the production
schedule. If a family tool is chosen
(produces both left and right parts)
the system automatically
combines the orders so that the
correct amount of colorant is
requested.

23. SELECT AND PLACE
ORDER
Choose the job from the list and
click the ‘SELECT’ button at the
top.

24. COLOR ORDER
PLACED
Toast box confirm order has been
placed.

25. OFF SCHEDULE ENTRY
If an order is not listed (emergency
mold change) you can use the
‘Off Schedule Entry’ screens to
place a manual order for colorant.

26. OFF SCHEDULE ORDER
Choose a tool. The keyboard is
‘smart’ and only allows you type
characters from existing known
tools.

27. CHOOSE TOOL

28. CHOOSE PART NUMBER
Cascading combo boxes narrow
the search fields

29. ENTER QUANTITY
Enter the quantity needed for the
operation

30. ORDER CONFIRMATION
If a family tool is chosen (produces
both left and right parts) the
system automatically calculates
the total weight needed.

31. COLOR ADD
When an order requires more
colorant than can be issued at
once the ‘COLOR ADD’ process is
used.

32. PRESS SELECTION
Employee selects the press that
more colorant is needed.

33. CURRENT ORDER
The currently running order
information is presented. If correct,
an order is simply placed.

34. ORDER DETAIL
The remaining pounds of colorant
is listed. The system keeps track of
the total pounds needed and how
much has already been issued.

35. NEW RESIN ORDER

36. PRESS SELECTION
Choose the press that needs resin.

37. ORDER SELECTION
Choose the job from the list and
click the ‘SELECT’ button at the
top.

38. ORDER CONFIRMATION

39. OFF SCHEDULE ENTRY
If an order is not listed on the order
selection screen a manual order
can be placed. Enter the tool,
part number, and the quantity and
submit the order.

40. MOLDING
COMPONENTS

41. PRESS SELECTION
Choose the press that components
are needed for.

42. OPERATION SELECTION
Choose the operation from the
production schedule.

43. SELECT QUANTITIES
Based off of the Bill of Material a list
of components for the selected
order are presented. Select the
quantities of each component
needed.

44. PLACE ORDER
Once the quantities are selected
click the ‘SELECT’ button at the top
to place the order.

45. OFF SCHEDULE ORDER

46. OFF SCHEDULE ORDER
Enter the tool, color, and quantity
needed for the manual order.

47. COMPONENT
SELECTION
Components are issued by
standard pack. Select the number
of standard packs needed for
each component. The system
calculates the total number of
components needed using the Bill
of Material and rounds up to the
next nearest standard pack. It
limits the order to that value.

48. ASSEMBLY
COMPONENTS

49. ASSEMBLY ORDER

50. CHOOSE ASSEMBLY
UNIT
An assembly unit is chosen to
narrow down the tool and color
search. An assembly unit is
typically made up of several tools
supplying the same customer.

51. CHOOSE TOOL
Select the correct tool number.

52. CHOOSE COLOR
Choose the color

53. ENTER QUANTITY
Enter the total quantity needed. If
a family tool is selected the correct
components will be selected.

54. CHOOSE QUANTITIES
Components are issued by
standard pack. Select the number
of standard packs needed for
each component. The system
calculates the total number of
components needed using the Bill
of Material and rounds up to the
next nearest standard pack. It
limits the order to that value.

55. PROCESS BOOK ORDER
Process and ODS books.

56. OPERATION SELECTION
Choose the operation from the
production schedule. Press the
‘SELECT’ button to place the order.

57. MANUAL ORDER
A manual order can be placed
using just the tool number.

58. PRODUCTION LABELS

59. ORDER SELECTION
Choose the operation from the
production schedule. Press the
‘SELECT’ button to place the order.

60. PURGE COMPOUND

61. SELECT PRESS
Purge compound is issued out by
weight. This weight is static based
off of the tonnage of the press.
Once you select the press an order
is placed. No need for an order
selection.

62. COLOR PHARMACY 3.0
Attendant Process

63. ATTENDANT SCREEN

64. BADGE INDICATORS
The badges on each button
indicate how many orders are
currently open for each category.

65. FLASHING INDICATOR
A red flashing badge indicates
that the category has the oldest
order still open.

66. COLORANT ORDERS

67. BLOWING AGENT
ORDERS
If a tool requires blowing agent an
automatic blowing agent order is
placed with the colorant. This is a
separate process and requires an
different bucket.

68. RESIN ORDERS

69. RESIN RETURNS
Partial containers of resin are
checked back in to the pharmacy
using this process.

70. COMPONENT ORDERS

71. FILL COMPONENT
ORDERS
Once component order labels are
printed the issuing process starts
here.

72. RETURN PARTIAL
COMPONENTS
Partial components can be
returned to the pharmacy using
this process.

73. PURGE COMPOUND
ORDERS

74. PROCESS AND ODS
BOOK ORDERS

75. ALTERNATIVE
PACKAGING ORDERS

76. PRODUCTION LABELS

77. FILL COLOR ORDER
Process to fill a color order.

78. BUCKET INFORMATION
Each press is assigned a specific
bucket. Label on bucket must be
present to get issued colorant.
Barcode is used to identify the
assigned press and the
order/colorant currently
associated to the press.

79. SCANNER
A Honeywell 4820i scanner is used
for all transactions within the
pharmacy.

80. ORDER SELECTION
Attendant selects the order to fill
from the list of currently open
orders.

81. ORDER TYPES
In the order type column either a
CC or a CA will be listed. CC
indicates the order is a full color or
tool change. A CA indicates that
a color add has been requested.

82. BUCKET SCAN
Attendant scans the bucket to
begin the color issuing process.

83. WRONG BUCKET/LABEL
If a label is scanned that is not
associated with the order/press
selected a warning will pop up
with an audible tone (buzzer) to
alert the attendant.

84. CORRECT LABEL
If the correct label is scanned the
screen flashes green and an
audible tone (ding) is heard to let
the attendant know the
information is correct.

85. BUCKET WEIGHT
The bucket is then placed on a
scale to determine the amount of
colorant that is being returned.
This is to allow the return of unused
colorant. If no colorant is being
returned a ‘0’ is entered here.

86. RETURNING COLORANT
A weight of 3.5 pounds was
entered in the previous screen.
The process to return colorant is
started. The returning colorant is
listed in the window and there is a
hatching pattern used as a visual
indicator to the attendant that this
is the colorant return process.

87. BARREL SCAN
The attended proceeds to the
correct barrel corresponding to
the returning colorant. The
attendant scans the part number
on the barrel of colorant. In this
example the attendant has
scanned the wrong barrel of
colorant.

88. WRONG BARREL
The screen flashes red and an
audible tone (buzz) is heard to
indicate that the correct barrel of
colorant was not scanned.

89. CORRECT BARREL
If the correct barrel is scanned the
screen flashes green and an
audible tone (ding) is heard. The
attendant now knows that the
correct barrel was scanned.

90. LOT NUMBER SCAN
The lot number is then scanned to
record the returning barrels
information. Lot numbers have a
1T prefix. In this example the barrel
weight barcode has been
scanned.

91. WRONG LOT NUMBER
The screen flashes red with an
audible tone (buzz) to indicate
that the incorrect barcode has
been scanned.

92. CORRECT LOT NUMBER
Once the correct lot number
barcode has been entered the
return process is completed by the
attendant. The colorant in the
bucket is dumped into the barrel
and the bucket is cleaned out.
The outgoing colorant process can
now begin.

93. OUTGOING COLORANT
The attendant proceeds to the
outgoing colorant barrel. The
colorant number is shown on the
screen and the hatching pattern is
no longer on the screen as a visual
indication that this is not a return
process.

94. WRONG COLORANT
The attended proceeds to the
correct barrel corresponding to
the outgoing colorant. The
attendant scans the part number
on the barrel of colorant. In this
example the attendant has
scanned the wrong barrel of
colorant.

95. WRONG COLORANT
Like the colorant return, the screen
flashes red and an audible tone
(buzz) is heard to indicate that the
correct barrel of colorant was not
scanned.

96. CORRECT COLORANT
If the correct barrel is scanned the
screen flashes green and an
audible tone (ding) is heard. The
attendant now knows that the
correct barrel was scanned.

97. LOT NUMBER SCAN
The lot number is then scanned.
This process has the same audible
indicators as the return process.

98. ORDER WEIGHT
A visual indicator is shown to let the
attendant know approximately
how much colorant is needed for
the order. This is based on the
calculated weight needed for the
order using the Bill of Materials. The
standard bucket can hold
approximately 21 pounds of
colorant. This visual indicator is
divided into thirds with each
representing 7 pounds. This is only
to assist the attendant from having
to make numerous trips to the
same barrel. Since more than 21
total pounds was needed for this
order a full bucket is issued.

99. SUMMARY
SCREEN/WEIGHT ENTRY
The full bucket is the placed on a
scale and the weight is entered
into the system.

100. NEW LABEL
A new order label is printed. The
old label is removed from the
bucket and discarded. The order
number on this label has a prefix to
indicate the type of order (CC or
CA). This new label is then placed
on the bucket and the colorant is
given to the material handler to
take to the press. This concludes
the color order fill process.

101. COLOR ADD PROCESS
The CA (Color Add) process is
similar to the full color change with
one exception. There is no process
to return colorant. The systems
assumes since it is a color add that
a completely empty bucket is
being returned. The system skips
the color return process and goes
immediately to the outgoing
colorant process.

102. RESIN ORDERS

103. ORDER SELECTION
Attendant selects the resin order
needed to be filled.

104. RESIN SCAN
The container of resin is scanned.

105. WRONG RESIN
If the wrong resin is scanned all the
same audible/visual warnings are
used.

106. LOT NUMBER
The lot number is scanned.

107. CONTAINER WEIGHT
The container is then weighed and
the weight is then entered into the
system.

108. RESIN LABEL
A resin order label is then printed
and placed on the container.

109. RESIN RETURNS

110. RESIN RETURN
Unused resin is returned to the
pharmacy. The hatching pattern
at the top is a visual indicator that
this is a return process. The label
that was printed in the outgoing
process is scanned.

111. CONTAINER WEIGHT
The container is then weighed and
that weight is entered into the
system.

112. RESIN LABEL
A new resin container label is
printed. This is used in the outgoing
process. The attendant can now
scan this label to enter the
outgoing information – including
the weight. This saves time when
issuing partial containers. This
completes the resin return process.

113. COMPONENT ORDERS

114. COMPONENT ORDER
SELECTION
The component order to be filled is
selected and the ‘Print Order’
button is pressed.

115. COMPONENT LABELS
A label is printed for each
component for the order. If
multiple standard packs are
needed a label for each box is
printed. Meaning if an order will
need a total of 3 standard packs
to complete then 3 individual
labels for that component are
printed.

116. FILL COMPONENT
ORDERS

117. SCAN LABEL

118. COMPONENT LABEL
SCAN
The process starts by scanning the
label that was printed for the
component.

119. SCAN COMPONENT
PART NUMBER
The attendant is prompted to scan
the part number on the container
of the component.

120. PART NUMBER SCAN
The barcode on the box is
scanned.

121. WRONG COMPONENT
The same audio and visual
indicators are used in this process
(buzz/red ding/green).

122. CORRECT
COMPONENT
If the part number is correct the
attendant is prompted to enter the
quantity. This is done by a scan of
the barcode on the container.

123. QUANTITY ENTERED
This completes the transaction.

124. COMPONENT RETURNS

125. SCAN COMPONENT
LABEL
Attendant scans the pharmacy
label on the returning component.
This is why it is important that every
box of components gets a label.
This label is needed for returns.

126. PART NUMBER SCAN
The part number on the box is then
scanned again to verify that it is
the same as the label indicates.

127. SCAN PART NUMBER
If part numbers match the
attendant is required to count the
pieces and enter that number on
the following screen.

128. ENTER QUANTITY
The total number of pieces being
returned is entered.

129. NEW COMPONENT
LABEL
A new label is then printed and
placed on the box. This allows the
attendant to quickly scan these
barcodes when issuing out this
partial box. This also speeds up
inventory as these partial boxes
already have the remaining
quantity listed.

130. BLOWING AGENT

131. ORDER SELECTION
The blowing agent order is
selected.

132. SCAN BLOWING AGENT
The same process is followed as
colorant. The same tones and
color poke yokes are used. The
bucket fill indicator is also used to
indicate how much blowing agent
should be issued.

133. WEIGHT ENTERED
Total weight is entered.

134. BLOWING AGENT LABEL
A blowing agent label is printed
and placed on the separate
blowing agent bucket.

135. BOOK ORDERS

136. BOOK ORDER
SELECTION

137. SCAN RETURNING
BOOKS
The returning books are scanned
back into the system.

138. OUTGOING BOOK
SCAN
The outgoing books are scanned
out of the system.

139. PURGE ORDERS

140. PURGE COMPOUND
ORDER SELECTION

141. PART NUMBER AND LOT
NUMBER ARE SCANNED
Bucket fill indicator is used to
indicate total weight of purge
compound needed.

142. PURGE LABEL
A purge label is printed and
applied to the purge bucket.

143. ALTERNATIVE PACK

144. ADDITIONAL SCREENS

145. SCRAP MATERIAL
Allows attendant to enter scrap
materials. Part number is entered
followed by a total amount. This
can be in pieces or pounds based
on the commodity.

146. EMAIL MATERIALS
Allows attendant to instantly notify
the materials team of an issue in
the pharmacy. Attendant can
select from a number of
predefined subjects. The body is
comprised of detail letting the
team know exactly what the issue
is.

147. ADDITIONAL SCREENS
Some maintenance screens for the
attendant.

148. ORDER HISTORY
Can list the last X amount of
transactions.

149. TOOL INFO
Lists the combination of tools, part
numbers, colorants, and resins that
the system uses.

150. FILTERED INFORMATION
Grid allows filtering to easily search
for specific strings. This makes
troubleshooting much easier.

151. SUPPLIER LABEL REPRINT
Allows the attendant to print a
label that can be applied to a
supplier component. On occasion
a container will come in with a
barcode that cannot be scanned.
This option prints a scannable label
for transactions within the
pharmacy.

152. PHARMACY LOCATION
LABEL
The pharmacy uses a visual system
for labeling in the racks. This allows
you to print a new colorant
location label if one is missing or
colorants get moved.

153. LOCATION LABEL
The colorants are stored 2 deep
under the racks. This is a visual
indication to the attendant of
which colorant is located in front
and which is in the back.

154. ADD USER
If a user is not found in the system
they can be added here. Enter
the employee’s name.

155. BADGE INFORMATION
Enter or scan their badge
information. This will allow them to
log in to the ordering system.

156. These indicators at the bottom of
the screen let the attendant know
how many of each order are
open. These also flash based on
FIFO. They are also shortcuts to
allow the attendant to jump from
screen to screen without returning
to the main window.
SHORT CUTS

157. If an order is more than X minutes
old a reminder on the attendant
screen will pop up and remain for 5
seconds. It then fades out. They
system can check every X seconds
to see if any orders are overdue.
GROWL LIKE
NOTIFICATIONS

158. It is just a reminder to the
attendant that these orders have
fallen outside of the
predetermined window of filling
orders. This is totally configurable.
GROWL CLOSE UP

159. THE END