Fujitrax Verfier issues parts out warnings for the tray unit-L based upon the user specified settings. When a parts out warning occurs for a tray, the operator has time to get a new tray, set it in a replacement drawer, verify it, and set it in the parts supply drawer. Once the drawer with the original tray runs out of parts, that drawer is moved to the parts removal area and the drawer set in the parts supply area is moved to the original drawer position without stopping production.
AVL data cannot be used for trays.
Required items
The following items are required in other to use the non-stop tray resupply function to resupply trays during production.
– NXT using machine software V3.10 or higher
– Fujitrax Verifier V3.04 or higher
– The NXT machine configuration options, [Use Verifier] and [Perform tray verification] must both be set to “ON”.
– The [Tray Supply] option for the NXT module configuration for the module with the tray unit-L must be set to “Use tray removal area”.
– In the Kit line configuration, verification is being used for the module with the tray unit-L.
Tray arrangement
While it is possible to put two different trays in one drawer, Fuji recommends arranging trays in a 1-tray-per-drawer format in order to ensure that trays are used in an efficient manner (so trays that are still in use are not unloaded), and to ensure that accurate part replenishment guidance messages are sent for resupplying parts when using the non-stop tray resupply function.
If alternate trays are to be used, put the alternate tray in the same drawer as the original tray (see 3.3.6 in this manual for information about making alternate positions in Fuji Flexa). If the alternate tray is set in another drawer, the parts out guidance messages will not be correct, because the parts out warning time is calculated based on the total number of parts in the original and alternate trays. Be sure to also set new alternate trays when resupplying trays in spare drawers.
Resupplying trays during production
1. A parts out warning is issued and seen from one of the various locations, the NXT operation panel, from one of the Kit Manager status displays, or from the Kit Handy Parts Status or Device Check screens.
2. Obtain a new tray of matching parts and position it in a spare drawer.
Note: If using an alternate tray, be sure to also set that tray before continuing on to the next step.
3. Start the Fuji Information Terminal and tap the Windows mark to display the [Start Menu]. Tap [Kit Handy] to display the [Log on] screen.
4. Enter the user ID and tap [OK]. It is possible to also scan the user ID. The Kit Handy menu displays.
5. Tap [Device Check] and the machine specification screen displays.
6. Enter or scan the name of the NXT machine on which to perform the splicing and tap [OK].
7. Tap [Mode] from near the top of the display and then tap [Splicing].
8. Tap the tray position for which the warning was issued to select that position. This position should have an * and error icon and have a “PartsE” or “PartsOutWarning” status and be a different color. The tray being resupplied should be the part that is going to run out the quickest.
Note: The non-stop tray resupply function cannot be used to resupply trays for errors other than parts out, such as pickup miss. In such a case, it is necessary to stop production and open the door to check trays and perform other tray operations.
9. Scan the part number of the new tray set in the spare drawer. A check is performed and if the part is correct, the dialog box is closed. If an error occurs, the part is not correct and a different tray is needed.
Note: If using alternate trays, be sure to also verify that tray before continuing on to the next step.
10.Open the part supply drawer and set the spare drawer with the verified trays in it.
Note: Ensure that the set drawer is properly set in the parts resupply drawer, and be sure to gently close the part supply drawer. Closing the drawer in an abrupt manner can scatter the parts.
11.Gently close the parts supply drawer and the machine picks up the drawer and checks the height of the trays. If the height check has no errors, then resupply of that drawer is complete. If an error occurs, the drawer is returned to the parts supply drawer. Recheck and verify the trays again.
12.Production continues until all of the parts in the original tray have been used. Once all of these parts have been used, the drawer in which the part are set is moved to the tray removal area and the new drawer is pulled out on the shuttle. Once the pulled out drawer is finished being used, it will be moved to the original drawer position in the tray unit. Remove the drawer with the empty trays from the tray removal area.
Note: If a drawer is in position 21 (the position that trays picked from the parts supply drawer are kept until the original parts run out) and this drawer needs to be removed from the machine for some reason, use the panel removal command from the manual mode commands. When this command is started, any drawers in position 21 are returned to the parts supply drawer (if it is empty). It is not necessary to actually remove the tray unit and pull forward the module, just push CANCEL to cancel the rest of the command.
Precautions
Be sure to note the following points when using non-stop tray resupply.
– Do not transmit a different job to the machine when a drawer is in slot 21. If the machine is changed to a different job while a drawer is present in Slot 21, use the panel removal command from manual mode to unload the slot 21 drawer to the parts supply drawer and then remove the drawer.
– The supply and removal area doors are locked when the magazine is in their vicinity. The parts supply drawer is also locked when a drawer is present in Slot 21. The parts removal area door is locked if there are no drawers in the removal area.
– If a height check error occurs for parts replenished to the parts supply drawer, the drawer is returned to the parts supply drawer, but “SetOK” remains displayed on Kit Handy. Check the tray height, and verify the parts again with Kit Handy.
– The non-stop tray resupply function cannot be used to resupply trays for errors other than parts out. In such a case, it is necessary to stop production and open the door to check trays and perform other tray operations.