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Using Carriers With Capacity#

Overview#

In many processes, one carrier cannot hold a whole lot. For example, a baking oven uses process trays that hold only part of a lot, so the operator spreads the lot across several trays. In this scenario, a process engineer or operator uses Carrier Materials with capacity tracking to split a 150 unit lot across two trays, such as SRMTray002 and SRMTray004, and then removes the trays at the next step.

This scenario extends Attaching a Single Carrier to a Material. Instead of attaching one carrier to the whole Material or to each sub-material, you assign a quantity of the Material to each carrier, and the system tracks how much of each carrier is used.

For the overall concepts, see Carrier Management Tutorial.

Before You Start#

  • The Material RTS512/1014054 of Product S512RM08 exists with a quantity of 150 units, in Queued state at the Baking SD Step.
  • The Product SRM-Tray of Product Type Carrier exists, with at least two Carrier Materials, such as SRMTray002 and SRMTray004, each with an available capacity of 100.
  • The MaterialCarrierCapacity table defines the capacity of SRM-Tray for each Capacity Class. For example: 0-50 holds 300 units, 50-100 holds 100 units, and 100-200 holds 40 units.
  • The Capacity Class of the Material, or of its Product, matches a class in the MaterialCarrierCapacity table.
  • The MaterialCarrierContext table has an Add Operation for SRM-Tray at the Baking SD Step, with Assignment Mode set to Main Material and Track Used Quantity set to true, and a Remove Operation for SRM-Tray at the cooling Step.
  • The Carrier Material Verification Mode of Baking SD is set to At Track-In.

Info

For the table and Step setup, see Configuration.

Use the following Master Data Files to load the model for this tutorial:

Sequence of Steps#

1. Assign the First Carrier With Partial Capacity#

From the Baking SD Step, assign a tray that covers only part of the lot, and see how the system blocks the process until the lot is fully covered. Open the Baking SD Step and proceed as follows:

  1. On the top ribbon, select the Step View tab.
  2. Select Materials from the left panel.

  3. In the Materials table, select the RTS512/1014054 checkbox to set the carrier materials assignment.

    Screenshot showing the Manage Carrier Materials wizard with SRMTray003.

  4. On the top ribbon, select More.

  5. In the Carrier Materials section, select Manage.

    The Manage Carrier Materials wizard opens. You can see the number of material units in the title. For example, 400 Unit.

  6. In the Carrier Material field, select a tray. For example, SRMTray003.

  7. Select Save.

    Screenshot showing the Manage Carrier Materials wizard with SRMTray003.

  8. Try to track in the RTS512/1014054 Material.

    The system blocks the operation and displays an error saying that there are not enough carriers, because 50 units still have no carrier.

    Screenshot showing the track-in error for missing carrier capacity.

2. Assign the Remaining Quantity to a Second Carrier#

  1. Open the Manage Carrier Materials wizard again, as described in Step 1.
  2. Select Add (+) and, in the Carrier Material field, select a second tray, such as SRMTray004.

  3. In the Assigned Capacity field, enter 50, and then select Save.

    The wizard lists both trays, and the assigned capacity covers all 150 units.

    Screenshot showing the Manage Carrier Materials wizard listing SRMTray002 with 100 Unit and SRMTray004 with 50 Unit.

  4. Track in the RTS512/1014054 Material.

    This time, the system accepts the track-in and the process continues.

3. Remove the Carriers Before Leaving the Cooling Step#

The Remove Operation in the MaterialCarrierContext table requires the trays to detach before the Material leaves the cooling Step.

  1. Move the RTS512/1014054 Material to the cooling Step.

  2. Try to move the Material to the next Step.

    The system blocks the operation and displays an error saying that carrier materials must be removed first.

  3. Open the Manage Carrier Materials wizard, as described in Step 1.

  4. Select the trash can icon of each tray to remove it, and then select Save.

    Screenshot showing the Manage Carrier Materials wizard after removing the trays at the cooling step.

  5. Move the Material to the next Step.

    This time, the system accepts the operation.

4. Validate the Result#

  1. Open the RTS512/1014054 Material page.

  2. On the details view, select Carriers.

    The list no longer shows SRMTray002 and SRMTray004 as assigned carriers.

What You Learned#

You split a lot across two carriers by assigning a quantity to each one, and you saw that the system blocks track-in until the whole lot has carriers. You also removed the carriers at the cooling Step, which the MaterialCarrierContext table required before the Material moved on.