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PLEX -CONTROL PANEL

Bopp-Busch
Flow Chart
Log In

Control Panel

Step #1 Step #2 Step #3 Step #4 Step #5 Step #6


Work Center Job Setup Operators Check Sheets Status Forklift

Tooling

Step #5
Status
Step #1 Log in

• User ID: 1st letter of first.last name (all small


letters. (ex. z.jones)
• Password: what you created (8 characters or more
minimum of 1 being a number)
• If you forgot your password, click on “Forgot
Password” this will let you answer the 3 questions
and create a new password.
• Click on login or hit enter.
• Click on Control Panel
Step #2 Work Center

• Click in Work Center box, upper right.


• Click on the required Plant, (Plant 1, Plant 2 or Plant 3)
• Click on machine you will be using, may need to scroll
down to find the machine you are running.
• This will automatically return you to the control panel.
Step #3 Setup, Jobs
• Click in Setup box, top center.
• Clear the previous job and inventory in the this work
center by clicking the clear setup button, which will take
you back to the Work Center screen.
• Click in Setup box again.
• Jobs for this machine will be listed.
• Click in the box for the job you need to run
• Click Load Job (green box).
• Click Continue (green box).
• This will automatically return you to the Control Panel.
Step #4 Operators
• Click on time clock, bottom left.
• If someone else is logged in to that work
center/job you will need to find out if they are
done entering production, before logging them off.
• Click on your name.
• Click production.
– Set-up will need to click Set Up/Take Down
• This will automatically return you to the control
panel.
• If checksheets need to be completed the Sa
Step #5 Check sheets
• Checksheets not completed or due will show up as
yellow.
– Setup checklists need to be completed by SetUp Technician
or Die-Setup while the status is in setup mode.
• Click on Operator Work Instructions
• This will bring up your check sheet.
• Read and answer all the questions,
DO NOT JUST CHECK BOXES, COMPLETE CHECKS AS SHOWN
• WATCH Instruction Area for instructions from Set-
up/Quality. (exp. Tap parts, burrs on right corner OTR,
etc.) (This stays on each check sheet.)
Step #4 Continued
• You can add notes in the note area at the top of the
page. (exp. Gage at plant 1, nuts are rusty need to sort,
etc.) (This will need to be added to each checks sheet
produced.)
• The 4 questions at bottom of page have to be answered
every time or it will not let you add check sheet. (even
if you are not setting up the job.)
• You need to make sure you are doing checks at stated
frequencies. (Note: time based coming)
• When finished click on ADD (green box)
• This will automatically return you to the control panel.
Step # 5 Work Center Status
• Click anywhere in Work center box.
• This will bring up several boxes, click on the one
named: PRODUCTION
• When setting up a job you need to do so in Set-
up/Take down mode.
• Maintenance needs to be done under maintenance
mode.
• This will automatically return you to the control
panel.
• Remember that after lunch you need to go back to
production. System will automatically remove you
if you punch out for lunch.
Step #6 Yellow Forklift
• Click on yellow forklift.
• You will see red/pink boxes across top of screen,
these are the components needed to run this job.
• Click in the red/pink box
• This will take you to another screen that will allow
you to enter the serial # of the container your are
going to be using.
• WATCH your serial #’s very closely, it is very
important to get the one you are using and only the
one you are using.
• You can only add one serial # at a time, this is a
MUST.
Load Container Screen
• Whichever container (serial#) you have, click on the
word Load at the end of the row.
• This will move that container to the top of the page
- stating it is Currently Loaded.
• You can also scan the bar code label if you already
have it at your work station.
• Click BACK (purple button).
• This will bring you to the Production/Scrap page.
• Continue to do these steps until there are no more
pink/red boxes on the top of the page.
Containers/Labeling
• Traditional
• In the center bottom box you will see a button that says
Start New Container (blue).
• Just above that button in red lettering it will say if there is a
partial for this part.
• If there is, click in the box with the red lettering. This will
show you serial #’s of the partials. You then click on which
partial you will be adding parts to. Once you have made
enough parts to fill this partial enter your production. It
will say: Production has already been enter against this
container “Do you wish to continue?” click yes. This will
give you a label for your tote that is now full. Remember to
only enter the quantity you made to fill the container.
Container/Labeling
• Traditional
• If there are no partials. Click on the Start New
Container.
• This will change the look of that box.
• It will also print out the identification tag (zero label)
and place it on the container.
• Go to work, until container full or it’s time to do your
checks. WATCH how often these are to be done. Record
production every check to keep with the live, most
current information in the system.
• When a container is full, you will need to come back
and enter production and get a label for that container.
Containers/Labeling
• Traditional
• Make sure you have the job you are working on up
before entering production. You can enter on another
persons job if you are not careful.
• If entering multiple times into one container it will ask
you if you want to add this inventory to the existing
container. If so, hit yes. If not you will need to do
Container Full (blue) on the open container then hit Start
New Container, prior to entering production.
• If you are seeing this message while packaging in totes.
You will need to watch that you are not making a
duplicate serial #.
Container/Labeling
• Simplified
• When you get done down loading parts, this screen is
ready to go. Use a blank white label, write the last 3 digits
of the part number on it and stick it to the 1st container
you make.
• Partials: you will need to make a tote for the difference.
So you will have a partial tote and make a second partial
for the amount needed to fill that tote.
– Take both labels to Dianna, Rick, Cheryle to have them merged
together, so you have on full tote and label.
• Once you have ran a couple containers, you will come
back and enter how many containers you made. You have
to make the parts first!
Containers/Labeling
• Simplified
• Make sure the number of containers is filled in, how
many that go in a tote automatically shows up, the type
of container should automatically be there (watch
incase packing in something different) & 1st labels you
will need to make sure in the Master Units says New.
• Once you have produced the second set of totes you
will need to make sure the Master Unit has a number in
that box. If not use the drop down menu to pick the one
you need.
• It will have a running count on the number of totes
produced on that Master Unit #.
Containers/Labeling
• Simplified
• When you are ready to send the skid away hit the
green button on top of the screen, it should match
the number in the Master Unit box. This will then
print you a master label for that skid.
• Check to see if number of containers on master
match what is on the skid. If not ask for help to get
this fixed.
• When you go back to work remember to change
the Master Unit # to New again for the next skid.
Check sheets
• When it is time to do your checks, click on Back
(purple) at the top of the page.
• This will bring the Control Panel up.
• Click on Operator Work Instruction.
• Your check sheet will show up, allowing you to do
your check and record you answers.
• WATCH instruction area for further instruction to
run this job.
• If you have a problem you can click on the word
NOTES: and it will bring up a screen for you to
type in. Once you have typed your note hit
UPDATE (green)
Check Sheets
• This will automatically take you back to Check
Sheet if done.
• NOTE: Make sure your checks are being done
according to the frequencies set in the system.
• Click ADD (green).
• This will automatically return you to the control
panel, so you can enter your production.
Production/Scrap
• After entering the information on the Operator
Work Instructions click on yellow forklift.
• This will take you into enter your production and
scrap.
• Get labels if needed at this time.
Production
• Traditional
• In the center bottom box you will see a place to enter
how many pieces you have produced. Or it can be filled
in with the amount that goes into that container.
• If you enter an amount different then what goes into a
container, the remaining balance to fill that container
will show up in the production box.
• Enter amount or if the amount is correct click on Record
Production (green). ONLY GOOD PARTS get entered
here.
• This will generate a label for your container.
Production
• Traditional
• If your label does not print you can reprint it.
• At this time, is the container full or are you going to put
more parts into it?
• If container is full click blue button; if not, go back to
work.
• You can do this as many times as needed through out
the day.
• If you have produced an amount larger than the job
quantity you must see your supervisor.
Production
• Simplified
• In the center bottom box you will see a place to
enter how many containers you have produced.
• Under that box you will see how parts that go into
a container. This will remain unchanged unless
you are producing a partial or parts department
order.
• Look over container size to make sure you are
putting parts into the correct container.
• Master Units either has a number or says “New”.
Production
• Simplified
• If everything is correct click on the Produce button
(blue).
• This will then produce labels for as many totes as
you requested.
• If they all don’t print, we can reprint them.
• Either Type Traditional/Simplified
• Reset your counter so you know how many to add
to production next time. No adding or subtracting.
Scrap
• Enter scrap in the box next to the words less scrap,
how many pieces you are scrapping.
• You will need to click on the down arrow at the
end of the box for scrap reason.
• Click on the one that best describes why the parts
are being scrapped.
• Click on Record Scrap (red). This will not remove
the amount from the production you have entered.
Only out of inventory of parts used. So don’t
include scrap when entering good parts produced.
Container Full
• When container is full click Container Full (blue)
• This will bring up a screen for you to get a master
unit #, final label and/or update.
• Master Units: After hitting container full on your
first container. Container full screen, you will be
able to assign a master unit number to your
containers.
• In the box centered on screen, you will see Master
Unit, click down arrow and choose “New”
• Click on Update (green)
• This will automatically return you to the
Production screen.
Container Full
• You will see a green button at the top of your screen
with a number in it. This is the Master Unit number for
this skid of parts.
• Make sure when you complete your second container,
this number shows up under the Master unit # on
Container Full screen.
• If not there, click on down arrow and choose the
number from the production screen. Should be there
too choose.
• At this time you can click Start New Container (blue),
go back to work (if not done) or if finished unload the
job.
Unload Components
• When you have completed the number of parts needed
for that job, ran out of parts, being moved or order is
complete, it is time to unload your parts and retag the
containers.
• Click on any of the components boxes at the top.
• This will take you to the Container Full screen.
• Click on Update and Label (green)
• This will generate a label for that container of
components. Showing what is left in that container.
Replace label on the container, for easier retrieval of
parts.
Unload Components
• Please re-label the component containers so the
tags are more accurate for later use.
• At this time you will be back at the
Production/Scrap screen.
• If you have more components follow the same
steps for each one.
• Once all component containers are tagged with
new labels you will be at the Production/Scrap
screen, click Back (purple)
• Now you should be at the Control Panel
Retire
• Retire: Containers that are empty, but Plex still
shows parts in it.
• Click on retire, then say yes to retire those parts.
• If it is a lot of parts let Rick or Dianna know,
otherwise get rid of them.
• If you are in doubt about the amount ask first.
Scrap
• If you are just scraping one (1) component or another
not a whole part
• Click on Scrap (at bottom of component box)
• This will bring up a screen for you to enter the
information. Automatically it will pull the full amount
in the container.
• Change amount to the quantity that is being scraped.
• Then pick a reason from the drop down menu that best
describes the reason.
• You can also put a note on the scrap screen to better
describe the problem.
Scrap
• Click on “+” sign this will move amount to bottom
of screen and allow for you to add more for
different reasons, if needed.
• When done click on add (green) button . This
removes component pieces only, not the whole
part.
• Be careful you can accidentally scrap the whole
container.
Inventory Increases
• If you are running and a container is showing on
Plex to be empty, but you still have parts.
• You need to contact Rick, Cheryle, or Gus to try to
determine what happened and correct the issue.
• You will not be able to enter production until the
problem is corrected.
• Please do not enter to empty container prior to
issue being resolved, this makes it more difficult
to correct.
Production Entries
• If for some reason you find that an entry is
incorrect you need to let Marvin or Amy know
right away.
• This includes: master units, duplicate serial #,
wrong amounts entered, retire or scrap parts that
should not have been, etc.
• If in doubt ask, please!
Control Panel Unload
• Click Step#5 Work center Status
• Click Idle
• This will automatically return you to the Control Panel.
• Click Step #3 Time Clock
• Click your name
• Click log off this work center.
• This will automatically return you to the Control Panel
• Click Step #2 Setup
• Click Clear setup (red)
• This will automatically return you to the Control Panel
Control Panel Unload
• You are done with this job and are logged off this
work station ready for your next assignment.
• Completely done?
• Click Exit Control Panel (red)
• Click Log-out (yellowish) upper left corner.
• Screen will popup asking are you sure you want to
log out of Plex.
• Click Yes
• You are done.
Reprinting Labels
• If for some reason the printer does not print a label for
you, you can go to the Control Panel.
• Click on the words “Production History” just above the
yellow forklift.
• Find the serial # you need reprinted. Be careful not to
print two (2) like serial numbers. If you have questions
ask before producing duplicate serial #’s.
• Click on the number, this will pop open a screen. At the
top you will see a green button that says “Print
Barcode”
• Click this button and it will reprint a label.
• Click back twice to get back to the Control Panel.
Over Produce?
• Over producing should only occur when instructed
by your supervisor to do so.
• If you are instructed to over produce the job your
supervisor will direct you what steps to take.
Misc.
• Reset your counter after each time you record your
production, this will help prevent mathematical
errors and enter more then you should when
entering production.

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