Reference · built on requestOperator by FibricProduction & maintenance

Scrap Rate

Charts rejects per SKU and station against control limits from PLC counters and camera rejects. Proposes a parameter check or a hold.

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About

A reject rate drifts before anyone sees it on a report. Scrap Rate keeps a control chart per station and SKU. The reject and good counts come from PLC counters over OPC UA. Rejects that a camera decided come from the camera-vision connector on the line's RTSP feeds. Center line and limits come from the SKU's own scrap history in Plex, Fulcrum, or MachineMetrics.

When a sample lands outside the upper control limit, or several sit above the center line in a row, it proposes a parameter check on the station, listing the process tags that moved since the last good run, or a hold on the lot in the MES. The technician decides what to touch. It writes nothing to the controller.

This is a reference listing. It documents what Fibric would read from Scrap Rate and what it could propose, based on the vendor's published interfaces. Fibric builds it under a managed deployment when you request it; selecting it here installs nothing.

Inputs

  • Reject and good counters per station and SKU over OPC UA subscriptions, or from Ignition and KEPServerEX tags
  • Reject events from the camera-vision connector on RTSP feeds, with the defect class where the configuration names one
  • The SKU or recipe running now, from a PLC tag or the current job in Plex or Fulcrum
  • Scrap history per SKU from Plex production and scrap records, Fulcrum NCRs, or the MachineMetrics Quality endpoint, for the center line and limits
  • Process tags on the station, such as temperature, pressure, and speed, read only, to name what moved

Proposed actions

  • Target capability: propose a parameter check on a station whose reject rate for the running SKU crosses the upper control limit, naming what moved
  • Target capability: propose a hold on the lot or job in Plex or Fulcrum when consecutive samples stay above the limit
  • Target capability: propose recomputed control limits for a SKU when a new run's center line has moved from the stored one
  • Target capability: propose a camera check when vision rejects rise while PLC rejects stay flat, which points at lighting or lens rather than parts
  • Target capability: propose a Slack or Microsoft Teams notice naming the station, SKU, and reject count since the shift began

Proposed actions are target capabilities. Every action runs propose-first and needs a validated deployment and the appropriate permissions.

What you can build

  • Counter and camera agree

    Both the PLC reject counter and the camera rejects step up on one SKU. Scrap Rate proposes a parameter check naming the barrel temperature tag that moved an hour earlier.

    With OPC UA, Camera Vision (RTSP)

  • Hold the lot in Plex

    Consecutive samples sit above the limit. The operator proposes a hold on the Plex job and a Slack notice to the quality lead, with the chart attached.

    With Plex, Slack

  • Lens, not parts

    Camera rejects climb while the PLC counter is flat. The proposal is a camera check posted to Teams, not a hold, so good parts are not scrapped for a dirty lens.

    With Camera Vision (RTSP), Microsoft Teams

  • NCR history sets the limits

    A job shop's Fulcrum NCRs give each part its own center line. Counters from the Logix controller are charted against it from the first run.

    With Fulcrum, Allen-Bradley Logix 5000

Requirements

  • An OPC UA, Ignition, KEPServerEX, or Allen-Bradley Logix connector with reject and good counters per station on its allow-list
  • A camera-vision connector configured on the station's RTSP feed to emit reject events
  • Scrap history per SKU in Plex, Fulcrum, or MachineMetrics, enough to set a center line
  • The process tags you want named in a parameter check, listed per station
Authentication
Scrap Rate holds no credentials. Counters and process tags arrive through your OPC UA or PLC connector, reject events through the camera-vision connector, and holds go through the MES connector's scopes.

Limits

  • Limits are statistical. A point beyond three-sigma limits warrants investigation; it is not proof of a cause.
  • Vision rejects reflect the camera configuration you supply. The operator does not train or change detection.
  • It never writes to a PLC and never changes a setpoint. The parameter check is a proposal for a technician.
  • A station whose reject counter is shared across SKUs cannot be charted per SKU; it is charted per station only.

Access and pricing

Reference listing. Fibric builds the operator under a managed deployment when you request it. Your quote covers the build, capabilities, usage, and support.

Request Scrap Rate ↗

Questions and answers

What does a person approve?
Every parameter check, hold, limit change, and notice. The proposal shows the chart, the sample that crossed, the SKU, the counter values, and the tags that moved. Approve, change the action, or dismiss. A dismissed signal returns only when the rate crosses again after coming back inside the limits.
What record is left?
The chart per station and SKU with every sample. A receipt per proposal: the limit used, the counts, the vision events, who approved, what was written to the MES, and how to lift a hold.
What stays off limits without approval?
It never places a hold, changes a limit, or posts a notice without approval. It never writes to a controller, never adjusts a camera, and never scraps a part.
Ask about Scrap Rate

Ask about the capabilities and requirements in this listing.

For project-specific requirements, contact Fibric.

This operator is developed, published, and supported by Fibric. Third-party names and logos identify the systems an integration connects to; they are the property of their respective owners, who are not affiliated with Fibric and do not sponsor or endorse this listing. Trademark policy