@seedtactics/insight-client 16.4.0

package/docs/material-quarantine.md

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+---
+title: Material Quarantine
+nav: Procedures > Material Quarantine
+description: >-
+  FMS Insight can help track and manage material that has been temporarily
+  removed from the FMS cell for re-machining or rework.
+---
+
+# Material Quarantine
+
+FMS Insight provides an optional feature to help track and manage material
+that has been temporarily removed from the cell for re-machining, more
+detailed inspection, or some other rework. FMS Insight displays all the
+material currently on hold, allows a supervisor/manager to update the status
+of quarantined material, and finally allows the material to be re-introduced
+to the cell or scrapped.
+
+The implementation extends the [material tracking](material-tracking) to
+also include whiteboard regions for quarantined material. By default, FMS
+Insight creates whiteboard regions for each pallet, inspection stand, the
+wash stand, and any in-process queues of material between processes. These
+are the "active" whiteboard regions and contain material which is flowing
+through the normal workflow. FMS Insight keeps these whiteboard regions
+updated automatically by recording the log of automated cell activity.
+In the [server configuration](server-config), FMS Insight allows you to
+define a list of Queues and this list of queues must contain a queue for
+each "active" in-process queue defined in the flexibility plan and used to
+hold material in the normal workflow. Any queue which is listed inside
+the flexibility plan is treated by FMS Insight as an "active" queue.
+
+To support quarantined material, you can create extra whiteboard
+regions/queues for the various tasks that might be performed on quarantined
+material. To the list of queues defined in the [server configuration](server-config),
+you can add extra queues to represent the various quarantined material tasks.
+A queue that is not listed inside the flexibility plan is considered as a
+quarantined material queue and FMS Insight will not update the queue
+automatically. Instead a supervisor, manager, or engineer can manually move material
+between the various quarantined material queues to assist with tracking the
+material. The material can also be moved back into an "active" queue to
+reintroduce it into the cell or removed completely if scrapped.
+
+The [operations](client-operations#material) and [quality](client-quality#quarantine-material)
+webpages allow supervisors, quality engineers and others to manually move
+material between the various quarantined queues, view all the material, add
+notes, re-introduce material to "active" queues, or scrap material. In
+addition, the [server configuration](server-config) contains a setting
+_QuarantineQueue_ for the initial quarantine queue. If this setting is given,
+the [station monitor webpages](client-station-monitor) will contain a
+button _Quarantine Material_: if pressed the material is moved out of the
+"active" whiteboard regions/queues and into the quarantine queue specified in
+the server configuration file.
+
+FMS Insight allows arbitrary quarantined material queues, but we suggest you
+follow a scheme similar to the "TODO, In-Progress, Done" Kanban task
+management/project management technique.
+
+- _Initial Quarantine_: We suggest a quarantine queue called _Initial Quarantine_.
+  When an operator removes material from a pallet/load station/inspection
+  stand/etc. the material is initially moved into this queue to get it out of
+  the "active" queues and allows the operator to continue with normal
+  operations. A supervisor/manager should then decide what is to be done with
+  this material and move it into a more specific quarantined material queue.
+  The _Initial Quarantine_ queue acts similarly to the TODO column on the task
+  board. Most of the time the _Initial Quarantine_ queue should be empty; if
+  there is anything in the _Initial Quarantine_ queue, it signals to the supervisor
+  that a decision on the material is required and once that decision is made,
+  the material is moved to a more specific quarantine queue, emptying the
+  _Initial Quarantine_ queue.
+
+- In-Progress quarantine queues: each potential action on the material should have
+  a corresponding in-progress quarantined queue. For example,
+  _Rework on Standalone Machines_, _Sent to Foundry_,
+  _Waiting for Customer Inspection_, etc. FMS Insight allows notes to be attached
+  to each piece of material, so you can keep a log or status on each piece of
+  material. Material can move between one or more of these queues while it is quarantined.
+
+- Done queues: There are no specific done queues (unlike Kanban task management);
+  instead, if the material is ready to be re-introduced into the normal workflow
+  of the automated handling system, it can be moved back into an "active" queue.
+  If instead the material is scrap, it can be removed from the quarantined queues.
+
+![Screenshot of Material screen](screenshots/insight-operations-material.png)

package/docs/material-tracking.md

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+---
+title: Material Tracking
+nav: Procedures > Material Tracking
+description: >-
+  Tracking each piece of material by marking it with a unique serial and
+  barcode is vital by helping operators load/unload material, increase quality,
+  fill workorders, and long-term tracking of material.
+---
+
+# Material Tracking
+
+Tracking each piece of material by marking it with a unique serial and
+barcode is vital for operating a system with a mix of automated and manual
+handling. The key design objectives and goals are as follows:
+
+1. Assist the operators with loading and unloading by providing information about what to produce,
+   what material is available, the status of all the in-process material, and load/unload instructions.
+
+2. Increase quality by allow the inspection operator to learn the history of the
+   exact piece of material under test (the pallet, machine, program, date and time, etc.).
+
+3. Track unloaded material through manual processes such as final wash or any in-process work
+   between automated machine cycles.
+
+4. Properly fill workorders, ensuring that all produced material is assigned to a workorder and that enough
+   material is produced to fill workorders on time.
+
+5. Make it as easy as possible for the operators to keep the data in the computers matching
+   the reality of the material on the shop floor.
+
+6. When the data in the computers no longer matches the reality on the shop floor, provide
+   an easy way of rectifying this situation by updating the data in the computers.
+
+7. Provide long-term tracking and part identification for downstream customers.
+
+The key challenge is in points 5 and 6; the system must make the normal,
+everyday operator tasks easy and straightforward but also be robust to the
+unknown.
+
+## Sticky Notes
+
+Consider the following method of tracking material not using a computer. On a
+whiteboard, divide the whiteboard into regions for all the possible places
+that material could be, so a region for each pallet, a region for each
+in-process transfer stand, a region for material waiting to be inspected, a
+region for material waiting to be washed, a region for in-process queues and
+conveyors, a region for castings, a region for material sent out of the
+factory for external work, and so on. Any place that material could be has a
+corresponding region on the whiteboard.
+
+Now for each piece of material, a new sticky note is used. The part name and
+serial is written on the sticky note and on the back is written a log of
+activity. At the start of the process, a new sticky note is created and
+placed on the whiteboard. As the process unfolds, the sticky note moves
+around on the whiteboard corresponding to the material moving around the
+factory floor.
+
+For example, a part just completed process 1 and is waiting on pallet 6 at
+the load station to be unloaded into the transfer stand. The sticky note for
+the material is currently on the whiteboard in the region for pallet 6. As
+part of the unload operation, the sticky note is moved on the whiteboard from
+the pallet 6 region to the transfer-stand region. (Also, if any material is
+loaded, its corresponding sticky note is moved into the pallet 6 region.) The
+fact that there is a sticky note existing in the transfer stand position on
+the whiteboard signals to the operators that the pallet for the second
+operation should be brought to the load station. When the pallet for the
+second operation arrives and the material is loaded, the sticky note will
+then move from the whiteboard region for the transfer-stand to the region of
+the whiteboard for the pallet.
+
+This whiteboard of sticky notes has several great features:
+
+- By centralizing all material on a single whiteboard, it is easy to visualize the
+  entire process and make decisions about what actions to take (what material is
+  available for loading, what material needs to be inspected, what material to wash and assign to
+  a workorder, etc.).
+
+- Operators can at a glance determine if the whiteboard matches the reality on the factory floor. If there is
+  a mismatch, the sticky notes can be moved so that the whiteboard matches reality.
+
+- Operators at a single station can focus only on a section of the whiteboard to carry out their tasks. For example,
+  at the wash station, only the section of the whiteboard corresponding to the wash stand is relevant.
+
+- It is straightforward to accommodate all sorts of material tasks both inside and outside of
+  automation. For example, if a part must be quarantined as potential scrap, its sticky note can be set on
+  the side of the whiteboard. Once examined, if the part is determined to be scrap the sticky note can
+  be thrown in the trash can. If the part needs some re-machining, the sticky note can be added
+  back onto the whiteboard once the re-machining has completed and the part is ready for the remainder of the
+  process.
+
+- By using a metaphor of physical sticky notes, the design provides an intuitive understanding for users.
+  The design is motivated by Google's Material Design, whose founding idea is: "A material metaphor is the unifying
+  theory of a rationalized space and a system of motion. The material is grounded in tactile reality,
+  inspired by the study of paper and ink, yet technologically advanced and open to imagination and magic."
+  In fact, we suggest that operator training start with actual physical sticky notes on a whiteboard before
+  transitioning the training to the computers.
+
+Of course, there is one main downside to using a physical whiteboard; it is
+tedious for the operators. This is solved by keeping the whiteboard and
+sticky notes in software and using software monitoring to automatically move
+around the sticky notes. We believe that when using automation and software as
+part of process control, you must always start with a design that could be
+done without software. This produces a design which does not force the
+process to conform to the software but allows the software to support the
+process. It also eases user understanding because it provides a
+straightforward metaphor for the user to understand how the software
+functions. The software should exist just to support the process by removing
+the tedious and error-prone tasks.
+
+## Software-Based Sticky Notes
+
+![Screenshot of Load/Unload Station Screen](screenshots/insight-loadstation-small.jpg)
+
+The tactile metaphor of moving around sticky notes, with one sticky note per
+piece of material, is the basis for the FMS Insight Station Monitor page. See
+the screenshot above, which shows the whiteboard with regions for Raw
+Material, the two faces on Pallet 1, and Completed Material. Insight
+allows the operator to view a section of the virtual whiteboard of material
+sticky notes relevant to the current station, in this case the load station 1.
+
+Insight monitors the machines and automation and moves around the material
+sticky notes on the virtual whiteboard as parts are loaded, unloaded, and
+machined. Also, by watching the virtual whiteboard, Insight can control the
+pallets. For example, Insight will prevent a pallet from arriving at the load
+station if the transfer stand queue virtual whiteboard region is empty.
+
+Insight allows the operator to keep the virtual whiteboard in sync with the
+material on the factory floor. Operators can remove virtual material sticky
+notes from the whiteboard by clicking a button and add sticky notes by
+scanning a barcode or manually entering a serial. Each queue or conveyor or
+place where material is under manual control has a corresponding whiteboard
+region. By placing a computer or tablet at that place in the factory, the
+operator can at a glance see if the virtual whiteboard matches the reality on
+the factory floor, and if not simply edit the virtual whiteboard to match.
+
+## An Example Design
+
+The virtual whiteboard implemented by FMS Insight is versatile and can adjust
+to a huge variety of processes with parts moving in and out of automation and
+manual handling.
+
+For example, consider a process with two cells: a horizontal machining cell
+and a lathe cell. Parts are manually loaded and unloaded and transfer between
+cells via a conveyor. The conveyor between the cells will correspond to a
+region on the virtual whiteboard. Also, right next to the conveyor, there is
+a computer or mounted tablet with an attached barcode scanner. The computer
+uses FMS Insight to display the region of the whiteboard for the conveyor. As
+parts are unloaded from one cell, FMS Insight automatically moves the
+corresponding material sticky note from the pallet to the conveyor region.
+Similarly, FMS Insight is configured to monitor the virtual whiteboard region
+for the conveyor to know when to bring pallets to the load station to load
+material out of the conveyor.
+
+During normal operation, the operator does not need to manually edit the
+virtual whiteboard. As parts are completed in one cell, their sticky notes
+are moved to the whiteboard region for the conveyor and when the material is
+loaded into the second cell the sticky notes are removed from the whiteboard
+region for the conveyor. The operator can at a glance see that the conveyor
+matches the virtual whiteboard by comparing the conveyor to the computer screen.
+
+Now consider that some parts are removed from the conveyor temporarily.
+Perhaps the parts are inspected, a part needs some re-machining, or it must
+travel elsewhere in the factory for a specialized operation. When the
+material is removed from the conveyor, the operator can click a button in FMS
+Insight to remove the sticky note from the virtual whiteboard. FMS Insight
+will then prevent a pallet from arriving to load this missing material. The
+material eventually returns and when it does, the operator can scan the
+barcode on the part to add the corresponding virtual sticky note onto the
+whiteboard. FMS Insight will then activate the pallet to load this piece of
+material in the second cell.
+
+## Whiteboard tracking design
+
+FMS Insight requires that you decide on a list of virtual whiteboard regions
+and how material will move between regions. The initial design is best done
+by using an actual whiteboard in a conference room with real sticky notes.
+Draw regions on the whiteboard, create some sample sticky notes, and step through
+the proposed process, moving the sticky notes around on the whiteboard. This helps
+design the whiteboard regions to configure in FMS Insight, but also highlights potential
+complicated material flow which you might consider changing the process.
+
+At the load station, use a computer or mounted tablet running Insight.
+Insight will display the section of the virtual whiteboard for the pallet,
+plus the region for material being loaded and the region to which material is
+unloaded. Insight will determine based on the whiteboard which specific
+material to load and display it with its serial. The operator should then
+load the material with the specific serial requested by Insight. But, if the
+serial that Insight wants to load is unavailable, the operator can just edit
+the virtual whiteboard. Insight will automatically adjust with a new
+instruction for the operator. (Hopefully this doesn't happen and the virtual
+whiteboard is kept in sync, but if it does happen it is easy to correct.)
+
+At any place where in-process material is queued outside of control of the
+automation, create a whiteboard region. This could be conveyors between cells
+or stands for holding parts between processes (e.g. large parts which have
+process 1 and process 2 on different pallets). At each location, dedicate a
+computer or mounted tablet with an attached barcode scanner to view and edit
+the whiteboard region. Insight can be configured to automatically move the
+virtual sticky notes during normal operations as parts are loaded and
+unloaded into these queues, but the operator can use the computer and scanner
+to adjust the whiteboard region as needed.
+
+For in-process manual operations such as manual CMM stations or custom
+processes outside the automated cell, create two whiteboard regions. One
+region for the input to the process and one region for the output from the
+process. For example, at an in-process CMM stand, create a whiteboard region
+for the unloaded parts not yet measured. FMS Insight can then be configured
+to automatically move the material sticky note from the pallet to the inbound
+CMM region. The CMM stand then has a computer or mounted tablet showing
+Insight; the operator can then see the material not yet measured, perform the
+CMM measurement, and if successful, use FMS Insight to transfer the virtual
+sticky note from the inbound region to the outbound region. FMS Insight
+monitors the outbound region and will bring a pallet to the load station once
+the CMM has completed. Insight will also transfer the sticky note from the
+outbound region to the pallet as part of the load operation.
+
+For raw material, Insight supports two options. Insight can just assume raw
+material is always available in which case Insight will create a new virtual
+sticky note during the initial loading. In this design, the first time a
+sticky note appears is on the pallet. Alternatively, Insight can be configured
+to draw initial material from a virtual whiteboard region. In this case, when
+material arrives, an operator must scan or add the material into the initial
+whiteboard region. Once added, FMS Insight will then activate the pallet to
+load this material.
+
+For completed material, Insight automatically adds the sticky notes to
+regions for signaled inspections and final wash. Technically, these could
+just be configured virtual whiteboard regions similar to in-process queues or
+operations, but inspections and final wash are so common that Insight
+automatically has special regions for them. Each configured inspection type
+has two regions: one for completed parts signaled for inspection but not yet
+inspected and one region for completed inspection. For final wash, Insight
+also has two regions: one for not yet washed parts and one for washed parts.
+A computer mounted at the inspection and wash stations can show Insight and
+allow the operator to move the virtual sticky note as the inspection or final
+wash is completed.

package/docs/mazak.md

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+---
+title: Mazak Palletech Integration
+nav: FMS Insight Server > Mazak
+description: >-
+  FMS Insight works with all Palletech cell controller versions from Mazak:
+  Version E, Web Version, and Smooth PMC. FMS Insight can read all events from
+  the cell controller and can also edit almost all the data in the cell controller.
+---
+
+# FMS Insight Mazak Palletech Integration
+
+FMS Insight works with all Palletech cell controller versions from Mazak:
+Version E, Web Version, and Smooth PMC. FMS Insight can read all events from
+the cell controller and can also edit almost all the data in the cell controller.
+
+## Open Database Kit
+
+To facilitate the communication between FMS Insight and the Mazak cell
+controller, you must acquire a program called "Mazak Open Database Kit". This
+is a software program developed by Mazak which allows safe access to the data
+inside the cell controller. Please contact your Mazak representative and ask
+to obtain "Open Database Kit" that matches the specific cell controller
+(Version E, Web, or Smooth PMC).
+
+## Enable Log CSV
+
+For Mazak Web and Mazak Smooth PMC, you must enable a setting in the Mazak cell controller
+which will cause the Mazak cell controller to create log files of all events (pallet movements,
+machine cycles, etc.) in the `c:\Mazak\FMS\Log` directory. Once enabled, FMS Insight will
+automatically find any log entries from this directory.
+
+To enable, go to the `c:\Mazak\FMS` directory. Rename the file `log-parameters.ini.sample` to `log-parameters.ini` and restart the Mazak Palletech software. The `log-parameters.ini` file
+contains settings for the path to use and how often to delete, but FMS Insight works fine with
+the default settings. If you want, you can change the log directory in `log-parameters.ini`
+and then specify the same folder in the FMS Insight server configuration file.
+
+## Load Instructions
+
+On Version E and MazakWeb, one parameter must be changed. If you are using Mazak Smooth PMC, this step can be
+skipped! Open the Mazak Palletech software, go to the parameter
+edit screen, select `X`, and scroll to the setting `X-31`. Set the `X-31` setting from 0 to 1.
+This setting will cause CSV files describing the current load and unload operation at the load
+station to be output to the `c:\Mazak\FMS\LDS` directory. FMS Insight monitors this directory
+and uses the CSV files to display the parts being loaded and unloaded from each pallet at
+the load station.
+
+## Simulation Lab
+
+The Mazak Palletech cell controller software has a great ability to be run in a
+simulation mode without any machines or carts attached. In this mode, the
+Mazak cell controller software has all features active but instead of sending
+commands to the actual machines and carts, just simulates their operation.
+
+We recommend that you set up what we call a simulation lab, which consists of
+two computers in an office. One computer will run the Mazak cell controller
+software in simulation mode, Open Database Kit, and the FMS Insight server.
+The second computer will run a browser and access the FMS Insight client.
+This mimics the actual layout in operations, where the cell controller
+computer runs Open Database Kit and the FMS Insight server and a separate
+computer on the factory floor or in the office runs the client views.
+
+A simulation lab allows testing, training, and experimentation. You can set
+up some dummy orders, create a schedule, copy the schedule into the Mazak
+cell controller, run the schedule inside the Mazak cell controller, see the
+assigned serial numbers, view inspection decisions, and examine efficiency
+reports of cell operations, all without impacting the real system.
+
+The simulation lab is also great for training before the machines are even
+installed, testing out new scheduling or inspection signaling techniques, or
+training new operators and managers.
+
+## Starting Offset and Decrement Priority
+
+The Mazak [config.ini](server-config) contains a setting `Use Starting Offset`
+which control how new schedules are added into the cell controller.
+
+When `Use Starting Offset` is enabled, new Mazak schedules will
+be created with a "Due Date" and "Priority" field based on the
+simulation's prediction of its actual start time. If disabled, a due
+date of January 1, 2008 and priority of 91 is used for all Mazak schedules, effectively
+disabling the use of due dates. Since Mazak uses due dates to decide which
+part or pallet to start producing first, due dates can help smooth production
+flow.
+
+The main downside to using due dates and priorities is that Mazak will empty out a pallet
+before switching schedules. For example, consider a situation where you have
+a part PPP with two processes and a fixture which can hold one process 1
+material and one process 2 material. Also, consider there are two schedules
+for part PPP; a schedule AAA for today's production and a schedule BBB for
+tomorrow's production. Say that the AAA and BBB schedules have different due
+dates (say AAA has the earlier due date). Then Mazak will first run the
+entire AAA schedule. In particular, the very last cycle of AAA will run with
+a process 2 part and an empty process 1 location. Instead, if the due dates
+of AAA and BBB are the same, Mazak will not empty out the pallet and instead
+on the very last cycle of AAA in the process 2 location will add the very
+first cycle of BBB in the process 1 location.
+
+In our opinion, due dates and priorities should be enabled; the pallet
+running empty is not typically that big of a deal. The primary goal of the
+system is to keep the machines busy and a pallet with an empty location will
+return to the load station after cutting just the material on the pallet (as
+long as each process has a separate program). This increases slightly the
+burden on the cart and load station, but these are not the bottleneck and
+there should be enough work in the system to keep the machines busy. In
+addition, occasionally a pallet will empty out in any case because today's
+schedule had a limited quantity to allow a different part some time on the
+machines. Finally, occasionally emptying out a pallet seems to help
+tremendously with preventing traffic jams.
+
+Finally, when FMS Insight adds a new day's schedule into the cell controller,
+then FMS Insight will first decrement the priority on all existing
+uncompleted schedules. Since each day a new schedule is downloaded, if
+priorities of existing schedules are first decrement then any unfinished work
+from the previous day gains higher priority and will finish before today's
+schedule starts.

package/docs/niigata.md

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+---
+title: Niigata ICC Integration
+nav: FMS Insight Server > Niigata
+description: >-
+  FMS Insight works with the recent Niigata ICC Cell Controller
+  FMS Insight can monitor the events from the cell controller and can also set
+  routes and control each pallet.
+---
+
+# FMS Insight Niigata ICC Cell Controller
+
+FMS Insight works with a modified version of the Niigata ICC Cell Controller.
+Contact your Niigata Sales or Support Representative to request more information
+about using FMS Insight with the Niigata ICC Cell Controller.
+
+## Configuration
+
+#### Reclamp Stations
+
+By default, all machine stops in the downloaded jobs are assumed to be machines.
+To support reclamp stops, a specific name of the reclamp stop can be defined
+in the FMS Insight [config.ini](server-config) file. Once defined,
+any machine stop in the downloaded jobs which match this configured name will
+be treated as reclamp stops.
+
+#### Custom Machine Names
+
+By default, ICC machine numbers are mapped to the identical machine number in
+the downloaded jobs. That is, ICC machine 1 is mapped to MC1 in the jobs,
+ICC machine 2 is mapped to MC2, and so on. The [config.ini](server-config) file can
+specify an alternative job machine name and number to be assigned to each ICC machine
+number. This allows different types of machines to be named differently in the
+flexibility plan and jobs.
+
+#### Machine IP Addresses
+
+If specified, FMS Insight will use the Machine IP addresses and ports to load
+tooling data from the machines, record it as part of the log of events, and display some
+[summary reports](client-tools-programs) of tooling data. FMS Insight does not
+require the IP addresses to be specified; if they are missing, no tool data is loaded
+but all other functions of FMS Insight work (managing jobs, logging events, etc.).
+
+#### Sized Queues
+
+FMS Insight supports specifying a size for each queue defined in the config file.
+FMS Insight will then hold and unhold pallets that are waiting to be unloaded so that
+the queue does not exceed the configured size. Note that by using the
+[queues page](client-station-monitor), an operator can manually insert more material
+into the queue beyond the configured size. The configured size is only used for holding
+and unholding pallets.
+
+## Operations
+
+FMS Insight translates the jobs into the Niigata ICC Cell Controller
+via three mechanisms: adding programs, setting pallet master routes, and controlling
+a few flags on the pallet tracking.
+
+#### Programs
+
+The jobs can optionally contain the program content for each process and machining stop.
+If the job does not contain the program content, FMS Insight assumes the program has
+already been manually registered with the Niigata ICC.
+
+If the program content is included, FMS Insight will manage revisions and register
+the program with the Niigata ICC. FMS Insight will compare the program content from
+the newly created jobs and the already existing program. If they are the same, the
+existing program is reused. If they are different, a new revision is created by
+selecting a new program number and registering the new program content with the
+Niigata ICC. This leaves the old program revision unchanged so both the old and
+new revisions are simultaneously in the cell controller. FMS Insight tracks all
+material and will use either the old revision or the new program revision
+based on which material is currently loaded onto the pallet. Once the old
+job completes, FMS Insight will remove the old program revision from the Niigata
+ICC. Program revisions and Niigata ICC program numbers can be seen on the
+[program report page](client-tools-programs).
+
+#### Pallet Master
+
+For each pallet, the Niigata ICC stores the "Pallet Master", a list of stops that
+the pallet visits. The route starts with LD (load), has a sequence of MC (machining)
+and RC (reclamp) stops, and ends with a UL (unload). Each load, unload, or reclamp stop
+contains a list of load station numbers to use. Each machining stop contains the
+machines to use plus a list of program to run.
+
+FMS Insight sets the pallet master steps based on the data in the created jobs. For
+each available pallet, FMS Insight sorts the jobs by date and priority and decides
+which job should run on the pallet. FMS Insight then uses the job data to completely
+replace the pallet master with the sequence of steps from the job. FMS Insight
+uses the comment field to keep track of which job is currently assigned to the
+pallet. FMS Insight continuously updates the pallet master data as jobs
+complete and other jobs are assigned to the pallet; FMS Insight will only update
+a pallet if it is waiting in the stocker with the "No Work" flag set (see below for
+more information about the No Work flag).
+
+#### Pallet Location and Status
+
+For each pallet, the Niigata ICC stores the "Tracking Data", consisting of the current
+pallet location, currently executing step, count of remaining pallet cycles, and a
+couple of boolean flags.
+
+FMS Insight reads but does NOT have write access to the current pallet location and
+currently executing step (Before-LD, After-LD, Before-MC, etc.). The Niigata ICC
+keeps these fields updated as the pallet moves through the route defined in the
+pallet master. FMS Insight watches these values change and uses them to create
+a log of what happens. The Niigata ICC does allow the user (but not FMS Insight)
+to override the pallet location or current step, which can be used in emergencies;
+overriding the pallet location and current step is not required during normal
+operation. FMS Insight uses the transitions of pallet locations and currently
+executing step to create log entries, so if they are manually edited by
+the user, FMS Insight may miss log entries for the current cycle. FMS Insight
+will recover once a new pallet cycle starts.
+
+#### Pallet Cycle Count
+
+For each pallet, the Niigata ICC tracks a count of remaining pallet cycles. The Niigata
+ICC decrements this on the completion of the UL (unload) step. If it is greater
+than zero and the operator presses the LOAD button, the Niigata ICC switches to the
+After-LD (load) step and thus starts the route again. If the count is zero OR the
+operator presses the button Niigata calls UNLOAD but might more accurately be translated
+"NOT LOADED", the Niigata ICC places the "No Work" flag onto the pallet, which
+causes the pallet to route to the stocker. (See below for more about the No Work flag.)
+
+FMS Insight always keeps the cycle count at 1 and increments it when the pallet arrives
+to be unloaded if needed. That is, consider when a pallet arrives to be unloaded. The
+current remaining cycle count is 1. FMS Insight will check the available material in the
+[queues](material-tracking) to determine if there is a piece of material to be loaded.
+If no material is available, FMS Insight will do nothing; the Niigata ICC will then
+decrement the cycle count from 1 to 0 and send the pallet to the stocker no matter if the
+operator presses the LOAD or UNLOAD/NOT LOADED button. Instead, if there is available
+material to be loaded, FMS Insight will increment the remaining pallet cycles to 2. When
+the operator presses the LOAD button, the Niigata ICC will then set the status to After-LD
+(load) and proceed to route the pallet back through the pallet master steps. If instead
+the operator presses the UNLOAD/NOT LOADED button, the Niigata ICC will set the No Work
+flag and route the pallet to the stocker.
+
+The FMS Insight [load station page](client-station-monitor) will always contain the
+expected operations to occur at the load station.
+
+#### No Work and Skip
+
+For each pallet, the Niigata ICC stores two boolean flags: "No Work" and "Skip".
+
+The "Skip" flag, also called hold, causes the Niigata ICC to move the pallet to
+the stocker and then ignore it. FMS Insight uses the "Skip" flag to implement
+sized queues. If there is an in-process queue with a specific size, FMS Insight
+will set the "Skip" flag on all pallets destined to be unloaded into this queue.
+FMS Insight then removes the "Skip" flag on only a single pallet at a time and only
+when the unload would not increase the number of parts beyond the size of the queue.
+
+The "No Work" flag is used to override the "Remaining Pallet Cycles" count. If the
+No Work flag is set, the Niigata ICC assumes that the pallet is empty, sends the
+pallet to the stocker, and ignores it. While similar to Skip, Skip is used to
+hold a pallet in the middle of the route while No Work is used to not start the
+pallet route at all. When the remaining pallet cycle count drops to zero, the
+Niigata ICC sets the No Work flag when the pallet is unloaded. Also, if the
+operator presses the UNLOAD/NOT LOADED button, the No Work flag is set
+no matter what the remaining pallet cycle count is.
+
+FMS Insight uses the No Work flag on a pallet in the stocker to trigger its
+check for new jobs to assign to the pallet. For each pallet in the stocker
+with No Work set, FMS Insight will sort the available jobs by date and
+priority. For each job, FMS Insight checks if there is available material
+to be loaded. If a piece of material for some job is found, FMS Insight
+will clear the No Work flag (and also optionally update the pallet master
+data for the new job, if required).
+
+## Operator Procedures
+
+#### Load Station Normal Operation
+
+FMS Insight's [load station page](client-station-monitor) will display what the Niigata ICC is
+expecting to happen at the load station. Specifically, the page will display the material
+to load, the material to unload, and the material to transfer between faces (if the pallet has
+multiple faces). If the operator performs all the tasks as specified, the operator presses
+the "LOAD" button. The Niigata ICC will then begin the route on the pallet for the material
+that was just loaded. (Note that if the instructions specify that nothing is to be loaded,
+the operator can press either "LOAD" or "UNLOAD/NOT LOADED", both will preform the same
+action.)
+
+#### Material which is unloaded must be reworked or scrapped
+
+Consider when the operator unloads a piece of material which cannot continue with the normal
+flow but must be set aside to be reworked or possibly scrapped. If this is on the final process,
+nothing needs to be specified. If instead this is an in-process piece of material, it
+can be signaled to be quarantined after the unload completes. To do so, on the
+load station page, click the material card for the piece of material. The dialog that
+opens will contain a "Signal For Quarantine" action. Once clicked, FMS Insight will move
+the material to the quarantine queue once the unload finishes.
+
+If the material has already been unloaded without clicking the "Signal for Quarantine" action,
+FMS Insight will add the material that was unloaded
+into the in-process queue, visible on either the
+[load station or queues pages](client-station-monitor).
+To remove the material, the operator must click on the material card and then
+click either the "Remove From System" or "Quarantine Material" action
+(depending on if [quarantine queues](material-quarantine) are configured).
+This will either remove the material from the system completely or remove it
+from the active FMS Insight queue and place it in a special quarantine queue.
+In either case, once the material is no longer in the queue, FMS Insight will
+not set pallet master or tracking data into the Niigata ICC for this material.
+
+Note that depending on timing and pallet availability, it may be the case that a
+pallet has already been activated by the time the operator removes the material.
+The operator must still remove the material from the queue as specified above,
+and then reject the load as specified in the next section.
+
+#### Load Station Material Can't Be Loaded
+
+Consider that a pallet arrives at the load station, the Niigata ICC is expecting something to be
+loaded, but the material is not available to be loaded. This could be because the material was removed
+from the queue as described in the previous section but because of the timing a pallet had already been
+activated. It could also be because the operator forgot to remove the material from the queue, or didn't
+notice that the material was bad until the load operation started.
+
+In any case, the operator should first confirm that the material is removed from the FMS Insight queue
+and then press the UNLOAD/NOT LOADED button. This will cause the Niigata ICC to route the empty pallet
+back to the stocker and as long as there is no material in the FMS Insight queues, FMS Insight will not
+reactivate the pallet until more material enters the queue.
+
+#### Reworked material is ready to re-enter the flow
+
+Consider when material was removed from the system or placed into [quarantine queues](material-quarantine)
+as described above, and now the material has been successfully fixed and is ready to complete the remainder of
+the process. Once the material arrives back at the load station and is ready to go, the operator adds the material
+back into the in-process queue. To do so, the operator clicks a button on the queues page, enters
+or scans the serial number of the material to be added, and then verifies the job and process number. The
+material will then be placed into the queue and FMS Insight will then activate the appropriate pallets
+in the Niigata ICC.