Scrap Table Setup
Summary
Scrap calculation in PrintVis is managed through tables attached to a cost center's configuration. Scrap tables are vital for accurately calculating scrap in processes such as printing, finishing, and other operations.
Setup
Accessing Scrap Tables
- Search for "Scrap Tables" and select "PrintVis Scrap Tables" to set up or modify scrap tables.
Parameters
- Scrap Group: Defines the parameters for scrap calculation.
Header Fields
| Field Caption | Description |
|---|---|
| Code | Enter a code for this scrap table. This can be selected in a cost center configuration. |
| Description | Enter a description for this scrap table. |
| Format Type | Select the format type for the format entered in the scrap table lines. Available options include: - Blank: No format required. - Job Item Format: Reads format from the job line (e.g., A formats), commonly for finishing processes. - Printed Sheet Format: Reads the printed sheet format, used for printing machines. The format is read for each process line in the job. - Paper Sheet Format: Reads the raw sheet format, typically for printing machines. - Plates: Reads from the individual printing process line (rarely used). - Film: Reads from the printing process line if films are attached to the sheet. |
| Weight Unit | Used for Imperial paper weights only. Select the weight unit for the weight entered into the table lines. Leave blank for M-Weight. |
| Formula 1/2 | Add up to two formulas if additional values or parameters are required. This is configured via the Formula Principle field. |
| Formula Principle | Determines how formulas are applied. Options include: - Parameter: Adds the formula's value as scrap quantity, allowing you to define custom scrap values. - Read from: Uses the formula value to determine which line to use, such as "Quantity From" or "Scrap Group." |
Fields in Scrap Table
| Field | Description |
|---|---|
| Product Group | Read from the job line. Use this if product groups impact scrap calculation, e.g., for rotary machines or finishing processes. Create a blank section for cases where no specific product group applies. |
| Scrap Group | Contains predefined groups like "easy," "medium" (blank), and "difficult." Use these groups to grade the scrap table. |
| Format Code | Uses sliding format lookup, reading the nearest value. Create a blank section to handle unexpected formats. |
| Weight | Works as intervals. For sheet-dependent processes (e.g., printed sheets), the system reads the paper weight. For processes across sheets (e.g., stapling), it reads the job line weight. |
| From Signature Quantity | Reads the number of sections in a printing process from the job item table as intervals. |
| No. of Runs | Functions as an interval. Reads the number of runs for the individual printing process from the value on the line up to the next. |
| Formula 1 / 2 | Defines scrap calculation for selected formulas. Example: Formula 2 (number of colors) with a value of 25 calculates 100 scrap units for a 4+4 job (4 x 25). Use "read from" mode to return the formula's calculated quantity instead. |
| From Quantity | Indicates the net printing sheet quantity. Scrap is calculated for one sheet set by default. To calculate for all sheet sets, use a formula. |
| Per Sheet/Section Scrap | Quantity of scrap sheets assessed per printed sheet (e.g., start scrap). |
| Sheet/Section Following Scrap | Adds scrap for subsequent sheets, influencing only the first sheet of the process. |
| Scrap % Running | Fixed percentage of scrap used for control purposes or machine operations. Added to other defined scrap. |
| Per Plate Scrap | Layout scrap based on the number of plates used in the printing process. |
| Plate Following Scrap | Scrap for additional plates, influencing only the first plate. Adds values for subsequent plates. |
| Per Processing Scrap | Scrap generated when the machine starts a run. Number of runs depends on colors and rolls/towers. For example, 4 colors on a 2-color machine require 4 runs, increasing scrap. |
| Per Shift Scrap | Scrap caused by machine stops for plate shifts, such as changing languages. Calculated if specified in the sheet settings. |
| Per Plate in Shift Scrap | Scrap for additional plates during shifts. |
How PrintVis Calculates Scrap
- From Quantity: Actual quantity indication in the scrap table.
- Per Sheet/Section Scrap: Scrap quantity per printed sheet.
- Sheet/Section Following Scrap: Scrap for additional sheets.
- Scrap % Running: Fixed percentage of scrap during running.
- Per Plate Scrap: Scrap based on the number of plates used.
- Plate Following Scrap: Scrap for additional plates.
- Per Processing Scrap: Scrap expected at the start of a run.
- Per Shift Scrap: Scrap for machine stops during a shift.
- Per Plate in Shift Scrap: Scrap for additional shift plates.
- For finishing operations, use "Per Processing" rather than "Per Sheet" to calculate scrap for the entire job.
- Scrap is calculated for each process and totaled backward from the last to the first process.
Calculation of the "Quantity Fromm" Field
- Formula Principle = "Read From"
- Formula 1 = 62: Determines fixed scrap based on the number of colors.
- Formula 2 = 221: Determines total net rotations for the sheet.
If a job has: - 1 sheet set of 100,000 rotations for a 4-color job: Line 1 applies (4000 fix + 20% running scrap). - 2 sheet sets of 100,000 rotations: Line 2 applies (4000 fix + 18% running scrap).
For different quantities, the "From Quantity" remains as per the formula used.
