On a Coil tail-out the tailed coil must be classified as Completely Used, Returned to Inventory or Not Unloaded. There is an Unload Coil Window that requires this classification to occur.

The software was not accounting for the possibility that an operator may turn power off to the machine while the Unload Coil screen is active. The window is displayed as soon as the coil tails out. It is very possible, near the end of a shift, that there may be no more production for the day and the machine gets turned off before threading the next coil. Because the tailed Coil was not classified, it is still considered the current coil. When the new coil is threaded, the software has no reason to prompt for a new coil. All the new coil’s production was getting attributed to the tailed coil.

The result of this scenario is the tailed coil gets double production tracked to it and the new coil gets none. The customers inventory still believes it has the new coil available for use.

To fix this issue, the state of tail-out will now be remembered throughout a power cycle. The Unload Coil screen will be presented after the power-up, requiring the tailed coil to be classified.