Warren Systems, Inc.
A b o u t    U s

TWP Expansion Software Modifications (Exhibit A)

The following details the software modifications to be made to the IDAB and/or the PLC software to change the functionality of the existing system.

  1. define key bundles at truck pre-Check-in
  2. The system is currently responsible for producing a current list of key bundles required by the distribution system. Each program scan, the list of key bundles is recreated from the trucks that are checked in and released. In order to minimize the impact of this functionality, no changes to the existing process is proposed.

    Rather, a program process will be added to the end of this cycle. This process will loop through all the trucks that have pre-checked in, but are not actually checked in. Once that determination is made, the identical routine as currently used will be called. This will ensure that no errors are made in the calculations, and ensure that as rules for the building of key bundles change, all affected processes are consistent.

    The strict demand priority of the key bundle list can no longer be enforced, as these trucks will be added to the key bundle list's end, but that gives an added benefit as well. A lower priority truck that is already checked in will have an entry in the list before the pre-checked in trucks, allowing valuable, occupied dock space to be freed up sooner. As the other trucks finally check in, their place in the key bundle list will rise according to its priority.

  3. credit key bundles at a hand build station
  4. The single modification necessary in the Springfield Tray Control software is to make to the display program call the demand crediting routine whenever the destination for a key bundle is not connected to the network. There is no need for special flags to incorporate this hand build line. This will allow additional Key Bundle Stations to be defined in the future by simply placing entries in the data base tables.

    To implement the Key Bundle Station, a new super-entity, KYR1, will be added to the database. (By the creation of this entity, a place to hold the object record that is created when an operator builds a key bundle is defined.) This entity will not be connected to any place in the existing Springfield Tray Control network. The super entity is required for the link between the Springfield Tray Control network and the data base entry for the touch control screen. The screen device will be named KLMR1, to indicate that the device is the first Key Line Monitor in the Robinson. The mapping between the screen number defined for KLMR1, and the terminal server port will also be defined in the database.

    The hand-build Key Bundle Station will consist of a floor-mount pedestal containing a touch control monitor. The equipment required is detailed in Exhibit B, item A5. It will be connected to the terminal server in the Annex by the Electrical Contractor.

  5. augment final draw amounts at truck pre-Check-in
  6. The Pre-Checkin stations will be able to perform an interactive dialog with the truck driver. Upon entering the truck identification, the touch screen will display the draw amount for the first load the truck must pick up, along with unique product identification information. The driver will be able to accept that amount, or enter a new amount. This process will repeat for all of the different loads, if any, that the driver must receive.

    By defining a data base flag for Pre-Checkin stations that will have this functionality, flexibility is given to the system network programmer, and a phased implementation of the project as a whole, is realized. A restart of the software will be required to change the function of a Pre-Checkin station.

    As the new amount is typed in, the characters will echo in both of the New Quantity fields. Pressing the Reject key will remove the keypad and New Quantity fields, and the display will return to the prior screen, while pressing the Accept key will cause the new value to be accepted by the control system. The next demand for the truck, if any, will then be displayed. This process will repeat, until all draw amounts have been accepted.

    The product code and draw amount for this demand entry will be displayed on the touch control system screen, along with instructions to accept or modify the amount. The driver can accept the amount displayed, if it is correct. If the amount is to be changed, a numeric keypad will be displayed. The driver can then "key in" a new amount. Keys to allow backspacing and clearing the new entry will be provided. The "accept" button will again be displayed, along with a button to revert to the original amount. This process will continue until the "accept" option is selected. All demands that the truck must deliver will be displayed for acceptance and/or modification in this fashion. The pre-Check-in status will only be set at the completion of this dialog.

  7. socket communication
  8. A new task will receive messages when pallets are to be credited to the truck that is checked in to the Pallet Load Dock in the Robinson Terminal Annex. A new Check-in station, CINRP, for the "Robinson Palletizer" station will be added, and a Truck Load Monitor, TLMRP, will be added for driver Check-in.

    The task to receive pallet messages, SOCKET_HOST_CP will be added to the software startup file, and to the data base list of monitored tasks, used to alert the console operator of any failures. This task will be modeled after the existing socket communication software will be added to the set of software that runs on the VAX. The task will create a socket, bind to it, and listen on that channel. When it receives a message of type ‘CP', it will Credit the Pallet to the truck that has been checked in. The proposed format of the message is:

    CP, truck name, product name, dateline, package type, manifest info, bundle quantity, paper quantity, time stamp

    All parameters are identical in format to the existing "HP" command that is sent to the warehouse system by the VAX when the Tray Control console operator executes the "RHP" command. The time stamp parameter has been added as an aid in debugging, and should indicate the time the message was originally generated. Ideally, this time should closely match the time of the bar code scan.

    The port number of the socket must be furnished by TWP for inclusion in the software source code. No special coding is required for the network devices, Check-in operation, automatic logout operation at load completion, nor the TLM. Logs of all messages may be activated, and errors will also be logged to the standard logging facility of the Tray Control software.

    The warehouse system may need to be modified to send the Annex designation. This modification will not be performed by WSI, and is not part of this agreement.

  9. Wonderware interface for the additional straight-throughs
  10. The Man Machine Interface (MMI) will be a PC based system consisting of a Pentium processor running Wonderware operator interface software under Windows NT operating system. The screens will be developed to provide the same level of control interface and display as the current system.

    Communications from the PLC to the MMI will be through the Ethernet Hub. A 120 VAC UPS, provided by TWP, will supply the power for this PC.

    The Wonderware interface will prove to be user-friendlier than the panel view currently in use in the Upper Mailroom tray control office. The Wonderware Development tools are listed in Exhibit B, items A11, and B1. It is strongly recommended that the sub-contractor for future support issues retain this. Assembly and Installation are provided.

  11. credit bundles delivered to non-warehouse trucks at Straight-through Conveyors
  12. Modifications to the VAX will be necessary to cause bundle countdowns for non-warehouse trucks receiving bundles directly from the Straight-through Conveyor system. In this fashion, when the demand at the dock has been satisfied, the pacer will shut and allow no more bundles to be delivered.

  13. provide conveyor running status from new Straight-through Conveyors
  14. The PLC interface will be modified to accommodate a dock running status.

  15. automatic dock assignment after truck pre-checks in
  16. The VAX resource allocation task will process all trucks that are in the transition phase, and determine the best dock by selecting the first (lowest numbered) dock that is in the range for the manifest code of the demand. A designation of "W" is used for warehouse demands to be satisfied at the straight-through docks in the lower mailroom. No designation is used for the normal truck docks in the lower mailroom. An "A" can be used to denote warehouse demands to be satisfied only at the straight-through docks in the Annex. If all are occupied, the determination will be according to the closeness to completion. Once a determination has been made, it will not be changed. However, the truck driver can check in to any dock, regardless of the displayed information.

    As trucks are checked in, the message information will be updated to remove the truck from the marquee display. Any messages generated by the Tray Control operator will be interlaced with the display of dock assignment messages.

    Message modification will be required if the warehouse information (Annex versus Lower Mailroom) is to be returned in the response. This effort is not part of this agreement.

  17. warehouse product request after truck pre-checks in
  18. The program that processes the Pre-Checkin stations will be modified to check for a warehouse product in the manifest for the truck. If one is found, the RHP command will be sent to PCS_USER. This simulates the same function as the Tray Control operator issuing the command, and will cause the manifest record to appear on the warehouse display screens of the Tray Control system.

  19. key bundle credit on Straight-through Conveyors
  20. The VAX socket communication task that accepts the Warehouse product availability response will be modified to place the key bundle at the head of the entity, and the remaining bulk sized bundles behind. In this fashion, the key is credited when the first bundle goes by the pacer, and the remainder is credited as bulk.

    The warehouse system may need to be modified if the parameter is given to the VAX as bundles, instead of papers. This effort is not part of the agreement.

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May 1, 2001
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