Finding 1 — [InjectionMolding → InspectionSorting] No PartTaken ACK After CycleDone
FINDING TYPE: Inter-Station Missing Handshake
INJ_MOLD_Status.CycleDone is produced outbound to InspectionSorting but no PartTaken or BinReady ACK is consumed back before the next cycle is permitted.
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INJ_MOLD_PLC
● 5 Programs● 18 Routines● 32 AOI Logic● 75 Tags
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RLL
ST
AOI
Tags
TASKS
18 items
MainTaskCONTINUOUS · P1012 items
MainProgram11 items
ROUTINE
r_Main
● ST
ROUTINE
r_IOMap
● ST
ROUTINE
r_PressureAndTemp
● ST
ROUTINE
r_TCU
● ST
ROUTINE
r_RFID
● ST
ROUTINE
r_CycleInterlock
● ST
ROUTINE
r_CycleManager
● ST
ROUTINE
r_Purge
● ST
ROUTINE
r_Alarms
● ST
ROUTINE
r_ProducerTags
● ST
ROUTINE
r_OutputMap
● ST
MaintenanceProgram1 item
SafetyTaskPERIODIC · 20ms · P14 items
SafetyProgram4 items
IOUpdateTaskPERIODIC · 20ms · P51 item
IOMappingProgram1 item
DiagnosticsTaskPERIODIC · 100ms · P101 item
DiagnosticsProgram1 item
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Project: InjectionMolding · Line: Line 1 Brick creation(3 stations)
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<> Control Engineer (Owner) · Packaging (auto-detected)
Audit safety interlocks
Find race conditions
Line cycle-time bottleneck
PackML compliance report
Find me missing handshakes on the line level and provide a downloadable report.
Thinking...
🤚 Line-level Handshake Analysis in progress...
Looking across 3 stations — checking handshake pairs at boundaries...
Generating response... · 00:09
Line-Level Missing Handshake Audit — Line 1 Brick Creation
Analysis covers every Producer/Consumer pair and cross-boundary sequencing gap across all 3 loaded L5X projects.
5 issues identified:
•
INJ_MOLD_Status.CycleDone sends to InspectionSorting but no PartTaken ACK returns.
•
MAT_PREP_Status drives material-ready toward ST10 but no MaterialConsumed ACK flows back.
•
INJ_MOLD_Status.CO_Done is flagged but never assigned — downstream never sees a valid changeover-complete signal.
Writing report...
line1-missing-handshake-report.md
| 1 | InjectionMolding → InspectionSorting | Missing Handshake (no PartTaken ACK) | HIGH |
| 2 | ST10 → InjectionMolding | Missing Handshake (no MaterialConsumed ACK) | HIGH |
| 3 | InjectionMolding → ST10/InspectionSorting | Undriven Produced Tag CO_Done | HIGH |
line1-missing-handshake-report.md
Report · 19.8 KB
SOURCES:
← [ST10] MaterialPrep
← InjectionMolding
← InspectionSorting
SKILLS
/cycle-time— Detects waiting times and bottlenecks