Diecut Production

The Diecut Production module manages die-cutting and conversion operations, tracking unit production, waste rates, die series usage, and multi-activity workflows for both rotary and flatbed die-cutters.

Overview

The diecut production system handles:

Multi-activity tracking for diverse conversion processes
Die series management and tooling status
Unit-based production tracking
Waste/scrap monitoring and rates
Frequency tracking for flatbed die-cutters
KPI dashboard with real-time metrics

Component: ProductionDiecutComponent
Location: src/features/production/production-diecut.component.ts

Data Models

DiecutActivity Interface

Represents individual activities within a diecut report:

type

string

required

Activity type (e.g., “TROQUELADO”, “SETUP”, “REPUJADO”)

startTime

string

required

Activity start time in HH:mm format

endTime

string

required

Activity end time in HH:mm format

qty

number

required

Quantity produced during this activity (0 for non-productive activities)

observations

string

Activity-specific observations or notes

DiecutReport Interface

Main report structure for diecut production:

string

required

Unique report identifier (e.g., “REP-TRQ-1000”)

date

Date

required

Report timestamp

string

required

Work order number

client

string

required

Client name (Razón Social)

product

string

required

Product description

machine

string

required

Machine name (e.g., “Plana 1”, “Rotativa 2”)

operator

string

required

Operator responsible for the shift

shift

string

required

Shift identifier (e.g., “Día - A”, “Noche - B”)

dieSeries

string

required

Die series/number used (e.g., “TR-8245”)

frequency

string

Frequency setting (flatbed die-cutters only)

goodUnits

number

required

Total good units produced

waste

number

required

Total waste/scrap units

dieStatus

'OK' | 'Desgaste' | 'Dañado'

required

Die tooling condition status

activities

DiecutActivity[]

required

Array of production activities

productionStatus

'PARCIAL' | 'TOTAL'

required

Production completion status

observations

string

General observations for the report

Activity Types

The system supports multiple conversion operations (operator-form.component.ts:557):

diecutActivityTypes = [
  'SETUP',
  'TROQUELADO',
  'ESTAMPADO',
  'LAMINADO',
  'REPUJADO',
  'TROQUELADO + PREPICADO',
  'PREPICADO',
  'PARADA-MANTENIMIENTO',
  'PARADA-TROQUEL DAÑADO',
  'PARADA-FALLA DE MÁQUINA',
  'PARADA-OTROS'
];

Activity Classification

Productive
Setup
Downtime

TROQUELADO: Standard die-cutting operation
ESTAMPADO: Hot foil stamping
LAMINADO: Lamination process
REPUJADO: Embossing operation
TROQUELADO + PREPICADO: Die-cutting with pre-perforation
PREPICADO: Pre-perforation only

KPI Metrics

The dashboard displays four key performance indicators (production-diecut.component.ts:420):

Unidades Producidas

const totalUnits = this.reports.reduce((acc, r) => acc + r.goodUnits, 0);

Sum of all good units produced
Displayed with comparison (e.g., “+8% vs semana anterior”)

Tasa de Mermas

const totalWaste = this.reports.reduce((acc, r) => acc + r.waste, 0);
const wasteRate = totalUnits > 0 ? (totalWaste / totalUnits) * 100 : 0;

Percentage of waste relative to total units
Lower percentages indicate better efficiency

Horas Operativas

const totalHours = this.reports.length * 8; // Estimated hours per report

Total operational hours across all machines
Estimated based on report count

Desgaste Herramental

const toolingIssues = this.reports.filter(r => r.dieStatus !== 'OK').length;

Number of reports with die issues (Desgaste or Dañado)
Indicates maintenance requirements

Die Status Management

Status Values

Die condition tracking (production-diecut.component.ts:442):

OK
Desgaste
Dañado

Color: Emerald (green)
Meaning: Die in good condition, normal operation
Class: bg-emerald-500/10 text-emerald-400 border-emerald-500/20

Color: Yellow/Amber
Meaning: Die shows wear, maintenance recommended
Class: bg-yellow-500/10 text-yellow-400 border-yellow-500/20
Action: Schedule resharpening or replacement

Color: Red
Meaning: Die damaged, cannot be used
Class: bg-red-500/10 text-red-400 border-red-500/20
Action: Immediate replacement required

Status Logic Example

// From production-diecut.component.ts:380
const dieStatus = index % 5 === 0 ? 'Desgaste' : 
                  (index % 20 === 0 ? 'Dañado' : 'OK');

Flatbed vs Rotary Die-Cutters

Machine Type Detection

The system automatically detects machine type (operator-form.component.ts:617):

get isFlatbed(): boolean {
  return (this.machineName || '').toUpperCase().includes('PLANA');
}

Flatbed-Specific Features

Flatbed die-cutters require frequency tracking, which specifies the number of strokes or cycles per operation.

// Flatbed frequency input (operator-form.component.ts:299)
<div *ngIf="isFlatbed" class="bg-purple-500/10 border border-purple-500/20 rounded-xl p-4">
  <label>Frecuencia (Troqueladora Plana)</label>
  <input type="text" [(ngModel)]="formData.frequency" 
         placeholder="Ingrese frecuencia...">
</div>

Report Workflow

Access Module

Navigate to operator terminal and select Troquelado station (ST-02)

Select Machine

Choose die-cutting machine from available equipment:

Rotary die-cutters (Rotativa 1, Rotativa 2)
Flatbed die-cutters (Plana 1, Plana 2)

Search Work Order

Enter OT number or use autocomplete to find:

Work order number
Client name
Product details

Enter Die Series

Record the die series/number being used (e.g., “TR-8245”)The system may auto-populate from OT data:

dieSeries: ot.troquel || `TR-${ot.OT.slice(-4)}`

Set Frequency (Flatbed Only)

If using a flatbed die-cutter, enter the frequency setting

Add Activities

For each activity during the shift:

Select activity type
Enter start time
Enter end time
Enter meters produced
Add activity-specific observations
Click Agregar

System tracks total meters across all activities.

Record Die Status

Inspect and select die condition:

OK: Continue normal operation
Desgaste: Note for maintenance scheduling
Dañado: Requires immediate attention

Set Production Status

Choose:

PARCIAL: Shift closure, work order incomplete
TOTAL: Work order fully completed

Add Observations

Document:

Die performance issues
Quality concerns (e.g., “Troquel presenta rebabas en bordes derechos”)
Material issues
Handoff notes

Submit Report

Click Confirmar y Guardar ReporteSystem creates audit log:

details = `Op: ${operator}, Troquel: ${dieSeries}, ` +
          `Actividades: [${activitySummary}], Total Mts: ${totalMeters}`;

Activity Tracking Example

Typical diecut shift activities (production-diecut.component.ts:383):

const activities: DiecutActivity[] = [
  { 
    type: 'SETUP', 
    startTime: '08:00', 
    endTime: '09:00', 
    qty: 0 
  },
  { 
    type: 'TROQUELADO', 
    startTime: '09:00', 
    endTime: '12:00', 
    qty: Math.floor(goodUnits * 0.4) 
  },
  { 
    type: 'REPUJADO', 
    startTime: '12:00', 
    endTime: '14:00', 
    qty: Math.floor(goodUnits * 0.3) 
  },
  { 
    type: 'TROQUELADO', 
    startTime: '14:00', 
    endTime: '16:00', 
    qty: Math.floor(goodUnits * 0.3) 
  }
];

Clicking a report row opens detailed view showing:

Product Information Section

Client name
Product description
Machine assigned
Operator name

Production Metrics Section

Unidades Buenas

Total good units produced (large emerald display)

Mermas

Total waste units (large red display)

Troquel Usado badge shows die series with status indicator

Activities Table

Columns:

Actividad: Activity name with status dot
Horario: Time range
Duración: Calculated duration
Cant. Prod.: Quantity produced
Obs: Activity-specific observations

Footer displays Total Producción sum.

Search and Filtering

Real-time search across multiple fields (production-diecut.component.ts:410):

get filteredReports() {
  const term = this.searchTerm.toLowerCase();
  return this.reports.filter(r => 
    r.ot.toLowerCase().includes(term) ||
    r.machine.toLowerCase().includes(term) ||
    r.dieSeries.toLowerCase().includes(term) ||
    r.client.toLowerCase().includes(term)
  );
}

Searchable fields:

OT number
Machine name
Die series
Client name

Waste Rate Analysis

Calculation

const totalWaste = reports.reduce((acc, r) => acc + r.waste, 0);
const totalUnits = reports.reduce((acc, r) => acc + r.goodUnits, 0);
const wasteRate = (totalWaste / totalUnits) * 100;

Visual Indicator

Waste rate is displayed with a progress bar:

<div class="w-full bg-slate-700/50 h-1.5 rounded-full">
  <div class="bg-red-500 h-full rounded-full" 
       [style.width.%]="kpis.wasteRate * 10">
  </div>
</div>

Interpretation:

< 2%: Excellent
2-4%: Good
4-6%: Acceptable
> 6%: Requires investigation

Best Practices

Inspect die condition before starting production

Record exact die series number for traceability

Document any die wear immediately when noticed

For flatbed machines, always record frequency setting

Track waste by activity to identify problem areas

Add observations for any quality issues or die performance

Never continue production with damaged dies - mark as “Dañado”

Schedule maintenance when die status is “Desgaste”

Verify unit counts match expected quantities for the OT

Print Production - Printing operations
Rewind Production - Rewinding operations
Operator Mode - Full-screen operator interface

Overview

Getting Started

Core Features

Production Modules

Inventory Management

Quality & Analytics

Administration

Diecut Production

Overview

Data Models

DiecutActivity Interface

DiecutReport Interface

Activity Types

Activity Classification

KPI Metrics

Unidades Producidas

Tasa de Mermas

Horas Operativas

Desgaste Herramental

Die Status Management

Status Values

Status Logic Example

Flatbed vs Rotary Die-Cutters

Machine Type Detection

Flatbed-Specific Features

Report Workflow

Activity Tracking Example

Product Information Section

Production Metrics Section

Unidades Buenas

Mermas

Activities Table

Search and Filtering

Waste Rate Analysis

Calculation

Visual Indicator

Best Practices

Build docs developers (and LLMs) love

Overview

Getting Started

Core Features

Production Modules

Inventory Management

Quality & Analytics

Administration

​Overview

​Data Models

​DiecutActivity Interface

​DiecutReport Interface

​Activity Types

​Activity Classification

​KPI Metrics

​Unidades Producidas

​Tasa de Mermas

​Horas Operativas

​Desgaste Herramental

​Die Status Management

​Status Values

​Status Logic Example

​Flatbed vs Rotary Die-Cutters

​Machine Type Detection

​Flatbed-Specific Features

​Report Workflow

​Activity Tracking Example

​Report Detail Modal

​Product Information Section

​Production Metrics Section

Unidades Buenas

Mermas

​Activities Table

​Search and Filtering

​Waste Rate Analysis

​Calculation

​Visual Indicator

​Best Practices

​Related Modules

Build docs developers (and LLMs) love

Overview

Data Models

DiecutActivity Interface

DiecutReport Interface

Activity Types

Activity Classification

KPI Metrics

Unidades Producidas

Tasa de Mermas

Horas Operativas

Desgaste Herramental

Die Status Management

Status Values

Status Logic Example

Flatbed vs Rotary Die-Cutters

Machine Type Detection

Flatbed-Specific Features

Report Workflow

Activity Tracking Example

Report Detail Modal

Product Information Section

Production Metrics Section

Activities Table

Search and Filtering

Waste Rate Analysis

Calculation

Visual Indicator

Best Practices

Related Modules