GES Manufacturing Service (M) Sdn Bhd (Venture Corporation) · Senai, Johor
Introduced via MLR Machinery (Eric Chew), Prisma Technology is delivering the software layer for GES's factory floor traceability and oven data management initiative.
"After verified with Master Data then send PASS/FAIL to conveyor controller (at least 1 output, for IO module) to allowed/blocked the parts — with tower light alert."
— Meeting notes, 6 Aug 2026 (MLR Machinery / Prisma alignment)
Scan 5 items per cycle against a master list. Send PASS/FAIL signal to conveyor controller via DI/DO module. Full audit trail for every cycle.
Read Heller oven JSON recipe files from a Windows shared folder on the Heller PC, convert to Excel/CSV, detect changes against a master reference, and alert management via email when recipe changes.
At each of 12 production lines, an operator logs in and scans 5 items. The system checks all 5 against the master list and releases the conveyor stopper only on PASS.
The Heller reflow oven exports recipe files in JSON format. This module reads those files, displays them in-system, exports to Excel, and gates any significant changes through an approval workflow.
Eric Chew sent the Heller reflow oven JSON recipe file and the Excel controlled form on 7 Aug 2026. The analysis below is drawn directly from those files.
SW v3.12.1J8-A16382H9C2-RSSBelt label: Main · setpoint: 85.0 cm/min
idsetpointhiProcAlarmloProcAlarmhiAlarmloAlarmhiWarnloWarnalarmkpkikddeadbandoffsetlabelnitrogenControl| Field | Value (all 13 zones identical) | Meaning |
|---|---|---|
| hiWarn / loWarn | ±15 °C | Zone temp deviates >15 °C from setpoint → oven issues warning |
| hiAlarm / loAlarm | ±40 °C | Hard alarm — oven triggers directly |
| hiProcAlarm | 400 °C | Absolute upper limit — prevents overtemperature |
| loProcAlarm | 0 °C | Absolute lower limit — detects broken thermocouple |
| deadband | 2 | PID dead zone (°C) — prevents hunting |
| offset | −1.0 | Thermocouple calibration correction |
GES currently records oven recipes manually on form QR-AS-100 B/AS-02-062 — an auditable controlled document. Module B must produce an equivalent digital output.
2 sheets · ~12 recipe blocks per file · same model appears twice (CS row + SS row)
| Excel Field | JSON Source |
|---|---|
| TOP 1–13 | topZones[].setpoint |
| BOTTOM 1–13 | bottomZones[].setpoint |
| SPEED (CM/MIN) | belts[0].setpoint |
| MODEL | NOT in JSON — must come from master data or filename convention |
| CUSTOMER | NOT in JSON — must come from master data |
| LINE | NOT in JSON — inferred from file path / source PC |
| CS / SS | NOT in JSON — may be in recipe filename (e.g. RSS suffix) — pending GES confirmation |
The JSON file and GES's verbal requirement each describe a different kind of tolerance. They are not interchangeable. Conflating them would produce the wrong system.
The JSON warn/alarm fields protect the oven from overtemperature during a run. The tolerance GES requires protects the process from unauthorised recipe changes before a run. Different timing, different purpose, different data source. The Prisma system must build and manage the Tolerance Master independently — it cannot read it from the oven JSON.
The following items are unconfirmed and must be resolved before Module B development can be fully specified. Items are marked as INFERENCE (reasonable assumption, not confirmed) or EVIDENCE (from received files or meeting notes).
INFERENCE awaiting GES confirmation. If per-zone per-model, the Tolerance Master table is significantly more complex. Impact: database schema and maintenance UI design.
INFERENCE awaiting GES confirmation. Determines the comparison engine formula. A ±5 °C tolerance at 150 °C is very different from ±5%.
INFERENCE awaiting GES confirmation. Hard-block = recipe cannot be used until approved. Approval-gated = recipe can proceed but requires management sign-off within a time window. These have different development complexity and operational risk profiles.
INFERENCE awaiting GES confirmation. The Excel form shows the same MODEL appearing twice (CS row, then SS row) with different temperature profiles. Industry convention = Component Side / Solder Side (two oven passes). If confirmed, the master reference must store two profiles per model — more complex than a single profile per model.
INFERENCE awaiting GES confirmation. The sample recipe is named J8-A16382H9C2-RSS. J8 may be the line number; RSS may encode the profile type (matching CS/SS). MODEL and LINE are not inside the JSON — if they can be reliably parsed from the filename, that resolves the mapping gap without needing a separate lookup table.
Context from sample. Each zone contains 16 fields; across 28 zones the total is ~460 comparable values. If all fields are monitored, minor PID tuning (kp/ki/kd) will generate frequent alerts. GES must define which parameters are process-critical (likely: setpoint, offset, belt speed, alarm bands) vs which are routine machine maintenance (PID gains, deadband).
INFERENCE awaiting GES confirmation. Customer audit requirements may specify a minimum retention period (e.g. 3 years, 5 years). Determines storage capacity planning for the oven history log.
Fully on-premises. Factory floor network is completely isolated from the office network. One industrial server hosts both modules; 12 mini PCs run a browser and connect via factory LAN.
| Role | Parts Scanning | Oven Module | Admin Functions |
|---|---|---|---|
| Operator | Run scans, view own results | View recipes, run exports | — |
| Technician | Operator + (TBC overrides) | TBC | TBC |
| Admin | Full + master list mgmt + override log | Full + approve recipe changes | User mgmt, system config, full audit |
Phase 1 pilots on a single production line for validation and sign-off. Phase 2 rolls out to all 12 lines after pilot acceptance.
Prisma Technology leads software delivery. MLR Machinery handles all hardware and physical installation.
The following items require confirmation from GES or the team before development can begin on the respective components.
Without a real sample, Module B cannot be scoped or developed. Please share any recent recipe export from the Heller oven PC.
GES to provide full model, brand, and I/O spec by 8 Aug 2026. Required to confirm DI/DO port availability for stopper control.
Name, phone number, and role of the primary contact at GES for this project. Required before direct requirements alignment meetings.
Exact wiring, port assignment, and protocol for the DI/DO module connecting the server to the conveyor controller. Dhai to align with Eric after receiving mini PC specs.
Exact fields GES's customer mandates for traceability reports (IPC-A-610 or customer-specific format). Affects audit log schema design.
Prisma proposes to auto-load the Model from the production planning document (work order / schedule). GES to confirm: what format is the planning document? Is it a file, an ERP export, or a printed sheet? This determines how the system reads it.
Mentioned in post-meeting notes. To be confirmed with GES: is the Squeegee one of the items to be scanned and tracked in this system?
How many consecutive FAIL attempts before the station locks and requires Admin/Technician unlock? Dhai to recommend a number for Jay's approval.
How many years / months must audit records be retained on the server? Required for storage capacity planning.
What specifically can a Technician do that an Operator cannot? E.g., override FAIL, view full logs, modify settings.