PacketStation/docs/PAPER-FALLBACK.md

Packet Station paper fallback

What the shop does when Packet Station is down, so work keeps moving, and how the paper is brought back in afterwards. This is requirement O3. It was written from the build and the old paper packet. Seth and the shop supervisors check it before go-live. Points they still have to settle are marked TBD.

The incident steps for IT (who to call, restore) are in GO-LIVE.md, "Incident notes".

What "down" means

Packet Station is down when people cannot open it or cannot save in it. Some outages are partial:

What is down	What still works	Go to paper?
Packet Station (the VM, the app or its database)	Nothing in Packet Station. VISUAL and the labor kiosk are separate and still work.	Yes
Active Directory	Screens that are already signed in keep working. New sign-ins, by password or PIN, fail.	Only for people who cannot sign in. Keep signed-in screens open.
VISUAL	Every packet already in Packet Station. The feed stops, so no new drafts and no closes from VISUAL until it is back.	No. Clerical waits for the feed.
M-Files	Every packet that has its drawing. New drafts wait for their drawing, or Clerical uploads it by hand.	No
Email	Everything. Notices are sent when mail is back.	No
The network in one building	Packet Station, from the other buildings.	That building only.

Who declares it

• Anyone who cannot work calls their supervisor. The supervisor calls Spencer (IT).
• Spencer says what is down and how long it may take.
• Seth decides whether the shop goes to paper, and tells the supervisors. TBD (Seth): how long to wait before going to paper. The suggestion is 30 minutes, or at once when Spencer expects a long outage.
• Seth also says when the outage is over and the paper is to be entered back.

Before an outage: what is kept ready

Kept ready all the time, so nobody has to print during an outage. TBD (Seth): who keeps each set up to date, and how often.

Form	Where it comes from	Kept by	Where
Job traveler for each packet in the shop	Packet Station, the traveler print on the packet. It has the job details, the work orders with their QR codes for the labor kiosk, the BOM with heat numbers, the department checklist with blanks to stamp, the weld log, the weld record, the sign-offs and a notes box.	The department supervisor	With the job at the station, or in the supervisor's folder
Drawing with the heat or weld map	Packet Station, the drawing print on the packet	The department supervisor	With the traveler
Blank checklist for each department	The department's list on the Checklists screen, printed with the browser's own print (Ctrl+P)	Each supervisor	Supervisor's desk
Blank weld log and heat number sheet	TBD (Seth and Q.C.): a blank form. Packet Station has no blank form; the traveler's weld log is filled in for a known packet.	Each supervisor	Supervisor's desk
Blank warehouse pull and short sheet	TBD (Warehouse supervisor): a blank form, or the traveler's BOM table	Warehouse supervisor	Warehouse desk
Blank Q.C. inspection sheet	TBD (Q.C. supervisor): Q.C.'s own form. Packet Station has no blank Q.C. form.	Q.C. supervisor	Q.C. office
The list of jobs in the shop with their status	Packet Station, the board of each screen, printed with Ctrl+P, or the PM report PDF	Clerical	Clerical office
A printed copy of this file and of the GO-LIVE.md incident notes	This repo	Clerical and each supervisor	With the forms

Every print from Packet Station carries the PRINTED COPY stamp with the drawing revision and "verify revision before use". A printed traveler or drawing can go stale if a change order comes in later. Print fresh copies when a change order is approved.

The suggestion is that a supervisor prints the traveler and the drawing when a packet is assigned to a station, so every job in the shop always has its paper copy at the station. TBD (Seth): whether to do that for every packet or only keep blank forms.

During an outage

General rules for everyone:

• Keep working the job you have. Nothing in an outage changes how the work is done, only where it is written down.
• Write on the paper traveler or the blank form for that job: the job and lot, the date and time, your name and employee ID, your stamp, and what you did. Write the time a step was done, not the time it is entered later.
• One sheet per job per department. Do not write two jobs on one sheet.
• Keep the sheets with the job until the outage is over, then give them to your supervisor.
• Clock labor at the VISUAL labor kiosk with the QR codes on the traveler, as usual, if VISUAL is up. Over target is decided on those ticket hours, not on the station clock.

By department:

Clerical

• Stops releasing new work in Packet Station. VISUAL keeps releasing; the feed makes those drafts when Packet Station is back.
• Does not file anything. Filing needs Packet Station (the seal and the data book are built on the server). Jobs ready to file wait.
• Keeps the list of jobs in the shop and notes any job that moves between departments on paper.
• Collects the paper sheets from the supervisors at the end of each shift.

Warehouse

• Pulls parts from the printed traveler's BOM. Writes the heat number, the quantity issued and the location for each line on the sheet.
• Writes shorts on the sheet with the reason (use the same reasons as in Packet Station) and the quantity short.
• Keeps the MTRs for the job with the sheet.
• Hands the parts to the department with the sheet, as on the old paper packet. The release is entered in Packet Station afterwards.

Shop supervisors

• Assign work on paper: write the station and the welder on the traveler.
• Approve received shorts by checking the part and its heat against the sheet, and initial the line.
• Verify change orders that were already approved before the outage, on paper. New change orders wait for Packet Station.
• Collect every sheet from the stations at the end of each shift and hand them to Clerical.

Stations and welders

• Work from the printed traveler and drawing.
• Mark each weld on the printed drawing's weld map, and the heat numbers on its heat map, as in the old paper packet.
• Fill in the checklist blanks, the weld log (weld, welder stamp, process, filler) and the weld record (filler metal and lot, preheat).
• Write the start and stop times on the traveler. The station clock in Packet Station cannot be set by hand; the times go into the notes when entered back.
• Sign off on the traveler with your stamp where you would sign in Packet Station.

Q.C.

• Inspects from the traveler and the drawing, on the Q.C. inspection sheet.
• Writes accept or reject, with the reason for a reject and the NCR number when there is one.
• Keeps NDE and other reports with the sheet.
• ITP lines and block signatures are written on the printed ITP and entered afterwards. TBD (Q.C. supervisor): whether Q.C. keeps a printed ITP for each open unit.

Project Management

• Uses the last printed report. Packet Station has no reports during the outage.

After an outage: entering paper back

Start when Seth says the outage is over. Enter everything before new work starts on that job.

Who enters what:

What	Entered by	In Packet Station
Warehouse pulls, heats, shorts, MTRs	Warehouse	The pull table on the packet; MTRs uploaded on the line
Release to the department	Warehouse	Release on the warehouse board
Assignment to a station and welder	The supervisor	Assign on the supervisor board
Welds, heat marks, checklist, weld record	The welder who did the work, or the supervisor	The weld map, the heat table, the checklist and the stage fields
Submit and send to Q.C.	The welder, then the supervisor	Submit (with the welder's own PIN), send to Q.C.
Short approvals	The department supervisor	Approve each received short, with a signature
Q.C. inspection, accept or reject, reports	Q.C.	The Q.C. tab, accept or reject with a signature, documents
ITP lines and signatures	Q.C.	The unit's ITP

Rules for entering back:

• Each person enters and signs their own work, with their own PIN or password. Nobody signs for someone else. If a person is not there, their supervisor enters the data and the person signs when back.
• A signature records the time it is entered, not the time on the paper. Write in the notes of each step: "Entered from paper, done by ."
• The station clock cannot be back-dated. Write the paper start and stop times in the stage notes.
• Packet Station checks every entry as it always does. If it refuses a step (a heat number missing, a checklist item not ticked), the paper is incomplete. Ask the person who did the work. Do not invent the missing value.
• An Admin can enter data outside custody only with an IT reason, and it is marked as an IT edit. Use that only when the department cannot enter it, and say why.

Who checks it:

• Each department supervisor checks, the same shift, that everything on their paper sheets is in Packet Station for their department, and initials the sheet.
• Q.C. checks the welds, heats and inspection results against the paper before the Q.C. accept, as on any packet.
• Clerical collects the initialed sheets and keeps them with the job file. TBD (Seth): whether the paper sheets are scanned into the packet (a packet document of kind "Other" goes into the data book, which goes to the customer), or kept on paper in the job file only.

After a restore

If Spencer restores from the nightly backup, the work of up to one day before the outage is lost from Packet Station as well. That work is entered again in the same way, from the paper the shop kept, the travelers and what people remember, and checked the same way. Spencer says from what time the data was lost.

Practice

TBD (Seth): a short paper drill on the test system before go-live, so every department has used the forms once.