My FR5 pick-place-advance sequence completes uninterrupted tray transfers for our planned 162 sleeves. Stop between those actions and the saved pocket can disagree with the physical state. I need a recovery design before normal production, not another assumption that the counter tells the whole story.
Map each interruption boundary against source occupancy, whether a sleeve may be held, destination occupancy and saved progress. For each, identify what evidence can confirm the state and what must remain unresolved before an authorised recovery decision.
Keep that case separate from pick-before-save, where the sleeve may be held. A single increment or repeat rule cannot resolve both. Review the proposed states with controls and the people responsible for the approved recovery procedure.
I've drafted both cases and a hold for uncertain occupancy. Controls review is pending. The draft does not authorise repeating a pick or place from the saved index alone.
Include tray replacement and restart with retained data in that review too; they can invalidate the relationship between a saved pocket and the tray now present, even when the index arithmetic is correct.