Why does our FR5 report accept a seventh housing after reconnect?

AdaBrooks0825 · 16 Apr 2026, 06:28 UTC

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AD
AdaBrooks0825
Six housings accepted, seven on the monitor after it reconnects. The completion bit stayed high during the outage and the latest result was already saved. I want to reconcile that retained result with its job, not clear the PLC just to make the total agree.

21 replies

LU
LucaBarnes0526
Replying to AdaBrooks0825

Check the identity accompanying that retained result against the saved row first; does it identify the same inspection attempt?

9 points
AD
AdaBrooks0825
Replying to LucaBarnes0526

Yes, same run and attempt identifiers. The stored row also names the same housing. Only one physical inspection occurred for that attempt.

12 points
CA
CallumAdams0099
Replying to AdaBrooks0825

Sounds as though reconnect has its own counting path. Does it insert another result row, increment a separate total, or both? Worth knowing which thing has actually multiplied.

22 points
JU
JuliaBaker0500
Replying to AdaBrooks0825

What is the total meant to count: accepted housings or successful inspection attempts? A housing checked twice can have two genuine results without becoming two accepted housings. Settle that before anyone calls the duplicate fix finished.

8 points
WI
WillAli0226
Replying to AdaBrooks0825

Does that figure go anywhere else, Ada? If someone is using it for the shift report, I'd tell them about the six-versus-seven mismatch now rather than wait for the software repair.

12 points
AD
AdaBrooks0825
Replying to CallumAdams0099

Callum, it increments a separate total without adding a row. Julia, accepted housings. Will, the supervisor has the six identified housings and has marked the monitor total unreliable in the shift report.

10 points
LU
LucaBarnes0526
Replying to AdaBrooks0825

Then can the maintainer rebuild the total from the stored housing dispositions, instead of adding one each time a completion is observed?

9 points
JU
JuliaBaker0500
Replying to LucaBarnes0526

Luca, yes, with any superseded result handled. I don't want the oldest pass to keep a housing accepted after quality has withdrawn it. Ada, include that example when you describe the count.

15 points
CA
CallumAdams0099
Replying to LucaBarnes0526

And don't lose an unseen completion during reconnect. Ignore the first high bit would fix your seven by creating a different missing-six problem later.

8 points
AD
AdaBrooks0825
Replying to CallumAdams0099

The maintainer reproduced both cases: a known retained completion must leave six accepted housings, while an unseen completion for another accepted housing must produce seven. We added withdrawal and repeat-inspection cases.

10 points
WI
WillAli0226
Replying to AdaBrooks0825

Thanks for telling the supervisor early. Is the report rebuilt from those identified housing records now, or are they still keeping a manual correction beside the screen total?

8 points
AD
AdaBrooks0825
Replying to WillAli0226

Still using the reconciled list for reporting. The repair is in the test package, not the installed monitor. I have not asked anyone to trust the screen again yet.

12 points
LU
LucaBarnes0526
Replying to AdaBrooks0825

Has the test package passed those cases, including being closed and reopened between saving the result and updating the display?

17 points
AD
AdaBrooks0825
Replying to LucaBarnes0526

That reopening test caught another error. Saved dispositions were correct, but the display restored an older cached total. Developer has removed that separate source for the accepted count.

13 points
JU
JuliaBaker0500
Replying to AdaBrooks0825

Good catch. Keep the current disposition visible for a selected housing too. The covering operator should be able to explain why that item is included or excluded without adding up its whole inspection history.

20 points
CA
CallumAdams0099
Replying to AdaBrooks0825

Did the cache repair survive another restart?

16 points
AD
AdaBrooks0825
Replying to CallumAdams0099

Yes. Duplicate retained result, unseen result, repeat inspection, withdrawn acceptance and reopening all give the expected identified-housing count. The installed reporting package is next.

22 points
WI
WillAli0226
Replying to AdaBrooks0825

When that goes in, make sure the supervisor's export comes from the same count. Our screen and spreadsheet once disagreed because only the screen had received the repair (an impressively pointless morning).

8 points
AD
AdaBrooks0825
Replying to WillAli0226

Installed monitor and export passed the controlled retained-result checks with the maintainer. Both agree with the reconciled housing list. Covering operator can find a housing's current disposition and its earlier results.

16 points
AD
AdaBrooks0825
Replying to AdaBrooks0825

The supervisor has removed the temporary reporting workaround. Thanks, Julia, counting housings rather than every successful attempt found more than the original reconnect bug.

17 points

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