Training Manual

TrueLogic Inc.
All Rights Reserved

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 Table of Contents
Chapter 1 Overview ............................................................................................................ 6
1.0 Overview of TrueChem .......................................................................................... 6
1.1 What is TrueChem? ............................................................................................ 6
1.2 TrueChem History .............................................................................................. 6
1.3 Who Uses TrueChem .......................................................................................... 6
1.4 TrueChem Features ............................................................................................. 7
1.5 TrueChem’s Layout ............................................................................................ 8
1.5.1 TrueChem’s Main Screen ............................................................................... 8
1.5.2 Graphic Button Tool-bar ................................................................................. 9
1.5.3 Tree View........................................................................................................ 9
1.5.4 Pull Down Menus ........................................................................................... 9
1.6 Creating a Facility ................................................................................................. 10
1.7 Setting up Processes .............................................................................................. 10
1.8 Setting up Tanks ............................................................................................... 11
1.8.1 General Tab Setup......................................................................................... 11
1.8.2 Notes Tab Setup ............................................................................................ 12
1.8.3 Test Setup...................................................................................................... 12
1.8.4 Add Sheet Setup ............................................................................................ 13
1.8.5 Schedule Setup .............................................................................................. 14
1.8.6 Make-up Setup .............................................................................................. 17
1.8.7 Docs (Document) Setup ................................................................................ 18
2.0 TrueChem Functions ............................................................................................. 19
2.1 Performing a Test .............................................................................................. 19
2.2 Graphing Tools ................................................................................................. 21
2.3 Data Log............................................................................................................ 23
2.4 Sampling Module .............................................................................................. 24
2.5 Inventory Module.............................................................................................. 25
2.6 User Setup ......................................................................................................... 28
2.7 User Log In ....................................................................................................... 30
3.0 Dashboards ............................................................................................................ 31
4.0 Rules ..................................................................................................................... 33
4.1 Custom Rules .................................................................................................... 33
4.2 System Rule Sets............................................................................................... 34
5.0 Sign off Requirements .......................................................................................... 34
5.1 Add Sheet Log Sign Off ................................................................................... 35
5.2 Corrective Actions ............................................................................................ 36
5.2.1 Corrective Action Log .................................................................................. 36
5.3 Event Log .......................................................................................................... 37
6.0 Reports .................................................................................................................. 39
Chapter 2 Setting up TrueChem ....................................................................................... 41
1.0 Setting up TrueChem ............................................................................................ 41
1.1 Program Installation .......................................................................................... 41
1.2 Types of TrueChem Installs .............................................................................. 41

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 1.3 The Installation Process .................................................................................... 42
1.4 Starting Up TrueChem ...................................................................................... 42
2.0 TrueChem Layout ................................................................................................. 43
2.1 Graphic Button Tool-bar ................................................................................... 43
2.2 Tree View.......................................................................................................... 44
2.3 Status Bar .......................................................................................................... 45
2.4 Working Window.............................................................................................. 45
2.5 Pull Down Menus ............................................................................................. 46
2.5.1 File Pull down ............................................................................................... 47
2.5.2 Edit Pull Down.............................................................................................. 47
2.5.3 View Pull Down ............................................................................................ 48
2.5.4 Inventory Pull Down ..................................................................................... 48
2.5.5 Tools Pull Down ........................................................................................... 48
2.5.6 Help Pull Down............................................................................................. 49
2.6 Window Resizing .............................................................................................. 50
2.6.1 Main Window Resizing ................................................................................ 50
2.6.2 Hiding Tree View ......................................................................................... 51
3.0 Initial Setup after Installation................................................................................ 51
3.1 Creating the Facility.......................................................................................... 53
3.1.1 Process Hierarchy Setup ............................................................................... 53
3.1.2 Creating a Process ......................................................................................... 53
3.2 Creating Process Elements ................................................................................ 56
3.2.1 Renaming a Processes and Tanks ................................................................. 57
3.2.2 Deleting a Processes/Tanks........................................................................... 57
3.2.3 Copying Tanks .............................................................................................. 58
4.0 Setting up Process Elements ................................................................................. 59
4.1 General Tab ....................................................................................................... 59
4.2 Tank Setup Notes Tab ....................................................................................... 60
4.3 Make-up Setup .................................................................................................. 61
4.3.1 Additive Set up ............................................................................................. 63
4.4 Test Setup.......................................................................................................... 64
4.4.1 Adding a Test Item........................................................................................ 65
4.4.2 Adding a Test Description ............................................................................ 66
4.4.3 Adding an Input Item .................................................................................... 67
4.4.4 Adding a Result Item .................................................................................... 68
4.4.5 Adding an Adjustment Item .......................................................................... 69
4.5 Addslip Setup .................................................................................................... 71
4.6 Schedule Setup .................................................................................................. 72
4.6.1 Other Schedules ............................................................................................ 75
4.6.2 Sample Module ............................................................................................. 77
4.7 Docs Setup ........................................................................................................ 78
4.8 HMIS Tab ......................................................................................................... 79
4.9 User Setup ......................................................................................................... 80
4.9.1 Defining Users .............................................................................................. 80
4.9.2 User Groups .................................................................................................. 83
4.9.3 Assigning members to a Group..................................................................... 85

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 4.9.4 Changing a Password .................................................................................... 85
5.0 Advanced Setup Variables, Scripts and Rules ...................................................... 86
5.1 Variables ........................................................................................................... 86
5.2 Scripts ............................................................................................................... 87
5.3 Rules ................................................................................................................. 88
5.3.1 Global Rules.................................................................................................. 89
5.3.2 Rule Notifications ......................................................................................... 93
5.4 Custom Rules (Tank Level Rule) ..................................................................... 93
5.4.1 Custom Rule Set up ...................................................................................... 93
6.0 Inventory Module.................................................................................................. 94
6.1 Creating the Inventory ...................................................................................... 95
6.2 Enter a Transaction ........................................................................................... 97
6.3 Create a Purchase Requisition .......................................................................... 98
6.4 Receive a Lot .................................................................................................... 99
6.5 Inventory Reports............................................................................................ 100
6.6 Manage Inventory Lots ................................................................................... 101
7.0 Dashboards .......................................................................................................... 102
7.1 Dashboard Setup ............................................................................................. 104
7.1.1 Shop Limits ................................................................................................. 104
7.1.2 Dashboard Rules ......................................................................................... 104
7.1.3 Building the Dashboard .............................................................................. 106
Chapter 3 Using TrueChem ............................................................................................ 107
1.0 User Log In/ Logout............................................................................................ 107
1.1 User Login ...................................................................................................... 107
1.2 User Log Out................................................................................................... 108
2.0 Using the Schedule to Organize Work................................................................ 108
2.1 Laboratory Tests ............................................................................................. 108
2.2 Other Schedules .............................................................................................. 111
3.0 Collecting Data ................................................................................................... 112
3.1 Logging Samples ............................................................................................ 112
3.2 Conducting Tests ............................................................................................ 113
3.3 Saving Data ..................................................................................................... 116
3.4 Process Level Addslips ................................................................................... 117
3.5 Performing Other Schedules ........................................................................... 119
4.0 Graphs and Statistical Tools ............................................................................... 120
4.1 Controlling a Process ...................................................................................... 120
4.2 Basic Statistical Calculations .......................................................................... 121
4.3 Drift in Chemical Processes ............................................................................ 123
4.4 Histogram ........................................................................................................ 124
4.5 Capability Index .............................................................................................. 125
4.6 Statistical Functions Graphs in TrueChem ..................................................... 127
5.0 Using the Statistical Features .............................................................................. 128
5.1 X-Bar Chart ..................................................................................................... 128
5.2 Run Chart ........................................................................................................ 130
5.3 Histogram ........................................................................................................ 130
5.4 Graph Settings ................................................................................................. 131

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6.0 Data Log.............................................................................................................. 133
6.1 Data Point Features ......................................................................................... 134
6.1.1 Test Detail Screen ....................................................................................... 134
6.1.2 Test Summary Screen ................................................................................. 135
6.1.3 Adding a Bookmark .................................................................................... 136
7.0 Data Points and SPC ........................................................................................... 137
7.1 Data Editing .................................................................................................... 137
7.1.1 Changing a Data value ................................................................................ 137
7.1.2 Deleting a Row of Data................................................................................... 138
7.2 Hiding a Data Point from the SPC .................................................................. 138
7.3 Marking a Test as a Start up Test.................................................................... 138
8.0 Sign Off Requirements ....................................................................................... 139
8.1 Addslip sign off............................................................................................... 139
8.2 Corrective Actions .......................................................................................... 141
8.2.1 Completing a Corrective Action ................................................................. 143
8.3 Events .............................................................................................................. 144
8.3.1 Events that TrueChem logs ......................................................................... 144
8.3.2 Rule Driven Events ..................................................................................... 145
8.3.3 Event Log .................................................................................................... 146
9.0 Reports ................................................................................................................ 148
10.0 The Placard System............................................................................................. 149
11.0 Lookup Tables .................................................................................................... 150
12.0 Selection Tables .................................................................................................. 151
13.0 Miscellaneous TrueChem Features ..................................................................... 153
13.1 Printing, E-Mailing, and Exporting ................................................................ 153
14.0 Getting Help ........................................................................................................ 155
Appendix A: TrueChem Variable List ............................................................................ 159

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Chapter 1 Overview

1.0 Overview of TrueChem

This chapter describes the structure of the TrueChem software and introduces the features
of the program.

1.1 What is TrueChem?

TrueChem is a PC or server based windows application designed for chemical process

laboratory analysis and management. It provides a facility with the framework and
functionality to implement a process control system. TrueChem helps manage the
collection and automates the analysis of laboratory data. The features of the program
provide improved process control for the facility by making logic based decisions on the
data collected. TrueChem’s features are very useful in organizing, tracking, and
analyzing process changes and to enhance process control. TrueChem also provides the
facility the ability to schedule process analyses, and to certify through “sign offs” that the
activities were completed. TrueChem can also track chemical usage. The inventory and
dashboard module provide system enhancements to TrueChem. The inventory module
allows users to track and manage chemical stores with usage information collected
directly from the analyses performed. The dashboard module presents the facility an
interactive webpage that can be accessed by any facility computer designated with access
to the company server. This allows the user to observe the status of the various processes
without having the full TrueChem program running on their computer.

1.2 TrueChem History

The first version of TrueChem was developed in the early 1980’s, at Texas Instruments’
Austin, Texas facility. In the 1980s a DOS version of the software was developed for use
on personal computers. The first commercial version of TrueChem was delivered to
Continental Circuits in 1988. Without much serious advertising, TrueChem reached
approximately 120 printed circuit board (PCB) manufacturer labs worldwide by the end
of 1999 and had captured roughly15% the market share. In the late 1990’s after requests
from PCB customers, a Windows-based TrueChem application was released. In 2000
TrueLogic Company acquired TrueChem and facilitated the further development of the
Windows version of TrueChem.

1.3 Who Uses TrueChem

TrueChem is specifically tailored to assist manufacturers who utilize chemical baths for
production of materials such as electroplating, surface finishes and printed PCB

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manufacturing. These users are broken into four major categories: (1) Aerospace, (2)
Automotive, (3) General Decorative/Household, and (4) Military. These manufacturers
generally detail quality requirements that demand that their laboratory functions,
methods, rules and reports must be strictly maintained. Without stringent control of these
chemical processes, the company can experience serious consequences including; loss of
process solutions from production mistakes, product loss from quality failures,
replacement costs for defective products and the potential for a loss of the company
reputation. Proper process control is important to the manufacturer as it can identify
problems before product assembly. Identifying problems early reduces the cost of
troubleshooting and implementing a corrective action. For example, a TrueChem client
reported a 65% chemical yield with $2MM in rejected parts in 2001 and was forecasting
$4MM in returned parts prior to implementing TrueChem in 2002. According to the
client, the 2002 rejects ended up being less than those in 2001 and the yields have
improved into the 90% range. This example illustrates the degree of improvement
possible by implementing the type of control TrueChem provides.

TrueChem is very valuable to the facility in reducing labor and materials while increasing
quality and simplifying compliance to standards with its traceability. Perhaps
TrueChem’s best attribute is that it can approach an expert system by incorporating logic
rules to make decisions. The design is thorough and it is easy-to-use. This makes data
collection easy, simplifies data analysis, and the embedded statistical functions simplify
data interpretation. Many basic functions such as process solution make-up, solution
additions and maintenance are handled automatically. TrueChem’s variety of features
allows the facility to document and store facts about any given process thereby saving
that knowledge for training and troubleshooting purposes.

1.4 TrueChem Features

TrueChem is very intuitive and the basic functions can be learned easily. Common
computer use and windows navigation skills allow the user to access the various screens
and enter data with little formal training. Facility set up, scheduling and developing
simple logic rules requires a higher degree of computer mastery similar to using some of
the more advanced features of Excel.

Building the facility into the database constitutes a large portion of the set up work. This
requires the user to create process tanks, evaluate laboratory analysis procedures and
transfer those procedures into the calculations that define the parameters in TrueChem.
Facility set up also requires the creation of schedules, users profiles and the creation of
rules to govern situations the data identifies (for example when additions are required, out
of spec conditions etc.) The calculations in the equations used by TrueChem are actually
visual basic scripts. One can use visual basic to develop, test and implement complex
logic scripts to customize TrueChem into a highly effective laboratory/process
management tool that approaches an expert process control tool.

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 1.5 TrueChem’s Layout
The process layout is in standard WindowsTM “tree view” format. The screens for the
various features in TrueChem are accessed by selecting menu buttons from the top tool
bars or by selecting a tank in the process tree.

1.5.1 TrueChem’s Main Screen

The main TrueChem screen is laid out with a tree view down the left side of the screen. A
process line can be expanded down to select any of the various process tanks making up
the process. Pull down menus and a graphical button tool-bar allows selection of the
desired program function or activity. The bottom status bar displays current states.
Certain activities will cause additional windows to open with fill-in boxes to complete.
Failure to complete the required boxes prevents closing of the window and the required
areas are highlighted in pink.

Figure 1: TrueChem Main Screen

The largest area shown in Figure 1 is the “working window”. This is the area on
TrueChem’s screen where most of the application specific work will be done. The
default view of this area is a HTML browser that can be pointed at any web page on the
Internet, intranet, or local hard drive.

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 1.5.2 Graphic Button Tool-bar
The graphical button tool-bar allows direct access to commonly used features. (Hold the
cursor over the icon to display the icon title). These buttons allow the user to quickly
access features including Perform Tests, View Graphs, View Data log, Access Tank
Setup, User Login, View Addslip Log, Print, Email, View Schedule, Access System
Setup, View Corrective Action Log, Event Log, Create Reports, Access the Inventory
Module, User Setup, User Logout and Access the Help System.

Figure 2: Main Screen Graphic Tool Bar

1.5.3 Tree View

The Tree View is made up of processes and tanks that are user created to represent the
user’s facility. Like any standard windows menu clicking on the item or the + sign
expands the tree and clicking on the – sign collapses the tree. Most metal finishers assign
group names as processes and assign object names as individual process elements (tanks)
within the process. To select a particular tank simply click on the tank of interest to
highlight it. This activates the features related to that tank so that the data is available.

Figure 3: Main Screen Tree View

1.5.4 Pull Down Menus

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The pull-down menus are standard WindowsTM-style menus for accessing all of
TrueChem’s functions. Access to the pull down menu items may be limited to specific
users. If the current user tries to access an area their login is not set up for, a TrueChem
User Login Pop-up will appear to login to an account with the proper rights. This
account may or may not be available to the user attempting to login (more on this later in
User Setup)

1.6 Creating a Facility

The bulk of the work required to set up a facility is associated with creating the processes
and scheduling the testing of the parameters used to control those processes. Most
facilities organize their processes into process lines composed of the processing elements
(tanks). Organizing into processes helps facilitate accessing particular tanks in the tree
view and makes the dashboard more readable. Process chemistries often contain multiple
ingredients or require physical testing. TrueChem can easily handle either of these
situations

1.7 Setting up Processes

A process is composed of one or more steps in the processing sequence. For example, in
a chrome plating line composed of a cleaning step, an etch and the plating tank forms a
process. Rinse tanks are not generally included unless some sort of chemistry is added

Figure 4: Process Setup Screen

that needs to be tracked or if measurements like conductivity or pH are tracked. A

chemical formulation process like adhesive mixing would be a single tank with the
addition of each of the ingredients. Once the process is created then process elements

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(tanks) are created within that process. Tanks are objects that can have tests performed
on them. Using this thinking then a tank can be many things in a facility and using
TrueChem to control process elements is not limited to metal finishing process tanks.
Other process steps such as cure ovens, machine lubricant, scrubber operation and
wastewater treatment are a few examples of other processes that can be controlled using
TrueChem.

1.8 Setting up Tanks

Tank set-up is where the bulk of the effort to set up TrueChem is expended. Tank set-up
leads to creating the library of chemicals used. During set-up, the calculations used for
makeup and solution maintenance are entered. Set up is also where the various tests are
scheduled and the circumstances that generate activities (additions, decants, maintenance
etc.) that appear in the logs are created. Accessing tank set up begins by selecting a tank
and clicking the tank set up button on the tool bar. There are several tabs that then appear
in the main window. These include General, Notes, Test, Addslip, Schedule, Make-up
and Docs. Each tab will be discussed separately.

1.8.1 General Tab Setup

The first tab is the General tab and lists basic information about the process tank. In the

Figure 5: General Tab in Tank Set up Window

working window the tank name and the tank chemistry name are shown along with the
tank volume in the units desired. The window also allows calculation of the tank volume
by entering the tank dimensions in the area on the right of the screen. At the bottom right

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of the window the status of the tank is shown indicating when the tank was created, when
the last remake occurred, when the last time any changes to the set up were made, and if
the tank is currently active.

1.8.2 Notes Tab Setup

The next tab listed in Tank Set-up is the Notes tab. This tab allows the user to enter text
that will be displayed to anyone performing a test on this tank. Addslip Notes can be
entered that will be included on all Addslips created for this tank. One useful way to
employ the notes section is to keep a history of actions and events associated with a tank.
Tank make-ups can be noted, strange behavior, the result of trouble shooting activities or
solution maintenance activities can all be entered here so there is a running log of
activities relating to the tank.

Figure 6: Tank Setup Notes Tab Screen

1.8.3 Test Setup

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The Test tab is where the calculations used to control the various process solution
parameters or product physical tests are defined. Items are added to a list from top to
bottom that make up the necessary elements for testing this chemistry by clicking Add.
Existing items can be modified or deleted from this screen. The choices are Test
Description, Input Value, Result Calculation and Adjustment. Items are added by
pressing the add button.

Figure 7: Test Tab Screen in Tank Setup

1.8.4 Add Sheet Setup

The Addslip tab allows for the setup of Addslips. Standard Addslips are built into
TrueChem. Custom formats can be imported. If desired, the time allotted to complete the
addition can be modified from the system wide standard time.

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 Figure 8: Add Sheet Setup

1.8.5 Schedule Setup

Scheduling is a powerful feature of TrueChem. Schedules can be created for each test
result item listed. Schedule frequencies are customizable from several times per shift to
once a year, depending on the process requirements and facility needs.

1.8.5.1 Scheduling Tests

Each Result item created in the test screen creates an item that can then be scheduled on
the Schedule Tab and is shown in the figure. In addition non test items such as filter
changes or timed dumps can be scheduled in the “Other Schedules” section. Nearly any
frequency imaginable can be created in the schedule screen. Once a frequency has been
created it is available in the pull down menu for reuse. To schedule a test, the result item
is selected and the Modify button pressed to reveal the schedule set up dialogue. The
dialogue box shown in Figure 9 appears. Several decisions must be made including the
priority of the test and if this is the normal, accelerated or decelerated schedule. For new
items schedule the normal frequency first.

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 Figure 9: Schedule Set up

At the right of the normal frequency is a pull down with all the currently defined
schedules listed. One of the choices is to add a new frequency. Selecting add new
frequency opens the popup frequency selection box of Yearly, Monthly, Weekly, Daily
or by Shift. Selecting a frequency type will open a dialogue similar to Figure 10.
Scheduling details will appear, e.g., if Shift were selected, the number of times per shift
would be defined. In addition the start time can be set, as well as the time needed to
perform the task. One other important item is if a sample is needed.

Figure 10: Schedule Screen

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Filling in details in the sample section creates an additional time period for gathering and
processing the sample. This timeframe can be used for sending the sample out for
analysis or if special sample preparation is required.

1.8.5.2 Other Schedules

In the lower section of the Tank Setup Schedule tab is Other Schedules. In this section,
schedules for activities not covered by the calculations can be established. Items such as
filter changes, carbon treatment, dummy plating, calibrations, etc are scheduled here.
This function can be used for any event that might occur to a tank at any frequency.

Figure 11: Other Item Scheduling

Since these activities are not based on a calculation, each item must be created. Selecting
the Add a schedule in the Other Schedules section brings up the pop up shown in Figure
12. A description of the activity must be entered and the Print section must also be
constructed by selecting or creating from the print menu pull down. These instructions
will show up on an Addslip that is printed when the item comes due.

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 Figure 12 Other Schedules Setup Window

1.8.6 Make-up Setup

The Make-up tab opens a window in Figure 13 to define the chemicals (additives) and

Figure 13: Tank Setup Make up Tab Screen

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the amounts of each chemical needed when making up a particular process tank. The
bottom half of the window has space to enter instructions that will print out on the
Makeup Addslip. As shown, the make-up procedure instructions can be added here.

The top half of the window shows the additives (chemicals) used in the make up of the
process solution. Chemical ingredients are added by clicking on the add button in the
middle of the window that opens an additional pop up. Each chemical additive is
selected from a list. The additive list initially contains no additives. As processes are
defined, chemicals are added to the list and may be selected for other tanks using the
same materials. Defining a chemical requires the input of data about how the chemical is
ordered and stored, and forms the basis for tracking chemical usage.

Figure 14: Tank Make up Pop up

1.8.7 Docs (Document) Setup

The Docs tab allows the user to import documents directly into TrueChem for reference
or to create links to external documents. On the Document tab, multiple documents can
be attached to the tank. There is no limit to the number or types of documents that can be
attached. The attached document will be available to anyone performing a test on this
tank or with rights to access tank data. Specifications, material MSDS sheets, procedures
and work instructions are often attached. Another great use of the document tab is to
attach training videos. A video of the operating procedure, a titration end point color
change or a safety video are all commonly attached files as well.

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 Figure 15: Document Screen

2.0 TrueChem Functions

TrueChem comes equipped with a number of functions that assist the user with
accomplishing activities. Many of these functions are accessed from the graphic tool bar.
Some of these functions are introduced in this section.

2.1 Performing a Test

Tests are performed to transfer raw data from the laboratory into TrueChem. To perform
a test on an existing tank, select the tank by clicking on it in the tree and click on the
Perform Test button.

This will display the Perform Test window. Data can be entered into any, or all, of the
blue highlighted boxes. TrueChem can perform all the necessary calculations. The
calculations are initiated by pressing the enter key after entry. This also prepares the data
for saving into the database. Data can be reviewed for accuracy or recalculated. And
then one further step is required to save the data to the database.

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 Figure 16: Performing a Test

Alternately, a test can be initiated from the Edit pull-down menu. Also tests can be
initiated by selecting an item from the schedule. The current schedule can be accessed by
selecting the schedule button.

This button brings up the schedule log in the main screen. The log lists scheduled items
according to the following hierarchy; past due (late), due and not yet due. “Other”

Figure 17: Schedule Log

scheduled items, such as maintenance, can only be seen from the schedule log. The view
of the schedule log can be changed by clicking on any of the column headings allowing
the user to sort by process, type, due date, etc. A given task can be performed by clicking

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on the item and then clicking the “Do Now” button or by double clicking on the item.
Once a test has been performed the data is ready to be saved. In order to add the data and
calculated results into the database, the Output tab is selected. This begins the action of
saving the data. Data can only be saved on a computer with a software key installed. The
installed key activates the Print/Save button, and clicking that button completes saving
the data into the database.

Figure 18: Output Screen

2.2 Graphing Tools

Several different graphs are available in TrueChem, including X-bar, run charts, moving
run charts and histograms. Multiple process solution components can be displayed (as
long as each is tested for). In addition, TrueChem has built-in statistical calculations to
evaluate mean, standard deviation, Cpk and other relevant quantities. Also by clicking on
a data point on the run chart, comments relating to the test can be added. Individual
graphs can also be displayed. Multiple sets of control limits can be displayed. The graphs
of multiple components can be overlaid from the current tank or from other tanks to show
relationships. The graphs functions are accessed by pressing the graph icon in the button
bar.

The figure below shows the graph overview that displays all the different graphs. At the
top of the graph window are five tabs that allow the selection and enlargement of the
individual graphs.

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 Figure 19: Graph Screen

Figure 20: X-Bar Individual Graph

The X-Bar chart in Figure 19 is expanded to the full working window in Figure 20 by
selecting the “X-bar” tab. That chart shows calculated control limits that are statistical

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quantities indicating the natural process limits based on the current operation. Each of the
other graphs can also be expanded by selecting the appropriate tab.

TrueChem also has the ability to overlay multiple components from the same graph
(figure 21). Although the units are removed, this graph can still show common trends in
the data.

Figure 21: Graph Component Overlay

2.3 Data Log

Pressing the scroll icon accesses the data log for the particular tank selected at the time.

The data log presents all of the stored data in a tabular format. The columns match the
test screen result and adjustment rows rotated 90 degrees. Items at the top of the test
window appear at the left on the Data Log. The data log screen for the tank will display.
Data displayed is color coded depending on whether it is in specification or not and by
actions required that have not been completed. The coding key is shown in the bottom
right of the window.

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 Figure 22: Data Log

Advanced features in TrueChem allow the user to customize the display and save the
customized view and return to each time the Log is accessed. This customization feature
is available for all of the logs in TrueChem

2.4 Sampling Module

The sampling module is part of the standard TrueChem package. The sampling icon
appears next to the perform test icon

The sampling module allows the facility to separately record and track samples used for
monitoring processes. The sample feature is used by clicking on a process line or a tank
in a process line and then pressing the sample icon. A list of all of the tests used in that
process line appears in the working window and the tests desired for the sample are
selected by checking the check boxes. TrueChem then assigns a unique tracking number
for the sample and assigns the current date and time as the start time. TrueChem tracks
the time until the sample results are entered.

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 Figure 23: Sample Module Main Screen

The Sampling module is included in the base version of TrueChem. If the sampling
module has not been requested and the facility decides it would be useful, simply contact
TrueLogic and we will activate the module for the facility.

The sample module was designed for chemical suppliers that receive samples from their
customers, and needed the ability to track the processing of these samples and to report
the status of the analysis to their customers. This feature is also very useful for metal
finishing facilities that want to track samples sent offsite for analysis. Offsite for the
purposes of this discussion is out of the lab where TrueChem users enter data. Thus,
“offsite” includes labs in another part of the facility or outside labs that are contracted to
perform specific testing. The sample module can be used to initiate the gathering of a
sample for processing or it can be used to track the sample sent offsite. A time window
for completing the sample processing provides clear tracking of when the sample was
gathered/received and when the analysis results are recorded.
Many facilities choose not to use this feature especially when samples are gathered and
immediately analyzed. If the sampling module is not utilized, TrueChem assigns the
sample time to be the time when the results are entered.

2.5 Inventory Module

The Inventory Module is an optional add-on TrueChem feature that provides TrueChem
users with additional features to better manage chemical and material usage. Through the

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inventory module, users are able to expand on the ability to track chemical usage that is
available from the Add Amount Report. The Add Amount Report can be used to estimate
chemical usage by tracking chemical additions and make ups. The Inventory Module
allows the facility to track chemical usage more effectively and also control inventory
quantities. Basic TrueChem tracks usage of chemicals tested for and through tank
adjustments made. The inventory module expands on this to allow the tracking of
inventory levels, and chemical age by tracking lots. Also, items not included in tests,
such as laboratory materials, filters, and anodes can be tracked and inventoried by using
“manual transactions”. The inventory module can also be used to generate purchase
orders automatically based on inventory levels and predefined order points. Even if the
facility has a purchase order system, the inventory module still helps optimize chemical
inventory as it can be used to generate emails to buyers based on the inventory levels and
order points. The inventory module works best if TrueChem is installed on the facility
computer network so that the TrueChem users performing chemical tests, the inventory
manager, and shipping and receiving staff can all enter their data into TrueChem. The
inventory manager and the shipping and receiving staff do not require software keys to
enter inventory data.

The inventory module is accessed by clicking the Inventory icon on the tree structure.

On clicking the Inventory icon, the icons above the Tree view window are replace as
shown in the Figure 24. These buttons access the major features; Enter Transaction
(manual transaction), Enter Purchase Orders, Receive Lots and Inventory Reports.
Tracking material usage occurs by TrueChem deducting chemical usage from additions,
manual transactions and lot management from the chemical inventory created during
setup. Items are added to the tracked inventory by entering inventory lots, creating a tank
make-up or an adjustment test. The inventory reports provide lists of the chemicals and
supplies on hand. Inventory creates maximum and minimum set points, allows the
tracking of material lots, can receive new material into inventory and can even generate
purchase

26
 Figure 24: Inventory Module Active Buttons
orders automatically. The usage of materials that are called for in tank make ups and
additions are automatically tracked by the inventory module. Materials in stock can also
be tracked by expiration dates or by lot number. Manual Transactions can also be entered.
The inventory module is tied to the testing of process components so items not tested are
not tracked automatically. A manual transaction can be used to track these non-tested
items by making inventory adjustments. Items routinely tracked via manual transactions
can include laboratory chemicals and supplies, anodes, anode bags, filters and
maintenance materials like activated carbon. Manual transactions are created by selecting
the Inventory pull down menu and then Create Manual Transaction.

Figure 25: Create Manual Transaction

Several different inventory reports are available as well. The various reports are accessed
by pressing the fork truck icon in the tool bar and then selecting the desired inventory
report from the pull down list under View. The inventory report appears in the main
window. The standard reports available track Active Lots, Expired Lots, Retired Lots, All
Lots and purchase orders.

Figure 26: Inventory View Pull Down Menu

Inventory reports are easily accessed either by icon or pull down menu. The screen in
Figure 27 will appear and is the default view showing Chemical Balance. The entries
are color coded and the legend is in the bottom right corner of the screen. Other

27
 Figure 27: Inventory Reports

views are available, and sort the inventory based on the Lot Balance, material On Order,
by Transactions and by Expiration date.

2.6 User Setup

User access rights are an important part of TrueChem. Establishing user rights helps
define facility roles and responsibilities, as well as protects the integrity and access to the
data. Each user is required to log in to use the program, and TrueChem then assigns the
tasks completed to the user. In addition, email notifications can be sent to specific users
or user groups. To manage TrueChem users, select the Setup Users button from the
graphic tool bar.

TrueChem comes preloaded with two users, Admin and Default. These users have
special functions and cannot be deleted. The Admin user is TrueChem’s Super User and
can do anything within TrueChem. This user’s password should be changed and
maintained by the highest level TrueChem user. Individual users and groups can be

28
created to manage access, and to grant rights to certain TrueChem features. Once created,
a user cannot be deleted as any data or signoffs they completed would be compromised.

Figure 28: User Set up

New users can be added by pressing the Add User button. The information added defines
the user name, password, job title, etc. One other very important piece of user
information is the email address. If the email address is filled out, then that address
becomes part of TrueChem’s email address book and can be used in other features. User
rights are defined in the Function Rights section. An extensive list of functions that can
be performed in TrueChem is found in the rights section. Access to the function can be
On All, On None, or On Select which allows for the selection of tank(s) the right is
granted to the user. Rights can be assigned to individual users or user groups.

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 Figure 29: User Rights Set up

2.7 User Log In

By selecting the log in key, which is the unlocked padlock button, a login screen will be
displayed which allows the entry of the User ID and the Password. If the authentication
is successful then the user’s name will appear in the lower left hand corner of the main
TrueChem screen.

Figure 30: TrueChem User Login

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3.0 Dashboards
The Dashboard Module is an optional add-on feature of TrueChem that provides the
ability to present an overview of the facility analysis status in a “real” time fashion to
both TrueChem users and other facility personnel. The dashboard creates a PLC-like
facility status display that can be made available to anyone in the facility and does not
require TrueChem to be installed on their computer. Personnel such as managers,
engineers, process planners and maintenance can access TrueChem information through
the Dashboard. The dashboard displays the important elements of the database in a web
page format. In order to use this feature, a network must be available so that a short cut
to this webpage can be copied to each computer needing access to the dashboard. The
dashboard files query TrueChem periodically and update the status of the processes
displayed. Figure 30 shows the top level display of the dashboard.

Figure 30: Dashboard Process Line View

Three conditions are displayed; in specification (green), outside shop limits (yellow) and
out of specification (red). Clicking any of the buttons displayed allows the viewer to
“drill” down first into the line view and then into the tank view of the dashboard and
view the information on that level. For example clicking on the Electrolytic copper
(preceded by an asterisk) is shown in Figure 31. The deepest level is the tank level shown
in Figure 32.

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 Figure 31: Line Dashboard View

Other information about the processes and tanks is also available including whether the
tank is active or inactive, and when the next analysis is due. As shown in the figure, the
dashboard can also be configured to track the status of samples. Figures 31 and 32 show
additional information accessed by drilling down into the dashboard. The gray asterisk
seen next to the electroless copper line button in Figure 30 indicates the line contains a
deactivated tank. Figure 31 shows the process level, and lists all tanks in the Electrolytic
Copper process line. Figure 32 shows the tank level dashboard view of the demo line.

Figure 32: Tank Level Dashboard View

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4.0 Rules
The ability to create logic rules is one of the features that sets TrueChem apart from other
process control data programs. Simple spreadsheet programs have limited ability to
incorporate logic based rules that help transfer decision making to the process control
program. Creating rules in TrueChem allows the user to “train” TrueChem to become
more expert and make decisions based on the test results. Rules tell TrueChem what you
want to do when certain conditions exist. Rules can be applied directly to a result or
adjustment item as a custom rule, or they can be created in the TrueChem system setup as
a rule set. Rule sets can be applied to multiple results and/or adjustments. Basic rules help
with “mistake proofing” data entry and analysis results. More complex rules can look at
data trends or changes from previous calculations to determine if additional tests are
required. Rules can also activate visual basic scripts that perform complex functions.
Rules are either defined at the process tank level or as system rules that are applied to
tanks.

4.1 Custom Rules

A rule can be added to any result or adjustment item by selecting the result or adjustment
while working in the Tank Setup window under the Test tab for a particular. To set up a
rule, select the result or adjustment item and then click Modify at the bottom of the
window. Under Apply Rules in the new window, the Add button will open the window
shown in Figure 33. This window contains fill-in boxes for simple If/Then statements.
The majority of rules can be covered with the If/Then statements. The result of a rule can
cause a number of different actions to occur; from a pop up message to sending emails to
creating corrective actions requiring sign off. The versatility of the rule functions is one
way TrueChem is very unique.

Figure 33: Rule Setup Screen

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 4.2 System Rule Sets
System Rule Sets allow the creation of the rules, or groups of rules, under the same
heading. The rule set can then be applied to any result or adjustment in the TrueChem
system. Rule Sets may be applied to the entire facility (all results), to selected tanks or
even to a single result in one tank. Rules are assigned separately to results and
adjustments.

To create a system rule you must have rights to the System Setup. Once the System Setup
window has been opened, go to the Rules tab to define the rule set (shown in Figure 34).
Directly beneath the tabs you can add new rules that will be members of that set. Once
you define a rule set, click the Add button to create a new rule (shown in Figure 33).
After the rule has been created, the lower section is used to assign the rule to the facility,
process, tank component tests results or adjustments. To assign the rule, click the check
box at the level desired (facility process, tank or component). Results are in the left hand
column, Adjustments on the right hand column.

Figure 34: System Setup Rule Set

5.0 Sign off Requirements

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Another powerful feature of TrueChem is the use of Sign off requirements. Several
activities can be set up that require the user to sign off that the activity has been
accomplished. In addition, TrueChem can also require that a reason be given at the sign
off. The sign off feature helps provide traceability for completion of activities and for
changes to the database.

Adding data into TrueChem through the Print/Save button automatically signs off the
data acquisition activity or begin the process of performing an “other” schedule item.
Additions automatically have a sign off requirement. Rules can be used to create
Corrective Actions or Events. These activities can require Sign Off.

5.1 Add Sheet Log Sign Off

An example of the sign off requirement is shown in Figure 35. Here, a past due add sheet
is accessed by going to the addslip log and double clicking on the red entry shown. The
pop up Sign off box appears. Selecting sign off assigns that activity to the user signed in
to TrueChem (they must have rights to complete this activity).

Figure 35: Add Sheet Sign off

In the add sheet sign off dialogue, the list of add amounts that were called for in the
initial test are displayed with a check box to the left. These can be altered if the user has

35
the rights to do so. For instance, perhaps there was not enough material on hand to make
the full add called for.

5.2 Corrective Actions

It is important to note that Corrective Actions are only defined by rules. Rules can be
created for any result or adjustment. Corrective actions create a condition, or set of
conditions, that, if true, require some additional action. The “True” condition might be
when a result is outside of its specification limits. Figure 36 shows the dialogue screen
for a rule setup on a result. By checking the Require Corrective Action Sign Off check
box, you are saying that this condition should be flagged for sign off and tracked for its
completion. In the Require corrective Action Signoff section at the dialogue box bottom,
the type can be selected. These types are user defined. The corrective action can be
viewed and tracked by this type. The description will help identify the details of the
Corrective Action. Allotted time is used to determine how much time should be allowed
for the signoff to occur. At the expiration of this time, an email could be sent.

Figure 36: Corrective Action Setup

5.2.1 Corrective Action Log

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To view the list of corrective actions requiring sign off, select the Corrective Action log
button on the graphical menu bar. The Corrective Action Log can also be accessed from
the View pull down menu as shown in Figure 34.

The Corrective Action Log screen will be displayed. The initial view is always All
Corrective Actions Not Signed Off. Any Corrective Action listed in this view is awaiting
sign off. By highlighting any item and pressing Sign Off, the sign off screen is displayed,
and information about the cause can be added. When the sign off is completed, the item
will be removed from the screen after clicking Refresh or exiting the screen. Note you
must have rights to sign off corrective actions to complete the sign off function.

Figure 37: Corrective Action Log

5.3 Event Log

The event Log is accessed by pressing the Event Log icon shown below. It is located on
the top menu bar.

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TrueChem’s event log is much like an audit log entry. However, it cannot be edited or
deleted. Event log entries are created when an event has occurred that TrueChem was
told to track, or, when a user defined rule was true and had an action attached which
specified creation of an event log entry. Some general items such as changing tank set
ups changing data and a few others can be selected during setup on the Tracking tab to
create events.

Figure 38: Event Log Screen

There are several event types that TrueChem will automatically track. This tracking is
turned on in TrueChem’s System Setup under the Tracking tab.
Track Add Sheet Status: This will cause TrueChem to require add sheets be signed off.
Track User Activity: This will cause TrueChem to log events related to user rights such
as invalid password attempts, changes to user rights or changes to user status.
Track Setup Changes: This option will cause TrueChem to log changes to the setup of
processes, tanks and Rules.
Track Add Sheet Override: This causes a required reason be given for any changes to add
amounts.
Track Schedule Override: This will log events describing changes when a schedule has
been overridden.

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Track Data Editing: This will cause TrueChem to log any editing or deleting of test data
from any tank.

Figure 39: Set up Screen Tracking Tab

6.0 Reports
The report section is accessed by pressing the Report icon shown below. It is located on
the top menu bar.

Several standard reports are available covering the processes, materials testing and results
generated by TrueChem. These reports are defined by creating a “scope” and selecting a
time frame that the report is run over. In addition, custom reports can be created that
evaluate specialized facility requirements. The Reports screen allows for running
predefined reports. In the report description window, select the report to be run and the
format in which the report should be issued. In the scope description, selecting “All” will
have the report run against all items on your TrueChem tree. Using the custom scope
allows the use of specific items. Adding and defining individual scopes are then saved
and become a part of the scope description list. Shown in the Figure is a scope to look at

39
the tests performed on the facility gold plating tanks. The For Dates box requires data
range the report will scan.

Figure 40: Reports Screen

One important report is the Add Amount Report. It can be used to estimate chemical
usage by tracking chemical additions and make ups and various scopes can be defined
and is very useful for facilities without the Inventory Module.

40
Chapter 2 Setting up TrueChem

1.0 Setting up TrueChem

TrueChem is relatively easy to install. However coordination with the facility IT
department is essential for smooth installation of the program and insures that the user
computers have the system rights to access the program on the company network. In
addition, some assistance is generally needed to set up the email portion of the program.

1.1 Program Installation

TrueChem can be easily installed and set up on a single computer or on a network server.
TrueChem is available in both Microsoft Access or Sequel versions.

Server
For an Access 2000 Database: 200 MB of disk space on a file share.

For SQL Microsoft SQL 2000 or greater

Client PCs
Minimum Required Recommended
Operating System Windows 98, NT 4.0 Windows 2000, XP
Processor/Speed PII/450 MHz P4/2.0 GHz
Memory 128MB 512MB
Video 800 x 600 1024 x 768 or greater
Software MS IE 5.5 MS IE 5.5 or better

License Keys

There must be at least one Sentinel Pro key installed on the computer (normally the
computer in the lab) to allow TrueChem to save test data. USB Port Key goes on any
available USB port on the client computer but should not be installed until after
TrueChem has been loaded on the computer.

Figure 1: USB Port Key

1.2 Types of TrueChem Installs

TrueChem can be installed in several different manners depending on the user’s desired
mode of operation.

41
 Stand Alone

Installation where the access database and client software are both installed on the
computer’s local hard drive. In this configuration a local network can specify one
computer as the server.

Server with Access

Installation where the access database is installed in a file share, on a file server, or peer-
to-peer network and the client software is installed on one or more computer local hard
drives.

Server with SQL

Installation where the database is created on a Microsoft SQL and client software is
installed on one or more computers local hard drives.

1.3 The Installation Process

Place the install CD in the CD Drive. Wait for auto run. If auto run is enabled the
TrueChem install should start automatically. If it does not, select the drive that contains
the install CD and execute the setup program go to My Computer and manually select the
disk.

1.4 Starting Up TrueChem

Start TrueChem by clicking on the TrueChem icon on the desk top or choosing Start,
Programs, TrueChem, and TrueChem.

On a stand alone install, TrueChem will start right up.

On an install with a server, the first time a new client starts up TrueChem, the database
location must be set up. The dialogue box shown comes up and the user must navigate to
the location of the database (.mdb) file.

Figure 2: TrueChem Database Connection Window

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2.0 TrueChem Layout
TrueChem’s system is designed to be very intuitive and user friendly. As with most
Windows applications it is based around the “tree” view file organization scheme. In
TrueChem’s case the folders are process lines and the files are process tanks. Figure 3
shows the layout of the TrueChem screen. The main TrueChem screen is laid out with a
tree view down the left side for selecting the Process and Tank of interest. The pull down
menus and a graphical button tool-bar allow for quick selection of the action to be taken.
The bottom of the window has a status bar to display current states. Selecting an action
from the menu bar or the button bar opens a screen in the working window for the
selected tank highlighted in the tree view.

Figure 3: TrueChem Main Screen

2.1 Graphic Button Tool-bar

The graphic button tool-bar allows direct access to commonly used features. Holding the
cursor over any icon will display the icon title. These buttons allow the user to quickly
access features including; Perform Test, View Graphs, Data Log, Tank Setup, Login,
Addslip Log, Printer, Email, Schedule, System Setup, Corrective Action Log, Reports,
Event Log, Manage Inventory Lots, User Setup, Log Out and Help. The left four buttons

43
(Perform Test, View Graphs, Data Log and Tank Setup) apply to the selected tank in the
Tree View. The remaining buttons are system level buttons and display data about the
facility as a whole. For example, clicking the beaker (Addslip Log) displays all of the
outstanding Addslips for the facility.

Figure 4: Main Screen Graphic Tool Bar

2.2 Tree View

The Tree View is made up of items that are user created to represent the user’s facility.
Like any standard Windows menu, clicking on the item or the + sign expands the tree and
clicking on the – sign collapses the tree. Most users divide the facility into process lines
(processes) and assign individual process elements (tanks) within the process. From a
practical standpoint, the process/tank organization will minimize the space required to
view the entire facility in the Tree View. The width of the Tree View can be adjusted by
placing the cursor over the boundary between the Tree View and the working window. A
double arrow appears left clicking and holding allows the user to drag the boundary
making the Tree view area larger or smaller. In Figure 5 scroll bars are present because
expanding the anodizing line causes the tree view to be larger than the window.

Figure 5: Main Screen Tree View

44
The horizontal scroll bar is present because the names in the Tree View are too wide for
the window. To select a particular tank simply click on the tank of interest to highlight it.
This activates the features related to that tank so that the data is available.

2.3 Status Bar

The status bar is located at the bottom of the window and displays current information on
the following items.
1) Logged In: shows the name of the user currently logged into TrueChem
2) Add Slip: displays Past Due if there are add sheets that have not been
signed off within the allotted time and the Past Due will blink to draw
attention.
3) Schedule: displays Past Due when tests or other scheduled items are not
completed within their allotted time and the Past Due will blink to draw
attention.
4) Corrective Actions: displays Exist if there are corrective actions that need
to be signed off.
5) The number of Samples outstanding from the Sample Module.

Figure 6: Main Screen Status Bar

2.4 Working Window

The working window is the area on TrueChem’s screen where most of the application
specific work will be done. The default view of this area (Figure 6) is the TrueChem

Figure 6: The Default Working Screen

logo. This area is an HTML browser that can be pointed at any web page on the Internet,
intranet, or local hard drive. The default setting is to take the user to the TrueChem help
website.

When a tank in the tree view has been selected and a command from the pull down or
button bar has been selected, the action opens a new screen in the working window. In
the case shown in Figure 7, the Perform Test button has been selected. Notice that the
name of the screen open in the working window is shown at the top right of the window
(Perform Test). In addition some information about the tank selected will appear in the
top left of the working window.

45
 Figure 7: TrueChem Working Screen

The system level buttons cause information about the facility as a whole to be displayed
in the working window. For example clicking the fire extinguisher (Corrective Action
Log) displays all of the outstanding corrective actions present.

Figure 8: System Level Buttons

Hint: Holding the cursor over a button as shown in figure 8 (Document Manager)
will cause a description of the button to pop up.

2.5 Pull Down Menus

The pull-down menus are standard Windows-style menus for accessing all of
TrueChem’s functions. The following is a complete set of the pull down menus and
shows each of the functions available under each heading. Access to the pull down menu

46
items may be limited to specific users by “rights” selection made in User set-up. If the
current user tries to access an area that their login is not set up for, a TrueChem user login
pop-up will appear to login to an account with the proper rights. This account may or
may not be available to the user attempting to login (more on this later in User Setup).

2.5.1 File Pull down

File pull down menu shows several standard activities. The first item under File; New
expands further to add either a New Process or a New Tank. Print allows the user to print

Figure 9: File Pull Down Menu

the contents of the working window. Email and Export take the contents of the working
window and convert them to html format for emailing to a colleague or to save as file.

2.5.2 Edit Pull Down

Under Edit are the familiar Cut, Copy and Paste commands. The last two items under the
Edit heading Perform Test and Tank Setup are only active if a particular tank in a
process has been selected.

Figure 10: Edit Pull Down Menu

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 2.5.3 View Pull Down
The items under the View heading will switch the view in the working window to the
screens identified.

Figure 11: View Pull Down Menu

2.5.4 Inventory Pull Down

The Inventory pull down is only visible for users that have purchased the Inventory
module and provides the same features as the inventory buttons.

Figure 12: Inventory Pull Down Menu

2.5.5 Tools Pull Down

The Tools pull down accesses functions that largely require administrator rights to
activate. This pull down can take you to System Set up, User Set up and Reports. The
Manage choice expands further and provides a number of options. Each of the items
shown in Manage is a list created by other activities. For example the Additive list is
created by setting up process tanks and contains the entire list of chemicals used by the
facility in TrueChem. Using the Manage button allows the user to edit these lists to
correct spelling errors or change the details of the items. TrueChem will not allow

48
certain changes if they affect processes. For instance, the user cannot delete a chemical
from the Additive List that is used in a tank make-up.

Figure 13: Manage Tools Pull-Down Expansion

Note: To delete a chemical from the Additive list it must first be removed from use
in each tank it is used in.

2.5.6 Help Pull Down

The Help pull down provides access to TrueLogic Company’s help functions, and
provides access to their website if the computer has web access.

Figure 14: Help Pull Down

49
Clicking the About TrueChem choice displays version information about TrueChem.
This information is useful when trying to solve problems that occur.

Figure 15: About TrueChem Screen

2.6 Window Resizing

Both the main window and the width of the tree view window can be adjusted if desired.

2.6.1 Main Window Resizing

The main TrueChem window can be resized by selecting any edge and dragging. To
change any of the window edge sizes, hold the cursor over the desired edge until a double
ended arrow appears then click and hold while moving the cursor to shrink or expand the
edge. On machines with Windows XP, the icon in the bottom right hand corner of the
window has a resize grip point and resizes the window symmetrically.

Figure 16: Window Resizing

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 2.6.2 Hiding Tree View
Inside the working window in the upper left corner is a button with an arrow on it. This
button can be used to cover the tree view and allow the working window to take up the
full TrueChem area. To recover the tree view, press the arrow button again. Without the
tree view, it is located below the Graphic button tool bar on the far left side.

Figure 17: Hiding Tree View

3.0 Initial Setup after Installation

There are a several settings that should be reviewed first on a new TrueChem system

setup. Select the System Setup icon from the graphical tool bar. The group of tabs
shown below will appear in the working window. The user should familiarize themselves
with the tabs and the variety of features they access.

51
 Figure 18: TrueChem System Setup Screen
Most of the setup under the System Setup only needs to be completed once for the entire
system: Occasionally some setting may need to be revisited and adjusted. However,
once the system has operated in the facility for a few months almost nothing in the
system setup tab will need adjustment.

The default tab that appears when the system setup button is pressed is the Terms tab.

Terms define the terminology that your TrueChem system will use. These items can be
changed at any time, and the system will update the headings they are used in. The terms
relate to items that may have specific meaning for your facility. As the user goes through
the list of terms, highlighting each term will enable a description in the “hints” area to
assist with defining the term for the facility. To change a term, highlight the row, press
return, change the term, and press return again.

Fill in your company name in the top box shown

The other tabs should be reviewed. There are some initial set up activities under each of
the tabs listed below.

Schedule Tab: There are many items that need to be reviewed on the schedule tab.
The shift definitions must be filled out, and they should reflect the way your company
operates. Defining other scheduling options can also be accomplished by going
through the list. These options can be revised later.
Library Tab: No initial work is required.
E-mail Tab: set up the e-mail server settings. If the computer handling TrueChem is
not going to be attached to the internet, this needs to be disabled. For users in a larger
company you may need assistance from your IT department in determining the proper
email settings.

52
 Figure 19: Facility Defined Term List
Corrective Action Tab: Allows the locking of a tank and sending of an email when
corrective actions are generated.
Database Tab: This tab shows the file path to the data base, and tools for backing up
the database. No initial set up required.
Addslip: set up the way that Add Slips will print. Also, you can opt not to print on
Print/Save command.
Test Recall: No initial work is required.
Graphs: Define the default graph settings.
Tracking: Select the TrueChem items that should be tracked in the event log.
Rules: No initial work is required. More discussion later
Colors: Adjust the colors that appear in various places. No initial work is required.
Labels: Used to print inventory labels if this feature is to be utilized in the inventory
module. You must define a printer for the labels even if you don’t intend to use them.
Inventory Tab: Reviews a variety of settings and email condition relative to
controlling inventory.
Dashboard: This tab is used when activating the dashboard.

3.1 Creating the Facility

Some thought needs to go into setting up the facility processes. Many facilities organize
their processes into process lines composed of elements (tanks). Some processes might be
an individual element (tank) where multiple ingredients are added. TrueChem can easily
handle either of these situations.

Note: One of the key aspects of setting up a facility is to organize the tanks by
identifying the identical or very similar (e.g. cleaners are often similar) tanks
throughout the facility. Identical and similar tanks should be completely created
once with the makeup, tests and schedule are created and then copied to minimize
effort.

3.1.1 Process Hierarchy Setup

In TrueChem, Groups are containers that hold Objects. Groups can be used to define
Processes, Lines, Shop Areas, Customers, etc. Most metal finishing shops identify
process lines and their component process steps as process tanks. The arrangement often
mimics the physical set up the shop but that is not required. The organization should
present a logical organization of the facility to the user that facilitates quick navigation to
enter and evaluate data. The tree view will be mimicked on the dashboard.

3.1.2 Creating a Process

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To create a process, right click on the factory icon on the tree and select New, then
Process. A new process with the name <New Process> will be created. You may type
any name you like for the process in the description area (Figure 20) and click OK.
Activating and Deactivating processes will be discussed later.

Figure 20: Creating a Process

Note: Create all the process names and review the process tanks in your facility that
will belong to each process. If you change your mind on the organization, tanks
are easily copied.

Figure 21: Add Process Pop up

Once the process is created, the process setup function is accessed by pressing the setup
icon below or by right clicking on the process in the tree view.

54
In the working window, the Process Setup window will be displayed. There are four tabs
in that working window; General, Notes, Distribution and Addslips. These tabs relate to
how addslips will be managed and allow the user to add general information that will be
printed on each addslip generated. Shown is the distribution Tab which allows the facility
to distribute addslips to the named individuals.

Figure 22: Process Setup Screen

3.1.2.1 General Tab

The “Responsible” field tells TrueChem who to notify when issues arise within this
Process. Designating a responsible individual (or user group) can facilitate
communication from TrueChem when emails are generated. More on this later.

NOTE: Only users defined in User Setup can be selected here. User Set up will be
discussed in detail later.

In the “Type” field, the facility can distinguish between process types. For example, wet
processes and dry processes like shot peening and grit blast. The Notes tab allows
“Process Display Notes” to be viewed by anyone testing any tank within this process.
You can also create “Addslip Print Notes” which are added to all Addslips created from
testing any tanks within this process.

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 3.1.2.2 Distribution Tab

The distribution tab allows the set up a distribution list if multiple personnel need to be
informed about additions. Email addresses can be added and the addslip sent immediately
on generation.
3.1.2.3 Addslips Tab

The facility can choose to generate process line level addslips by checking the box. The
type of report (Addslip) that is created for any tank in this process can be defined. By
default, Addslips are created by tank. That is, each Addslip represents a test of one tank.
Notifications (emails) can also be set up, however these are discussed in detail later after
users are discussed.

3.2 Creating Process Elements

After the processes are created, the process elements (tanks) are created within that
process. For the purposes of TrueChem a tank is any process element that requires
testing. So in addition to process tanks that have chemicals added to produce the desired
effect, a tank could also be created that represented the physical testing of a particular
process. A tank can also be created to track a non-chemical process such as the
temperature of cure oven, control of a salt spray booth or a process ventilation scrubber.
Rinse tanks are not generally included unless some sort of chemistry is added that needs
to be tracked or parameters like conductivity or pH are tracked.

Creating a process element (tank) is similar to creating a process. Click on the process
where you are adding a tank select New and then Tank. A popup similar to the new
process pop up will appear where you fill in the name of the tank (Figure 23)

Figure 23: Creating a New Process Tank

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 Note: When creating a facility where there are several similar tanks. Create the
first tank completely and then copy it as all of the work done in the tank setup will
also be copied.

The Add Tank pop-up also allows the user to define some additional information about
the tank. The Vendor and Location entries are not required, but a volume must be entered
before the screen will allow you to close. The volume units are selected from the pull
down list next to the volume. If you are unsure of the volume it can be changed later
without affecting any work done to create the tank.

Note: Throughout TrueChem when required fields are not filled in clicking OK will
result in a message that some required fields were left blank. These fields will be
highlighted in pink.

Figure 24: New Process Tank Popup

3.2.1 Renaming a Processes and Tanks

The name of any process or tank can be easily changed. Right click the Process item to be
renamed and select Rename from the pop-up menu. Type the new name and click OK.

Note: Sorting is numeric and alphabetical. To have numerically numbered tanks in

the proper order, single digit numbers must be preceded by a zero.

3.2.2 Deleting a Processes/Tanks

Right click the Process/Tank items to be deleted and select Delete from the pop-up menu.
You will be asked to confirm.

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 WARNING: deleting a process from the tree will delete all items within that
process. This fact becomes very important after the process has been in use and the
database contains operating data. Deleting the process will delete all associated
data. At this point it is better to create a new process and deactivate the old in order
to preserve the archival data from the old process.

Figure 25: Deleting a Process

3.2.3 Copying Tanks

Once a tank has been created with all the dimensions, make up, schedules, and
documents, copying the tank can provide a great time savings if there are similar tanks in
the facility. For example the same cleaner may be used in different process lines with the
same analysis. Copying this tank to the new line would only require modification of the
tank size to the new line and perhaps modification of the schedule for the analysis.

Figure 26: Copy Tank

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To copy, right click on the tank in the tree and select Copy. Then select the new line
where the copied tank belongs, right click and select Paste. A pop up will appear to
confirm the copy to the selected line. The Copy and Paste commands can also be
accessed from the Edit pull down menu.

Note: You cannot change the name of a tank or copy it if it is the tank selected (maybe
you are in tank set up or looking at the data log). You must be working in another part
of the program to copy/paste. One way to do this is to first the select the Home button
from the button bar prior to changing the name or copying.

4.0 Setting up Process Elements

The tank setup activity requires the bulk of the effort to create a facility in TrueChem. It
is at the tank level that the tank size, make-up, analysis tests, physical tests, scheduling of
tests and the attachment of documents is completed. Tank set up also leads to creating the
library of chemicals used.

Note: TrueChem’s basic structure examines the facility on a tank by tank basis.
This means that if the user wants to compare data relating to a particular
measurement with the operation of the tank, that data must be located in the tank
data. A new feature of TrueChem allows the user to overlay graphical data from
other tanks and allows comparison of selected data. The data can also be exported
from TrueChem and analyzed externally by the creation of a custom report or in
Excel.

The process setup function is accessed by first selecting the tank to work on and then
pressing the Setup icon below or by right clicking on the process in the tree view.

In the working window, the Tank Setup window will be displayed. There are eight tabs
appearing in the working window; General, Notes, Test, Addslips, Schedule, Make-up,
Docs and HMIS. Each of the seven Tabs in the working window will be discussed.

4.1 General Tab

During the Tank Setup, the default view opens the General tab. On the General tab, you
must fill in the tank volume so that TrueChem can properly calculate additions. Tank
volume can be entered directly in the size field on the top left side of the window. The
units must be selected first from the pull down menu to the right of the size field.
Alternately the volume of the tank can be calculated by entering the dimensions into the
Physical Dimensions area on the right side of the window. In order for the tank volume

59
to be calculated, you will need the freeboard height as well. When all the dimensions
have been entered, press the Calculate button and the volume will appear on the left side.

The Vendor field can be used to store the chemistry vendor’s name. The Location field
can be used to identify where the tank is placed within the facility. The bottom part of
the window (Safety Equipment) can be used to define the personal protective equipment
(PPE) when working at the tank. In addition, the right side on the bottom lists tank
Status information including:

• When the tank was created

• When it was last remade
• When the setup was last modified
• Whether the tank is active or deactivated (more on activation later)

Figure 27: Process Setup Screen

4.2 Tank Setup Notes Tab

Selecting the Notes tab allows the user to enter text that will be displayed to anyone
performing a test or with granted rights on this tank. Addslip notes can be entered that
will be included on all Addslips created for this tank. Special instructions needed for
adding chemicals can be added. There is no limit to the amount of text that is entered. In

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the upper-left hand corner of the Notes tab is a check box that allows the Notes tab to be
the first tab that shows up when a test is being performed. One effective way to make use
of the notes section is to keep a history of actions and events associated with the tank.
Tank make ups can be noted, strange behavior, the result of trouble shooting activities or
solution maintenance activities can all be entered here so that there is a running log of
activities relating to the tank.

Figure 29: Note Tab Working Screen

4.3 Make-up Setup

The Make-up tab provides a way to define what add amounts and additives will be
needed when making up a Tank. The bottom half of the window has space to enter
instructions that will be printed on the Remake Report (it will look identical to an
addslip). As shown, the make-up procedure instructions can be added here. The top half
of the window shows the additives (chemicals) used in the make up the process solution.
Chemical ingredients are added by clicking on the Add button in the middle of the
window. This brings up a Make-up pop up (Figure 30). Additives are selected from a
list. The additive list initially contains no additives. As processes are defined, chemicals
are added to the list and may be selected for other tanks using the same materials (see
Figure 30). In defining additives, information such as its unit of measure is entered and a
vendor can be entered.

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 Figure 30: Tank Setup Make up Tab Screen

Figure 31: Additive List

Once a chemical is selected from the list the make-up information can be entered. For
example, if the process solution concentration is 0.1 lb/gal, the unit selected would be
pound. By clicking the volume based check box the program will access the tank volume

62
and determine how many pounds are needed for the tank. To complete the makeup
calculation, 0.1 is entered into the Per unit of Tank Volume field and the desired number
of decimal points. When complete, click OK and the additive, the concentration and the
amount required for make-up appear on the Tank Set-up screen (Figure 33).

Figure 32: Tank Make up Pop up

Figure 33: Additive added to Tank Make up

Warning: once a tank has been activated and used with a particular chemistry,
TrueChem will not allow the changing of the additive for that tank. So if the
chemistry is changed at some point a new tank must be created.

4.3.1 Additive Set up

The additive list is used to create the library of chemicals used by the facility. During
Make up, if an additive not on the list is needed, selecting < New additive > (located at
the very top of the list on the additive pull down) will display the pop up in Figure 34.
The Additive Type can be defined.” Chemical” is the default. The Name and Short
Name of the chemical is added along with Stock Units of measure. These units should
match up to how the chemical is added to the tank (i.e. weight or volume).

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 Figure 34: New Additive Pop up

If the facility has not purchased the Inventory Module, then the bottom portion of the
screen showing minimum and maximum inventory levels and expiration dates will not be
seen.

4.4 Test Setup

The Test tab is where specific details of the test for this a are defined. Tests can include
chemical analysis of the solution components, physical test results or process parameters
such as temperature or pH. Items are added to a list from top to bottom that make up the
necessary elements for testing this chemistry by clicking Add. Existing items can be
modified or deleted from this screen. The choices are Test Description (highlighted in
gray), Input Value, Result Calculation and Adjustment. Each new item added goes to
the bottom of the list. The order is important as it can affect how calculations are done
during a test (more on that later). In general, each input, result and adjustment for a
particular additive should be grouped together as this allows the individual tests to be
completed without testing the rest of the tank items.

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 Figure 35: Tank Setup Test Tab Screen

The arrows on the right side of the screen can be used to re-arrange the test items. Simply
click the item and then click the arrows to move the item up or down. Holding the shift
key down and selecting a group of items allows movement of the entire highlighted
group.

Double clicking the eye-shape on the right allows the line to be hidden. This is useful for
intermediate calculations.

Warning: Changing an input value, result calculation or adjustment calculations

will eliminate or invalidate all the data stored in TrueChem related to that item. If a
new method must be incorporated and the old data must be retained, then a new
tank must be created to use the new method.

4.4.1 Adding a Test Item

Choosing the Add Test Item dialog displays the choices listed. From this dialog you can
select:

65
 • Test Description: these items are simply title bars that help separate sections of
the test.
• Input Value: these items allow input of raw test values such as mls of titrant,
concentration of titrant or physical test items such as number pits in a salt spray
coupon. Any data recorded for a test can be input.
• Result Calculations: these items are used to calculate the value that is being
tested for (e.g., oz/gal of Metal, pH, etc).
• Adjustment: these items are used to calculate the amount of additive to be added
to the Tank to adjust a result item.

Figure 36: Add Test Item

4.4.2 Adding a Test Description

By selecting Test Description this screen will display:

Figure 37: Add Test Description

When adding a test description, simply type the Description or name of the test in the
description field and click OK. Once the Test Description, or any test item, has been
added, it will be listed in the window on the Test tab. The left-hand side of the row
created will indicate the type of test item added. Clicking Add again will allow more test
items to be added.

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 Note: The items in the Test tab of the Tank Set-up window can be rearranged by
clicking on the item and then clicking on the arrows at the right of the screen (see
Figure 33) to move the item up or down.

4.4.3 Adding an Input Item

By selecting Input Value option the screen in Figure 38 will display. Selecting the
Prompt text field allows a description, direction or prompt that will ask the testing
personnel to input the data. For example, “Please enter mls of HCl used to titrate”. The
Default Input field is optional and can be used to pre-fill the input field with a value that
can be modified at test time.

Figure 38: Input Value

Additional check boxes are provided to save the changes so the new value appears as the
next default value and to log changes. Input value restrictions can limit the Lowest and
Highest (also optional) input values and can be used to set the lower and upper limit of
acceptable inputs. When all the fields are complete, click OK.

Note: the Save input as text is used when an alpha numeric text is needed to be
input such as a part number.

Once the Input Value item has been added, it will be listed in the window on the test tab.
TrueChem assigns a number to the variable created by the input item (INP1) as the name
of this input item. This variable name is then used in other calculations.

Figure 39: Test Screen With Added Items Displayed.

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This is the variable name that will be used to access the input value in the Result
Calculation item. Clicking Add again will allow more test items to be added.

4.4.4 Adding a Result Item

When the Result Calculation option is selected, the screen in Figure 40 is displayed: In
the Calculation field enter the formula that will be used to calculate the result item. In
this example INP3 and INP4 have been entered with square brackets [ ] around them.
The square brackets are required and their function is to tell TrueChem that you want it
to translate the variable name in the brackets to the actual value it represents. The
equation reports the calculation result as “g/L XYZ” which has been entered in the Result
Description field. Notice that an equals sign is not required and that the formula syntax is
similar to ExcelTM. Both ExcelTM and TrueChem operate in Visual Basic and the syntax
is the same.

The Short Name is used in the log book view to label the column. Decimals should be
set to the number of decimals with which the result is to be stored. Result specification
limits should be entered in the Upper, Optimum, and Lower Spec fields. The User 1
limits fields are typically used to establish shop limits or “action levels” that require a
change to the tanks to prevent them from going outside the specification limits. User 2
limits can be used to refine that further. The Bailout section is used for solutions that
become too high in concentration, usually from contaminant growth. Set points calling
for a decant can be set along with the target level used to calculate the bailout.

Figure 40: Result Test Item Screen

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The Apply Rules section allows custom or global rules to be attached to this result item.
For more details on using rules see the Using Rules section of this document. When the
result item is completed, click OK to save it. Notice that the result item is now added to
the test window.

Note: A calculation can be changed after the tank has been in operation (data has
been entered). However changing the calculation may invalidate any previous data
recorded with that result. If saving the old data is important, a new tank should be
created for the changed calculation and the old tank de-activated.

4.4.5 Adding an Adjustment Item

Adjustments are additions to bring the solution ingredient concentration to a
predetermined set point. Adjustments can be set up two different ways. Most
adjustments can be handled by using the standard adjustment form. An example is
displayed in Figure 41. The other option is a custom adjustment shown in Figure 42. The
adjustment calculation follows the basic form in the equation below.

Adjustment (g) = (set point conc(g/L)-current conc (g/L)-) x tank vol(L)

Setting up the adjustment involves selecting the additive, the unit of addition (pounds,
gallons, grams, etc.) and supplying set points. The standard adjustment allows you to
select and/or fill in these items to create the equation. The first step is to select the
Adjustment.

In the Add pull down box, select the additive to be used.

NOTE: If the additive is not in the pull down list, select the item in the list <New
Additive> (refer to next image for adding a new additive to the list).
NOTE: Once an adjustment is created with an assigned additive it cannot be
changed. If the chemistry is changed and a new tank is not created, the adjustment
must be deleted and a new one created to allow the new reference additive.

In the example shown, the equation reads as follows:

“ABC” is added in the amount of 1 pounds to adjust RST1 g/L ABC concentration by
1.2 g/L ABC for every 100 gallons of volume to obtain a value of 2.4 (g/L). In the
sentence above the items in parenthesis are understood. Of course, if the concentration is
in oz/gal or grams/Liter then the entries would be changed to reflect the actual method of
addition. In addition, the Increment of the addition can be specified as well as the starting
point.

If the advanced button is pressed, the screen in Figure 42 appears and the minimum or
maximum add can be set.

69
 Figure 41: Standard Adjustment Screen.

The same adjustment could also be accomplished using a custom calculation as shown in
Figure 42. Here, the additive is selected as well as the unit of measure and the minimum
increment. The equation is entered as shown. The difficulty with the custom calculation
is that all the data must be entered into the calculation. Variables have been used for the

Figure 42: Sample Custom Calculation

optimum value ([rst.opt]) and for the tank volume ([obj.volume]). Notice that the
variables are not capitalized.

Note: TrueChem variables are not case sensitive. A complete list of

TrueChem variables is found at the end of the Training Guide. The most
up to date list is found on TrueLogic’s help website.

70
Decants are handled in the Result item. Many users find it more useful to define a
minimum add amount. This is accomplished by pressing the Advanced button. The
screen in Figure 43 will appear. The Minimum field is used to identify the minimum add
amount allowed, meaning that any adds smaller than the minimum will not be issued.
The Maximum field is used to set a maximum amount that will be added for any one
given test.

Figure 43: Advanced Options

Once the calculations for the adjustment (either standard or custom) are completed,
clicking OK will add the adjustment to the test tab in Tank setup.

Note: TrueChem makes all calculations in a step fashion. This means that in order
to analyze and adjust only one component, all calculations pertaining to that item
should be grouped together. Grouping all the adjustments at the end then forces the
calculation of all items before an adjustment is calculated.

4.5 Addslip Setup

The Addslip tab allows for the setup of Addslips. By default, all tanks use the settings
defined on the Addslip tab in the System Setup. By clicking on Use System Default you
can disable the fields allowing customization of the Tank Add Sheet. Even if the addslip
is not being customized, the allotted time fields can be adjusted if special circumstances
require a different than standard time for signoff (completion of adds) of the addslip for
this tank.

With the Use system defaults box unchecked, the Print Addslip (add sheet Template),
Store Image (Print/Store Options) and Track Addslip fields are activated. A standard
addslip template is loaded, but facility custom ones can be loaded into TrueChem. In
addition, TrueChem allows a paperless operation where addslips are viewed and not
printed. There are a number of options to choose from, such as, time allotted to complete

71
an add and what information will be placed on the Addslip. Each item has pull down
menus to assist with decisions.

Note: When establishing the times allotted for various activities, it is important to
provide sufficient time to complete the tasks. Exceeding the time allotted requires
sign off and creates additional activity to explain why things were not completed as
planned.

Figure 44: Add Sheet Setup

4.6 Schedule Setup

On the Schedule tab, tests and maintenance frequencies can be defined. In the top
section, any result item created under the Test tab will be listed. Each item can be
scheduled. You may not want to schedule items that are created as intermediate results of
multi-step calculations. It is sufficient to schedule the final result of the calculation.
When the screen is initially opened, none of the items listed will be scheduled. Schedules
are established by clicking on the item and then selecting Modify. In the lower section
(Other Schedules), activities such as tank maintenance, solution bleed and feed, remakes,
filter changes, calibrations, etc. can be added and scheduled.

72
 Figure 45: Schedule Set up

To access and schedule a particular item, click on the item and choose Modify. The pop
up in Figure 46 will open. The test item is listed near the top and Priority (1 highest, 10
lowest) can also be selected (10 is the default priority). There are three frequency options
“normal” “accelerated” and “decelerated”. Start by establishing the normal frequency.

Figure 46: Test Frequency Set Up

Initially, a result item will show “Not scheduled” in the frequency box. If the frequency
listed is selected, a pull down arrow on the far right of the “normal” frequency will list
each frequency already used. Any previously created frequencies can be selected by
highlighting the desired frequency from the list. When an existing frequency is selected,
the details of the frequency cannot be modified. They are shown grayed out. If these

73
conditions do not meet the current schedule requirement, then a new frequency must be
created.

To create a new frequency, select <New Frequency>. When a new test frequency is
requested the pop up below opens. The schedule selected depends on how the frequency
is used. Pick the increment needed. A few rules will assist in selecting the proper base
frequency. If the desired frequency is every two days select “daily” for the frequency. If
three times per week is desired pick “weekly”. The schedule is further refined as
described on the next figure. The same rational is used for biweekly, once per month or
once every six months - or for testing required several times per day.

Figure 47: New Test Frequency Set Up

The frequency selection opens another window with more details to select. Shown in

Figure 48: New Detail Frequency Set Up

Figure 48 is the window for weekly testing. There are several decisions to make for the
new frequency. When the choices are made, click OK to save and exit.

Note: Required items not completed will result in the window remaining open and
the required items highlighted pink.

74
 Note: When establishing the times allotted for various activities, it is important to
provide sufficient time to complete the tasks. Exceeding the time allotted requires
sign off and creates additional activity to explain why things were not completed as
planned.

4.6.1 Other Schedules

In the lower section of the Tank Setup Schedule tab is Other Schedules. In this section,
schedules for activities not covered by the calculations can be established. Items such as
filter changes, carbon treatment, dummy plating, calibrations, etc are scheduled here.
This function can be used for any event that might occur to a tank at any frequency.

Figure 49: Other Item Scheduling

Since these activities are not based on a calculation, each item must be created. Selecting
the Add a schedule in the Other Schedules section brings up the pop up shown in Figure
50. A description of the activity must be entered, and the Print section must also be
constructed by selecting or creating from the print menu pull down. These instructions
will show up on an Addslip that is printed when the item comes due. Other schedules are
completed by going to the schedule window by clicking the schedule icon. The default
display is for all currently due items. Other schedule items will be mixed in.

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 Figure 50: Other Schedules Setup Window

Since there are no calculations associated with these items, selecting an Other Schedule
item in the Schedule and clicking “Do Now” opens the output screen for printing and
saving. Items from the print menu will be printed on the Addslip form as instructions to
complete the task. Sample instructions are shown in the Figure 51. Changing the
instruction of a Library item requires going to the System Setup button and the Library
tab. The selected item can be updated as desired.

Note: Other schedule item addslips will show no addition due and appear blank when
opened in the Addslip Log

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 Figure 51 Print Library Instructions for an Other Schedule Item

4.6.2 Sample Module

The sampling module is part of the standard TrueChem package. The sampling icon
appears next to the perform test icon

The sample module allows the facility to separately record and track samples used for
monitoring processes. The sample module was designed for chemical suppliers that
receive samples from their customers and needed a way to track the processing of these
samples and report to their customers the status of the analysis. This feature is also very
useful for metal finishing facilities that want to track samples sent off site for analysis.
Offsite for the purposes of this discussion is out of the lab where TrueChem users enter
data. Thus, “offsite” includes labs in another part of the facility or outside labs that are
contracted to perform specific testing.

The sample feature is used by clicking on a process line or a tank in a process line and
then pressing the sample icon. A list of all of the tests used in that process line appears in
the working window and the tests desired for the sample are selected by checking the
check boxes. TrueChem then assigns a unique tracking number for the sample and
assigns the current date and time as the start time. TrueChem tracks the time until the
sample results are entered.

77
The default setting for TrueChem is with the Sampling Module deactivated, and then the
Sample and test times are the same. The Sampling module is included in the base version
of TrueChem. If the sampling module has not been requested and the facility decides it
would be useful, simply contact TrueLogic and we will activate the module for the
facility.

Figure 52: Sample Module Main Screen

The sample module can also be used to initiate the gathering of a sample for processing.
A time window for completing the sample processing provides clear tracking of when the
sample was gathered/received and when the analysis results are recorded. The default
sample completion time is 3 days.

Some facilities choose not to use this feature especially when samples are gathered and
immediately analyzed. If the sampling module is not utilized, TrueChem assigns the
sample time to be the time when the results are entered.

4.7 Docs Setup

On the Docs (Document) tab, multiple documents can be attached to this tank. Attaching
a document forms a link. This allows the referenced documents to be maintained and

78
managed outside of TrueChem. As long as the document filename is maintained and the
path is consistent, TrueChem will access the posted document. Documents typically
attached include specifications, procedures and MSDS. There is no-limit to the number or
types of documents that can be attached. The attached document will be available to
anyone performing a test on this tank.

Note: The documents must reside on a computer accessible by the computer that
TrueChem is located on - such as the computer itself or a shared drive on the
company network.

Figure 53: Document Screen

4.8 HMIS Tab

The HMIS tab helps the facility communicate the hazard level of the materials in use for
a particular tank and to define the personal protective equipment required to perform
work at the tank.

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 Figure: 54: HMIS Tab page

4.9 User Setup

Establishing who will enter, store, review and manipulate data is an important part of the
setup of TrueChem. Defining the users and their rights also helps the facility define the
roles and responsibilities pertaining to the process areas more clearly. The user setup is
where access to the TrueChem functions is established. Creating user accounts is an
effective way to build the email directory for personnel receiving notification for various
reasons.

4.9.1 Defining Users

Initially, TrueChem come with two users; the Default User that opens when TrueChem is
started and the Administrator (Admin). To create a user you must have administrative
rights. Select the User Setup button from the graphical menu bar.

The initial view is Active Users. There are additional views: Locked Users, Inactive
Users and All Users.

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 Figure 55: User Set up

TrueChem comes preloaded with two users, Admin and Default. These users have
special functions and cannot be deleted. The Admin user is TrueChem’s Super User and
can do anything within TrueChem. This user’s password should be changed and
maintained by the highest level TrueChem user. The default password for the
administrator is password.

The Default User is the user that is logged in when TrueChem first starts and when users
log out. The Default User has rights just like any normal user, and those rights should be
set up to allow for only the function in TrueChem that you would want any person
accessing TrueChem to perform. It is not recommended that the Default User ever be
able to perform functions that write data or information to the database. If this were
possible, the identity of the individual performing the update would not be known.

Users must be created individually but can be assigned to groups. Groups are also
created individually but allow the facility to establish common categories of user rights
and then assign users to the groups. The rights of any particular user are the sum of the
individual user rights and the rights of group(s) they are assigned to. New users can be
added by pressing the Add User button. Existing users can be modified by selecting
Modify.

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 Figure 56: User Setup Screen

The User ID field is the name a user will type in each time they log in. It can be
anything and can be changed any time but must contain no spaces. The Password and
Verify fields contain the password that the user will enter to authenticate. The First
Name, Last Name and Work Location fields allow users to be properly identified and
are required. The remaining fields in user information are not required. If you want
TrueChem to be able to send this user email, use the Email field. In the status area, the
Active User check box indicates this user can logon and use TrueChem. If Active User
is unchecked, the disabled date will be set and the user becomes disabled. When multiple
failed login attempts occur, the Locked check box is set and the date and time saved. To
unlock a user, a user with administrative rights must uncheck this box.

Note: The number of failed logins to lock the database is six.

There are two tabs to assign rights to users; individually and by group. The Function
Rights section lists functions that can be performed in TrueChem. By highlighting a
function and selecting On All, the user has the right to perform this function on all tanks.
On None says the right is granted on none of the tanks and On Select allows for the
selection of which tank of which the right is granted.

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 Figure 57: Pop up for Rights on Select Tanks

When On Select is chosen, the select button is enabled. Pressing select causes the Select
window to appear. The tree expands as does the tree view. Check boxes allow the
selection of entire process lines, individual tanks and, in some instances, individual
components to apply rights for a given group or user.

Another way to apply rights is to import them. By clicking on Import Rights, the list of
available users will appear. And by selecting a user, TrueChem applies those rights to
the desired user.

4.9.2 User Groups

Groups are created the same way that individual users are. The name of the group and a
description are created, and the rights for the groups are assigned. The advantage of
creating groups is that the rights are defined based on the job function and then
individuals can be assigned or removed without modifying the rights. If groups are not
used, as user responsibilities change, the user rights may have to be modified. It is much
simpler and more convenient to add or remove groups that a particular user belongs to.
The total rights of any particular user are the sum of the different functions of each group
to which the user is assigned.

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 Figure 58: Group Set up

The Groups tab allows the assignment of the selected user to one or more groups.
Groups are either created for assigning rights to a group of individuals or creating an
email group. In this example we have on the right hand side

Figure 59: User Group Affiliations

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the names of three groups: Engineering, Manufacturing and QA. This user is not a
member of any of these groups. But he is a member of the Inventory group and of the
Supervisor group. By selecting any group on the left or the right and using the arrow
keys in between to move that group, a user can be assigned to a group or unassigned from
a group. The user automatically inherits all rights associated with an assigned group.

4.9.3 Assigning members to a Group

By clicking the Users tab, the users can be assigned as Members or Non-Members of
the group by selecting the users name and using the arrow key to move them to either the
Members or Non-Members column.

Figure 60: Assigning Group Members

4.9.4 Changing a Password

On the Login screen there is a Change Password button that will allow any particular
user to change their password. First the User ID must be entered, and then the Change
Password button can be selected. When it is selected, a dialogue will appear showing
the User’s ID that was selected and a place to enter the Old Password and the New
Password. If this is successful, the user has changed the password, and may now log in
with the new password.

Note: In the User Setup the password is displayed as number of “*”. The
administrator can reset a password but not identify a user’s password.

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 Figure 61: Change Password Screen

5.0 Advanced Setup Variables, Scripts and Rules

Much of the power of TrueChem comes from the ability to write scripts. The syntax for
all of the equations and logic is from Visual Basic. The skilled user can develop scripts
that perform specific functions.

5.1 Variables
All of the variables have the same general form, and are enclosed in brackets:

[INP1]

The variables are not case sensitive and after the user gets used to the system, the name
describes the variable.

For example [RST.USER1UPPER] returns the values of the User 1 upper spec limit from
a result item. The user should become familiar with variables as they are also used when
generating emails that are sent by TrueChem. Knowledge of the variables and format is
also needed for advanced calculations and scripts.

Equations are written in the format shown

Result = ([INP1]*[INP2]/[INP3])+4

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Brackets enclose each variable name and parentheses are used as they would normally in
mathematics.

Variables are a great help when rules are written that generate either popup messages or
emails. If variables are used, a general message can be written that allows TrueChem to
fill process, tank or test information pulled from the database by variables used.

TrueChem has an extensive list of variables. The current list is attached in Appendix A.
Each variable and a brief description are listed. TrueLogic makes periodic additions and
updates the list on the website. For the most up to date list, go to
http://www.truechem.com/ and then go to the frequently asked questions (FAQ). The
variable list is the first one.

5.2 Scripts
Writing scripts is programming. Some scripts are simple IF/THEN statements, others
require several steps. Each calculation is actually a script. Many are embedded in the
functionality of TrueChem. A good example is the adjustment screen. The script shown
reads as follows: “sulfuric acid in the amount of 0.00438 gallons are added to adjust
[RST1] by 1 oz/gal for every gallon of tank volume to obtain a value of 33 oz/gal”.

Written as a script it would appear as:

[ADJ] gal = [OBJECT.VOLUME]*([RST.OPT]-[RST.CURRENT])* 0.00438

Figure 62: Adjustment Standard Script

Scripts are often used to describe complicated calculations or to incorporate logic into an
evaluation. Figure 63 shows a script for determining the highest number of pits present in
a group of salt spray coupons. The logic looks at each of the input values for the number

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of pits on each coupon and finds the one with the highest number of pits. The number is
compared to the limit (5 maximum) to determine pass or fail.

Figure 63: Salt Spray Evaluation Highest Pits Script

In this script, first the variable “Hival” is defined, and then it is set to zero. Next, the
value of Hival is compared to each of the input values for the number of pits on each salt
spray coupon ([inp9] through [inp13]). Note than [inp12] and [inp13] are off the screen.
If the value of the INP is higher than the current value of Hival, the higher value becomes
Hival. The last statement (off screen) is Result=Hival, which sets the result to the highest
value found. Scripting allows TrueChem basically unlimited capability to perform
calculations. The only limitation is the mathematical knowledge of the user.

5.3 Rules

The heart of transforming TrueChem from a laboratory database to an expert process

control database tool lies in the effective use of rules. Rules “teach” TrueChem to make
decisions from the inputs and or calculated results. The decisions made produce actions
without human intervention. Rules are logic statements that allow TrueChem to make
decisions based on the results calculated and the conditions setup governing the result.
Rules can be applied to either results or adjustment items. TrueChem provides input
screens that allow the user to quickly create a rule and select actions that fulfill the rule
that the conditions initiate. These actions could be a Popup box, automatically
rescheduling a test, or sending email notification to name a few. All rule setups start with
scripts.

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To create a rule, the user will start either in the Tank Setup, Test tab screen or more often
in the System Setup, Rules tab. Creating rules via both paths will be discussed as well as
the benefits of each. Regardless of whether the rule is initiated at the tank level or system
level, the Add Rule command opens the screen in Figure 64. The logic rule reads “If the
current [result] is < [Rst.LSL} (lower spec limit) or > [Rst.USL] (upper spec limit)
display a message (the check box selected).

Figure 64: Rule Pop up

The rule shown below was made with the pop up in Figure 64

Figure 65: Script Form of Rule

5.3.1 Global Rules

Some of the rules created will affect all process tanks. These are system rules and can be
applied globally by creating them in the System Setup tab rather than at the tank level.

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System Rule Sets allow the facility to create single or multiple rules under the set name
that are applied together. This rule set can then be applied to any result or adjustment in
the TrueChem facility. However, the same rule cannot be applied to a result and an
adjustment simultaneously because different variables are used. The rule set below is
accessed by going to System Setup and clicking on the Rules tab. Then the Rule Sets
pull down list is used to select the rule.

Figure 66: Accessing Rule Sets

Notice that in the bottom of the screen, all the results are checked and the names of the
process lines are highlighted gray. This indicates that a rule is applied to the results. At
the system level the rule can be applied to all the results, to a few, or to just one. Notice
also that the Adjustment side is unchecked. No rules are applied to adjustments here.
Creating a Rule Set

To create a new rule, select choose the <Add New Rule Set> from the pull down menu
under Rule Sets. A pop up will appear to name the rule set. Once named click OK and
the new rule set will appear in the pull down window where the rule set list was. The rule
set details window will be blank. To Add, Modify or Delete rules in the set, use the button
below the Rule Set Details window.

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 Figure 67: Creating a Rule Set

Click Add to add a rule to the set. The Rule Setup window will appear. Fill in the
required information. The rule shown in Figure 68 reads as follows:

Figure 68: Rule Set up Window

“If result (of this test) is greater than 1.25 (125%) of the previous result or less than 0.75
(75%) of the previous result then display the message ‘The current result varies by >25%
from the previous value. Check your data. If the result is saved a retest will be
scheduled.’ ” Displaying a message is one of many possible notifications and these are
discussed in detail later. When the rule setup is complete, click OK. The complete rule
will appear in the rule detail window.

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Note: rules are evaluated by TrueChem as soon as the calculation they are attached to
is completed which occurs in the Perform Test screen before data is saved.

Figure 69: System Rule Set

Next, apply the rule by clicking on the facility, Process, or tank Results or Adjustments.
The rule can be applied to every tank in the facility or to a single result or adjustment
item. Clicking the check box at a higher level applies the rule to every item below that
level. For example, in Figure 69 the pH Dump rule was applied to only the Stripper tank
in the Cleaner line and to the Developer tank in the Cupric Process

Figure 70: Multiple Rules

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Multiple rules can be generated for the same rule set. When there is more than one rule,
they will appear in sequence. In the case shown in Figure 70, the first rule checks to see
if the tank is outside shop limits, and turns the dashboard indicator yellow in each case.
The second rule checks to see if the tank is outside of the spec limits, and turns each one
red. The second rule here will override the first when true because it is executed second.

Note: Each rule in the set is applied to the tanks selected so if the order the rules
are executed in is important, some thought needs to go into the order of creation.
Rules can be added or deleted but they cannot be moved in the window like test
items can.

5.3.2 Rule Notifications

There are many possible outcomes from fulfilling a rule. The options are shown below.
• Display Message
• Protection
• Scheduling Options
• Log Event
• Print Message on Addsheet
• Create Bookmark
• Require New Makeup
• Require Corrective Action signoff
• Display Result as
• Send an email
• Set Result Status/State
• Execute a script
• Require Bailout
These options can be used individually or in any combination. They are selected by
checking the box.

5.4 Custom Rules (Tank Level Rule)

Custom rules are created similarly to global rules but are specific to a given tank. Global
rules were introduced first because the majority of rules can be written globally if they
are applied to more than one process tank. Specific custom rules usually involve
controlling unique behaviors for particular tanks and may involve complex scripts.
Complex scripts are not covered in this training guide.

5.4.1 Custom Rule Set up

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To apply a custom rule, go to the tank of interest and click on the Tank Setup icon, then
go to Test tab and select the result or adjustment item where a rule is needed and click
the Add button under Apply Rules. From this popup, choose Custom Rule.

Figure 71: Custom Rule Set up

Once Custom Rule is selected, the same rule Setup screen appears as in the system rule
set discussion (Figure 68) appears.

Note: A system rule set can be applied at the tank level. This is done by selecting
System Rule Set and selecting the desired rule from the pull down list.

6.0 Inventory Module

The inventory module is an optional feature to TrueChem. The inventory module is
accessed by clicking the Inventory icon on the tree view window that appears at the very
top of the Tree view below the facility name as shown in the Figure. Clicking the
Inventory icon replaces the left four buttons shown when a tank is selected. These buttons
access the major features; Enter Transaction, Enter Purchase Orders, Receive Lots and
Inventory Reports. The inventory module allows the facility to track material usage by
creating an inventory of the chemicals and supplies on hand, receiving new material into
inventory and can even generate purchase orders automatically. The usage of materials
that are called for in tank make ups and additions are automatically tracked by the
inventory module. Materials in stock can also be tracked by expiration dates or by lot
number.

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 Figure 72: Tree View Inventory Icon

Figure 73: Inventory Module Active Buttons

Note: Software key is not required to enter inventory transactions.

6.1 Creating the Inventory

The inventory of chemicals and materials used must be created. There are two ways to
accomplish this task. Creating tanks (and the additives used to make them up) creates
most of the inventory list. Alternately, entering chemicals from building the inventory
list makes those additives available for use in tank make up. Practically, most facilities
create the processes first and add in inventory control later. Items that are not used in
tests must be added. This would include things like laboratory chemicals used for
analysis only and other non-test items like filters, anodes or carbon.

If the additive was not initially created as an inventory controlled item, changing it to one
that is inventory controlled is a simple task. Go to Tools, Manage and Additive to access
the list of materials available for inventory control.

Note: If the Manage list shows additive list as inactive (grayed out), click on the Home
icon then retry clicking Tools, Manage and Additive to access the list.

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 Figure 74: Accessing Additives

Next, select the additive by highlighting it and clicking Modify. A warning will appear
that states “changes will affect each occurrence of the chemical use”.

Click OK and the screen in Figure 75 will open. There are three tabs available: General,
HMIS and Docs. The General tab contains several items that the facility may want to
complete regarding the inventory control of the additive. These include: Internal Part
Number, clicking the Inventory control check box, setting Minimum and Maximum
Inventory Levels and if inventory lots will have an expiration date. The HMIS tab opens
a screen that allows the defining of hazards associated with the chemical and the Docs
(document) tab allows the referencing of document s like product literature and MSDS to
the specific chemical.

When the information has been added, click OK. Now the chemical is ready to be
inventoried.

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 Figure 75: Additive Setup Screen

6.2 Enter a Transaction

To enter a (manual) transaction, click on the icon or go to the Inventory pull down and
select Create a Manual Transaction.

The screen shown in the Figure 76 will appear. Two actions are possible from the pull
down list shown; to add or subtract from the inventory. Fill in the required information
which includes the Lot number to work against and the quantity (the field to the right of
the Action field). A comment must be entered. When complete, click on the Save button
on the bottom left of the working window.

Note: if required sections of a form are omitted, TrueChem will turn them pink and the
screen cannot be exited until completed.

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 Figure 76: Enter Transaction Inventory Screen

6.3 Create a Purchase Requisition

Creating a purchase requisition is accomplished by clicking on the “shopping cart” icon.

The screen shown in Figure 77 will appear. The purchase order number is entered and the
Additive selected from the pull down list. Vendor and Manufacturer details are entered
or selected from their respective pull down lists. Quantity, Price, Order Date and
projected Delivery Date are entered and there is a note field for comments. When
complete, click Save.

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 Figure 75: Create a Purchase Order

6.4 Receive a Lot

To add to the inventory, click Receive a Lot either from the pull down menu under
Inventory or from the icon.

The screen in Figure 76 will appear. Enter the lot information and quantity amount
received and expiration date. The sections highlighted in pink are required. The Note
field is optional and can be used to enter comments about the lot (e.g. was the packaging
damaged or the order incomplete?).

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 Figure 76: Receive a Lot

6.5 Inventory Reports

To access the Inventory reports options, click on the scroll icon.

The screen in Figure 77 will appear. The default view is the Additive Balance. The
entries are color coded and the legend is in the bottom right corner of the screen.
Black text Active
Yellow highlight Alert
Orange text Retired
Blue text On Order
Red text Expired

Yellow alerts indicate that the balance contains material where there is some sort of
problem. Other views are available, and you can sort the inventory based on the Lot
Balance, material On Order, by Transactions, or by Expiration date.

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 Figure 77: Inventory Reports

6.6 Manage Inventory Lots

Several different inventory activities are available by clicking on the Fork truck icon on
the graphic tool bar as well.

The option is selected from the pull down list under View. The inventory report appears
in the main window. The standard reports available track Active Lots, Expired Lots,
Retired Lots, All Lots and Purchase Requisitions.

Figure 78: Inventory View Pull Down Menu

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The color coding of the lots is identical to that describe in the Inventory Reports section.

7.0 Dashboards
The dashboard is an add-on feature to TrueChem that displays the important elements of
the database in a web page format. The Dashboard provides the ability to present the
facility data in a “real” time fashion to both TrueChem users and other facility personnel
that need current process status information. Personnel such as managers, engineers,
process planners and maintenance can access TrueChem information through the
Dashboard. Users do not need TrueChem on their computer to view the Dashboard.
However, in order to use this feature a network must be available so a short cut to this
webpage can be copied to each computer needing access to the dashboard. The dashboard
files query TrueChem periodically and update the status of the processes displayed.

Three conditions are displayed: in specification (green) outside shop limits (yellow) and
out of specification (red). In order to establish the three levels, the facility must establish
shop limits that are inside of the specification limits for each process. Clicking any of the
left buttons displayed allows the viewer to “drill down” - first into the line view and then
into the tank view. For example clicking on the red Test line shown in Figure 79 opens
the screen in Figure 80. The deepest level is the tank level shown in Figure 81.

Other information about the processes and tanks is also available, including whether the
tank is active or inactive (asterisk or grayed), when the next analysis is due if samples are
out for the process, any pending adds, or if corrective actions (Exceptions) need action.

Figure 79: Dashboard Facility View

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 Figure 80: Process Level Dashboard View

Figure 80 shows the Process Level where the condition of the individual tanks making up
the line is displayed. The gray tank shown is inactive and resulted in the asterisk shown
in Figure 79. Figure 81 shows additional information accessed by drilling down to the
Tank Level. Here the status of each tested parameter is shown.

Figure 81: Tank Level Dashboard View

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 7.1 Dashboard Setup
Setting up the dashboard involves several steps. First, the facility must establish shop
limits for the processes. These limits will be inside of the specification limits established
for each process. The shop limits allow the cautionary yellow dashboard color to
function. Next, dashboard rules must be created. These rules tell TrueChem how to
interpret the results relative to the shop and specification limits.

Note: The dashboard rules are advanced rules and should be set up by qualified
personnel.

7.1.1 Shop Limits

Shop limits are established by using the User1 Limits available on the Result items
(shown in Figure 82). Each result tracked by the dashboard must have User 1 limits in
order for the yellow caution alert on the dashboard to function

Figure 82: Shop Limit Setup

7.1.2 Dashboard Rules

The dashboard rules have a specific format. To create the rules, click the System Setup
icon and then the Rules tab. Create a rule set called “Dashboard Rules (see Figure 83).
The details of rule setup are discussed in section of this chapter. The rule syntax must
match that shown in the figure exactly!!

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 Figure 83: Dashboard Rules

The first rule shown in Figure 83 is the cautionary rule (yellow for outside shop limits),
the rule setup screen is shown in Figure 84.The variable name [rst.user1lower] is the
name of user 1 lower limit. Similarly, the upper other limit is named [rst.userlupper] As
shown in Figure 84, the Set Result Status/State check box is selected and for the
cautionary rule Out of Control is selected. In addition, the Apply Additively pull down is
selected.

Figure 84: Dashboard Rule Setup

The second rule is the out Specification portion. This rule is similar to cautionary except
the variables [rst.lsl] and [rst.usl], in the Set Result Status/State check box the Out of
Spec check box is selected and the rule is again Applied Additively. Once the rules are

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completed, apply the rules to each result in the facility by click on the highest level check
box on the result tree shown in the Rule Setup screen.

7.1.3 Building the Dashboard

To build the dashboard, go to the Dashboard tab in the System Setup. In this screen, the
Source and Destination file paths have to be established. Browse to the TrueChem folder
and find the Dashboard folder. For the source path, select the source folder. Then repeat
to set the destination path. Here, however, you go to the Web Pages Output folder and
then to the Dashboard files folder. Once the paths are set up, click on Rebuild
Dashboard and then on Update Results Table. Then click on View Dashboard. Figure
85 shows the dashboard tab. The update time can be set to any desired interval.

Figure 85: Building the Dashboard

The final step is to create a short cut to the dashboard. This is accomplished by using
Windows File Explorer to navigate to the TrueChem folder and finding the Dashboard
folder and then the Output folder, and selecting Main.htm file. Right click on the file and
select Create Shortcut. Drag the short cut to the desktop and rename it to Dashboard.

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Chapter 3 Using TrueChem

1.0 User Log In/ Logout

When TrueChem opens, it automatically logs in as the Default User. Most facilities limit
the rights of the Default User so that important actions are performed only by authorized
employees. Each user should log in and out of TrueChem. This is especially important if
multiple analysts perform the tests on the process tanks. Logging in and out allows
tracking of the analyses each analyst performs. Login also helps regulate access to
particular areas of the program.

1.1 User Login

By selecting the log in key, a login screen will be displayed.

This allows the entry of the User ID and the Password. If the authentication is
successful then the users name will appear in the lower left hand corner of the main
TrueChem screen indicating logged in user.

Figure 1: User Login

If the user has no rights, the following screen will be displayed.

Figure 2 Failed Login

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If the User ID or password is entered incorrectly six times the login for that user will
lock. The administrator will have to go into the User Setup to unlock a locked out user.

1.2 User Log Out

Pressing the Logout button immediately logs out the current user.

This function allows the operator to preserve the identity of the data they have entered
into TrueChem. Other users may now log in and begin entering data without shutting
down TrueChem by simply logging in with their own User ID and passwords.

Note: Requiring Users to Login and out maintains the integrity of audit
traceability.

2.0 Using the Schedule to Organize Work

Although most facilities have a schedule for their laboratory work, TrueChem’s schedule
feature can provide a number of advantages in that it can be used to optimize laboratory
work flow, assist with balancing work assignments, and provide a low-cost solution to
preventive maintenance scheduling.

2.1 Laboratory Tests

The schedule page is accessed by clicking on the schedule icon in the tool bar.

The schedule organizes the tasks scheduled for a particular day. The tasks are organized
by the time due and shows late items first (red), then those currently due but not late
(black). The active button on the top right of the schedule window can be used to perform
tests or customize the view. Customization of the view allows the columns and sorting to
be changed to an arrangement that meets the facility’s particular needs, and the resultant
view can be saved and accessed over and over again. The items shown in the schedule
can be printed as a work sheet by pressing the printer icon.

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 Figure 3: Schedule Log

The schedule page is sortable. Clicking on any of the column headings will reorganize
the schedule. Shown in the figure is the view reorganized by process. Other sorting can
be useful such as sorting by priority or process line. The schedule is also printable from
any of the views. However if the view is not saved before exiting, then the schedule log
will have the default view upon return.

Figure 4: Schedule Organized by Process

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The View pull down menu allows for other views and for performing a schedule forecast.

Figure 5: Pull Down of Schedule Views

Selecting the schedule forecast from the pull down brings up the screen in Figure 6. To
select the date range of the forecast, simply select the start and stop dates.

Figure 6: Forecast Date Range Screen

The view of the schedule can also be changed to show a calendar view by clicking “show
timeline graph”. This view can be useful in visualizing the loading of lab days. The
forecast (1 week) is shown in calendar format. Items in the future are shown in blue.

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 Figure 7: Schedule Showing a Calendar view

2.2 Other Schedules

One very useful feature of TrueChem is the Other schedule. These items are not tested,
and the schedule is a notification that the activity is required. Activities like Carbon
treatment, Filter changes, or pump maintenance are easily controlled using “other”
schedules. The schedule forecast provides a work list of these activities that need
completion. Scheduling other items is unlimited and can be used to schedule all of the
facility preventive maintenance.

Figure 8: Printing a Schedule Worksheet

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3.0 Collecting Data
Getting the most out of TrueChem involves not only setting up the facility to collect and
evaluate the data and determine additions needed, it also involves using the data collected
to move the facility into statistical control. Excellent process control begins with the data
collection.

3.1 Logging Samples

The sampling module is part of the standard TrueChem package. The sampling icon
appears next to the perform test icon and is shown below

The sampling module allows the facility to separately record and track samples used for
monitoring processes. The sample feature is used by clicking on a process line or a tank
in a process line and then pressing the sample icon. A list of all of the tests used in that
process line appears in the working window. The tests desired for a particular sample are
selected by checking the check boxes. TrueChem then assigns a unique tracking number
for the sample and assigns the current date and time as the start time. There is a default
due date but this can be changed to suit the specific testing requirement. TrueChem then
tracks the time until the sample results are entered.

Figure 9: Sample Module Main Screen

This feature is particularly useful if the lab analyzing the process samples is in another
location or if the facility takes in outside samples for analysis. This feature provides clear
tracking of when the sample was gathered/received and when the analysis results are
recorded. Many facilities choose not to use this feature especially when samples are
gathered and immediately analyzed. If the sampling module is not utilized, TrueChem
assigns the sample time to be the same time as when results are entered.

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 3.2 Conducting Tests
Performing tests, entering and evaluating the data are some of TrueChem’s basic
functions. Accessing the Perform Test function can be done from the scheduled items
icon

or by selecting the tank in the tree view and pressing the perform test icon.

From the Schedule icon, a list of the items requiring tests will appear. Right clicking and
selecting Do Now will start the test. You can also click the perform test icon pointed to
by the arrow in Figure 10.

Figure 10: Performing a Test from the Schedule Screen

Alternately a test can be performed on an existing tank by selecting the tank on the tree
and clicking on the Perform Test button.

Figure 11: Beginning Test from the Tree View

Initiating a test from either the schedule or from the Perform Test button causes the
Perform Test screen to appear.

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 Figure 12: Perform Test Screen

When the sample module is used to track tests, performing the test must be initiated from
the sample log to close out the sample.

Clicking on the sample log icon (right of the schedule icon) brings up the sample log
shown in the figure below. To perform a test on the sample shown, double click on the
sample row or single click the Perform Test icon marked with the arrow.

Figure 13: Performing a Test from the Sample Log

Note: Tests must be performed on the computer with the software key in order to
save the date into the database.

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When the Perform Test screen opens in the working window, it will initially be on the
Test tab unless the check box on the Notes tab was selected. The check indicates the
facility wanted to show the Notes tab first on opening screens in the Tank Setup. At the
top of the perform test screen is the process line and tank being tested. Also shown are
the sample date and the test date. The default for both of these dates is the time that the
perform test was initiated. At the bottom left of the screen (noted by an arrow) is the user
that is logged in, which is who the test will be associated with.

Figure 14: Perform Test Screen

The Test tab shows all calculation created, and shows them in the same order they were
created during setup. Fields where input values can be entered are highlighted in blue.
By using the mouse, Tab key or Arrow keys, position the cursor inside the desired input
item. Type the value and press Enter. The Enter key advances the cursor to the next
field where another input can be entered. Any calculations in between the first entered
value and the next possible field are completed. In addition, any rules applied to the
calculation will be evaluated and acted upon. Although, some rule actions (like
scheduling a retest or sending email alerts) do not take effect until the data is saved.

At this point, the data is ready to be saved to the database. But the data has not been
saved yet, so exiting the Test screen to navigate to some other part of the program will
erase the data entered. If the data is saved, only values in fields that have been entered
will be recorded (blank fields are left blank and are not recorded as zeros in the data log).
The window also indicates if a test is late (marked in red on the left), and shows the
ranges for each result item calculated.

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 Note: The Enter key must be used to tell TrueChem that the value should be used
in the results calculations. If you enter a value and attempt to leave the cell, a
warning will appear “Ignored! Use enter key”.

Not all of the tests listed need to be completed. When finished entering data, press the
Output button. Only those entries followed by the Enter key will be saved to the
database. If raw data is being reviewed then exiting without saving erases the data. This
could be done on a computer without a software key to save the data.

3.3 Saving Data

Data can be re-entered at any time to replace the previous value. Once the test inputs
have been calculated, select the Output tab. Clicking on the Output tab initiates the
action of saving the data and brings up the screen shown in Figure 15.

Note: Data can only be saved by working at the computer with the software key
attached to it.

On this screen, you will see the results of the tests performed and it will display any
Adjustments that have been calculated. You may enter comments regarding the test. The
Addslip can also be previewed by clicking on the Preview button. With the appropriate
rights, the user can override the calculated add amounts by clicking Override. In addition,
the analyst can override next schedules of items and define the test as a Startup or Dump
and Remake. To save the test or an Add Sheet, click the Print\Save button. If the
Print\Save button is grayed out, this indicates that the button is not active and means that
the software key is not currently installed on the computer. To correct the condition,
check that the key is pushed into the connector completely, exit to another part of the
program, and return to the Test screen (the data entered will need to be re-entered as it
was not saved).

With the key properly installed, the Print\Save button will now be active. Clicking the
Print\Save button saves the data to the database, and it will print the Addslips to the
printer if that option had been previously selected.

Note: For facilities that have checked not to print the Addslip on Print\Save, the
Addslip can be printed as an option from the Preview button.

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 Figure 15: Output Screen

3.4 Process Level Addslips

Sometimes it is desirable to issue addslips on a process line basis. Process level
Addsheets combine the adds generated for the process line together, resulting in fewer
sheets of paper. This feature is activated by a right click on a process line and then
selecting Process Setup and then going to the Addslip tab. There is a checkbox for
process level addslips. Selection is done for each process line where process level
addslips are desired.

Figure 16: Activating Process Level Addslips

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Once the feature is activated, performing a test on a given line will not result in an
addslip being printed after Print/Save is clicked. Instead, each successive test will cause
the flask icon (indicated by the yellow arrows) for the tank tested to become highlighted
in blue as shown in the Figure. The process name also becomes highlighted. When the
testing for that line is complete (note all the tanks do not have to be tested at once), the
Addslip for the tanks tested is printed by right clicking on the process line and selecting
“print process addslip”. The additions called for by the various tanks tested appear the
same as they would on individual Addslips but are combined on fewer sheets of paper.

Figure 17: Printing Process Addslips

The sign off of process level addsheets (via the Addsheet Log) is the same as for normal
addsheets, except that all of the items from all the adds appear on the same signoff. In the
Figure, the tank Column shows “Process Add Sheet”.

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 Figure 18: Process Level Addsheet Sign off

3.5 Performing Other Schedules

Performing other scheduled items is somewhat unique because no test is performed.
Selecting an Other item from the schedule takes the user to the Output Tab to print and
save. The default schedule shows all currently due items.

Figure 19: Typical Other Item Addsheet

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Other schedule items will be mixed in. Since there are no calculations associated with
these items, selecting an Other Schedule item and clicking “Do Now” opens the output
screen for printing and saving. Performing an Other schedule item really says that the
task needs to be completed. In this respect, using a view in the Schedule of only the
Other items can be used to create a work list. The addsheet in Figure 19 will show only
the activity instructions. After the activity is complete, the Other schedule item is signed
off by going to the Addslip log and selecting the item. Notice that the addsheet has a
number in the upper left corner that can be found in the Addslip log to help locate it in
and sign it off.

Note: Other schedule item addslips can be viewed in the Addslip Log, but they may
have no additions on them.

4.0 Graphs and Statistical Tools

The ability to use the data in TrueChem to optimize the operation of a process is one of
the main reasons for using TrueChem. TrueChem has several different graphing tools
available, and it has built-in statistical functions to evaluate the data. TrueChem also has
the ability to overlay graphs of the different components tested in any given process tank
onto the same graph for that process tank.

The statistical functions in TrueChem provide the user with the ability to evaluate the
operation of the process relative to established statistical techniques commonly used in
statistical process control (SPC). TrueChem automatically plots the data and calculates
several parameters. It is possible to customize the settings of some of the statistical
functions to further optimize the data analysis to the needs of the facility.

4.1 Controlling a Process

The goal of all process control is to manage sources of variation so that only random
fluctuations occur and so that all systematic sources of variation have been eliminated.
Random fluctuations exhibit the bell shaped distribution that most are familiar with.
Maintaining a process within + or – 3 standard deviations of the mean value establishes a
process that will practically almost never fail. “Almost never” is used because random
variations can still cause a failure, but these will occur rarely.

There are several stages of establishing process control. First, process variables must be
identified, then measurements are devised, data is collected, and the data is used to
identify and remove systematic sources of variation. Removing these variations
establishes a process with lower variation. Then the process starts all over again
(continuous improvement) until any improvement suggested by the data is not cost
effective to implement.

In metal finishing, the goal is to produce a part with little or no variation from a series of
process steps. These process steps are controlled to minimize variation and establish

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process limits that result in a high quality product. Some of the variables are easy to
identify like the solution temperature, concentration, or current density. However, a
common mistake made by metal finishers is to apply variation analysis to the process
solution concentration. The solution concentration is maintained to eliminate variation in
the effect produced by the process. For example, the concentration of an etch solution is
not as important as the amount of material it dissolves from the surface in the allotted
time. The etch rate is a function of the processing time, solution temperature and the
concentration. Each of these parameters is managed so that the etch result is produced
consistently. TrueChem allows the user to easily compare etch rate or other physical
parameters to the control variables such as concentration and temperature if the physical
parameter is part of the analyses used for the tank.

The first step required to establish process control is to identify the variables that must be
controlled, and then implement methods that will assess these variables. Sources of this
information include:
• Vendor literature
• Process review by chemical experts
• End item Specification
• Practical experience from extended use of a process

Generally, metal finishers trust that vendors provide suitable tests for the process
chemicals they supply. However the tests provided should be validated, particularly for
the desired accuracy and precision needed to affect SPC. The methods should be
checked by applying SPC techniques to insure they perform acceptably. Once the
methods have been validated, then the process is evaluated to determine if it is operating
in control.

The run chart plots the process parameter data versus a time index. For a process truly in
control, the run chart will exhibit only random fluctuations above and below the mean.
This would be the kind of data expected if the plated thickness was measured from a
controlled plating process. If the process does not exhibit this behavior then it contains
sources of variation other than random. These must be identified and controlled. Basic
statistical calculations and tools can aid in this effort. From this simple definition it is
easy to see that solution concentration is not random because it exhibits a slow trend
(usually decreasing) over time.

4.2 Basic Statistical Calculations

TrueChem makes use of standard statistical calculations, and these calculations are
described in the following sections.

Sample Mean: One of the most basic calculations used in TrueChem is to determine the
sample mean. The sample mean is the average of all the data in the sample and is given
by equation 1, where x is the parameter measured for n samples.

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 n
X (Sample Mean) = 1/n
Σi=1 xi (Eq 1

Several other statistical parameters can calculated from the data collected. These
calculations include

Range: Measures the high and low values of x

Sample variance: sample variance measures the spread of the data from the calculated
mean. This is accomplished by summing the square of the differences between the mean
and each data point, and then dividing that sum by the sample size (Eq 2)

The units of variance are in the square of the units measured. Inspecting equation 2 shows
that the smaller the sample size, the larger the contribution seen from the difference to the
mean for each individual data point. Although the variation can be calculated for very
small samples, the utility of information on the data spread becomes meaningless.

Standard Deviation: standard deviation is the square root of variance and presents the
dispersion in the same units as the parameter measured. The sigma (σ) is the symbol
used for standard deviation. Data dispersion is commonly expressed by the standard
deviation. For any sample exhibiting only random variation, the data will be spread as
shown in Figure 20. 68.2% of the data is +/- 1 standard deviation from the mean, 95.4 %
of the data is +/- 2 standard deviations, and 99.8% of the data is +/- 3 standard deviations
from the mean. The general equation for the normal distribution is:

Where f(x) is the y value calculated, x is the parameter of interest, µ is the mean of all x
and σ is the standard deviation. The variables µ and σ refer to the population mean and
standard deviation. If the process limits contain +/- 3σ (6σ total) and only random
variation exists, then only 0.2% of the data measured would be outside the acceptable
limits.

It is impractical to assess the entire population, and thus data samples are gathered. The
sample standard deviation is S and is simply the square root of the variance (S2). And
these variables replace σ in equation 3.

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 Figure 20: Data Grouping by Standard Deviation

4.3 Drift in Chemical Processes

Most chemical processes do not remain completely constant. Some parameters such as
concentration, pH or contaminant levels change over the course of time. Contaminants
change from the action of the process, drag in and drag out, or chemical actions
introducing contaminants that grow over the course of operation. This behavior makes
the operation of a process solution less random. Thus, the x-bar chart is less valuable.
Typically, plots of the run data with the calculated mean are referred to as “individuals”
charts.

Moving Range Chart

A simpler way to deal with drift that many practitioners use is the moving range chart.
The moving range chart plots the change (range) between data points. A process where
the change between successive points was always the same would have flat moving range
chart. The moving range chart is always coupled with an “Individuals” chart as the
average range (R) is used to calculate control limits on the “Individuals” chart.

n
R = 1/n Σi=1 Xi – (Xi-1 +…+ Xi-m)/m (Eq 4

In the moving range calculation the subgroup size is important. Normally a subgroup of 1
is used. In this case, adjacent data points are evaluated to determine the range. A
subgroup size of 2 indicates that the previous two data are averaged to determine the
range. In equation 4, Xi-m is used to determine the points averaged in the subset of m data
points.

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Control Limits

Control limits are calculated from the average range derived from Equation 4 and placed
on the “Individuals” chart.

UCL = X + (R x d2) (Eq 5

LCL = X – (R x d2) (Eq 6

Where d2 is the factor for the subgroup size used (typically 2.66).

Table 1
D2 Subgroup Factors

D2
# Samples Subgroup
Factor
1 2.66
2 1.88
3 1.02
4 0.73
5 0.58
6 0.48
7 0.42
8 0.37
9 0.34

4.4 Histogram

Histograms provide a pictorial representation of the data that allows the user to easily
identify central tendencies and skewing of the data. Ideally, the histogram will depict the
normal distribution in Figure 20. Occasionally, outliers will occur well away from the
center, and this data can indicate special causes of variation that should be investigated.
In practice for metal finishers, a normally distributed histogram would only be seen from
well controlled processes that exhibit no drift. For example, one would expect the
histogram of anodizing coating weight to be normally distributed but not the
concentration of sulfuric acid in the same anodizing process tank as the acid
concentration would be expected to change over time.

Histograms are constructed by grouping the data into cells. Cells have the effect of
rounding the data because each cell has a range (the cell width W). The number of cells
is adjusted to optimize the data representation. Rigorously, the number of cells is the
square root of the sample size. Typically for samples less than 100 data points, 7 to 10
cells are used.

W = (Xmax – Xmin)/ #cells (Eq 7

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The data is sorted into the cells based on the cell width (range) and each cell is plotted.
The height of the cell is the number of data points in the cell. Figure 21 shows a
histogram of data. The figure also shows the upper and lower specification limits and the
calculated upper and lower control limits. Control limits were calculated from equations
5 and 6. The data in this histogram is well grouped with only a couple outlying values
and these are within the control limits. This process appears to be well controlled.

Figure 21: Histogram

4.5 Capability Index

Process capability compares the output of an “in-control” process to the specification
limits by using capability indices. An “in control” process means nearly all of the
measurements of the parameter of interest are within limits. The comparison is made by
forming the ratio of the spread between the process operating limits (usually the
specifications limits) to the spread of the process values, as measured by 6 process
standard deviation units (the process "width"). To make a valid capability assessment, the
sample size used must contain enough sample points. Generally, about 50 independent
data values are thought to be enough.

Common capability indices include: Pp, Ppk, Cp and Cpk. The Pp and Cp indices are
calculated against 6σ using the entire specification range where the Ppk and Cpk are
against 3σ but use the smallest of the upper or lower specification range from the
calculated mean value of the data. The P indices are also calculated using the actual
standard deviation of the sample where the C indices use an estimated standard deviation
from the average range and a factor for the sub-group size. Ppk is thought to measure
actual performance better (and more conservatively) than Cpk. This is because Cpk is
thought to be more sensitive to variation outside the sub-group because of using an
estimated standard deviation. In addition, Pp and Cp are not valid for process parameters
that have both upper and lower specification limits. Each will be discussed separately.

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Pp is the natural tolerance. It is calculated by dividing the difference between the upper
and lower specification limits and the population standard deviation. First, the standard
deviation is calculated as in Eq 8.

Pp = USL – LSL (Eq 9

6Sx

Ppk is the capability index to the nearest specification limit. First ZU and ZL are
calculated and then the smallest is used to estimate Ppk.

ZU = USL – X (Eq 10
Sx

ZL = X- LSL (Eq 11
Sx

The smaller of ZU and ZL become Zmin

Ppk = Zmin/ 3 (Eq 12

Cp is also the “natural tolerance” of the process sample calculated over 6 standard
deviations. However Cp uses a standard deviation estimated from the average range and
the subgroup size d2 used in the range calculation (Table 1)

Sest = R / d2 (Eq 13

Cp = USL – LSL (Eq 14

6Sest

Cpk is the capability index to the nearest specification limit. First ZU and ZL are
calculated and then the smallest is used to estimate Cpk.

ZU = USL – X (Eq 15
Sest

ZL = X- LSL (Eq 16
Sest

The smaller of ZU and ZL become Zmin

Cpk = Zmin/ 3 (Eq 17

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 4.6 Statistical Functions Graphs in TrueChem
Several different graphs (charts) are available from TrueChem. They include; the X-bar,
run moving range and histogram charts. Any of the process control parameters that result
items are defined for can be displayed. There is also an option to overlay all of the
parameters on the X-bar and run charts. TrueChem automatically performs statistical
calculations to evaluate data mean, standard deviation, and capability indices.

Graphs are displayed, along with the statistical results, by clicking on a particular tank in
the tree view and then on the icon from the menu bar.

At the top of the window the process, tank, and component displayed is identified. The
date range of the data displayed can be changed by pressing the calendar icon to the right
of the range currently displayed. In addition, check boxes allow the data to displayed
Time relative or with dates displayed. Also, by clicking on a data point on the run chart
comments relating to the test can be added. To the left of calendar icon are several tabs.
These tabs allow the user to change the view of the screen. The default view when
opening the screen is Overview. The individual graphs can also be displayed and are
enlarged by clicking on the tab desired.

Figure 22: Graph Display Screen

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5.0 Using the Statistical Features
TrueChem calculates the statistical parameters assuming that all the conditions have been
met for the quantities to be valid. This means TrueChem assumes that

• Samples size is large enough for X and R to be valid

• Systematic sources of variation have been removed and only random variation
persists
• Processes are in control and the capability indices are valid

If this is not the case, the validity of the calculations must be understood. Some of these
tools can also be used to bring processes into control. The primary tools are the X-Bar,
run charts and the histogram. These tools can be used to help identify sources of variation
and remove them. Once this is completed and the processes are “largely in control” then
the statistical calculations results can be used to assess the health of the process.

5.1 X-Bar Chart

Although listed as an X-bar chart in the heading, this graph may display data that is more
accurately an “Individual’s” run chart depending on the nature of the process. The X-Bar
chart displays any, or all (by overlaying) of the results calculated for the tank against

Figure 23: X-Bar and Range Chart

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time. In addition, TrueChem displays the calculated upper control limit (UCL),
middle control limit (MCL) and the lower control limit LCL from the data sampled.
These parameters are calculated from the moving range chart using Equations 5 and
6. Notice in Figure 23 that the data goes below the lower control limit. This may be
caused by a new source of variation and should be investigated.

In addition, this screen displays the range chart which plots the absolute value of the
difference between adjacent data points (Eq 19).

X = Xi – X (Eq 19

It is also possible to overlay all of the components in process solutions containing

multiple components. An overlaid X-Bar chart is shown in Figure 12. When
Component Overlay is selected, the components displayed can be pared down by
clicking the button that appears to the right of field and checking the components
desired from the list.

Figure 24: Component Data Overlay

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 5.2 Run Chart
The run chart shows data plotted against time compared to the location of several limits.
Shown are upper specification limit (USL), Upper shop limit (UO1) upper control limit
(UCL) Process optimum (OPT), Lower control (LCL), lower shop limit (LO1) and the
lower specification limit (LSL). Multiple components can also be displayed on this chart.
This window also displays the moving range chart. As in the range chart above, the
moving range displays the absolute value of the change between subgroups. Subgroup
may be one or some number of data points, and is specified in the set up window. The run
chart is very useful in determining adjustments to operating limits to center the process.

Figure 25: Run Chart

5.3 Histogram

The histogram displays the data locating both the specification limits and control limits
for the component displayed. This graph displays the data and provides a comparison to a
normal distribution of the process data. Clearly in this figure the data is not normally
distributed. This figure points out one of the great benefits of the histogram. It is a very
effective tool for identifying that additional sources of variation still remain in the
process. Work is needed on this process to identify the source(s) of the data spread and to
remove the spread resulting in more normally distributed data.

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 Figure 26: Histogram

5.4 Graph Settings

Pressing the Settings tab displays a number of features that can be used to customize the
graphs. Figure 27 shows the settings that can be modified for the Run Chart.

Figure 27: Graph Settings Screen

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The subgroup size for the X-bar can be modified by selecting the X-bar/individuals row
on the setting tab.

Figure 28: X-bar/Individuals Settings

Figure 29: SPC Settings

By selecting the Fixed SPC Limits row, the settings used for the capability indices is
displayed and can be adjusted if desired.

Note: The settings page only changes the properties for the current tank. To make
global changes go to the “System Setup”, Graphs tab.

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6.0 Data Log
Pressing the scroll icon accesses the data log (Figure 30).

The data log presents all of the stored data in a tabular format. The columns match up to
the test screen rows rotated 90 degrees. Items at the top of the test window appear at the
left on the Data Log.

Data displayed is color coded depending on whether it is in specification or not, and

by actions required that have or have not been completed. The default settings are
• white In spec or no specification associated (i.e. input item)
• gray Addslip not signed off
• blue Corrective action signed off with assignable cause
• yellow Corrective action not signed off
• red Corrective action signed off without assignable cause

Figure 30: Data Log

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 6.1 Data Point Features
By right clicking on a data point, a number of options appear in the menu shown. Some
reproduce the page active buttons. The others show test details, test summary, the change
history, create bookmark or allow data editing. You can also view the corrective actions
(if any), notes on the data, and the addslip resulting from the analysis.

Note: most of these functions require administrator rights. Editing data creates an
entry in the event log.

Figure 31: Data Log Right-click Menu

6.1.1 Test Detail Screen

The test detail screen is shown in Figure 32. This screen shows the input values and
results for the row of data selected. The arrow buttons on the right side of the screen
allow the user to move up and down the data row in the data log and display that
information in the detail screen.

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 Figure 32: Test Details Screen

6.1.2 Test Summary Screen

The test summary screen is shown below. This screen shows a great deal of information
about the test performed and includes sign off information. This screen also has a Print
function that will send the report to the printer. This screen contains all of the information
relating to the process tank and the row of data selected. The screen shows details about
the process tank chemistry, physical parameters, recaps additions made, signoffs and
corrective actions relating to the row of data.

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 Figure 33: Test Summary Screen

6.1.3 Adding a Bookmark

Bookmarks are used to flag events that occur to process tanks (overflow or remake for
example) and allow the insertion of a break in the data if desired. Breaks in the data can

Figure 34: Bookmark Screen

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be used to restart the statistical calculations. The bookmark screen appears by selecting
the data row in the Data Log and right clicking. Then select Bookmarks. From this
screen the user can Add, Modify or Delete bookmarks. A check box at the bottom allows
the user to create a break in SPC calculations and restart the statistical sample.

7.0 Data Points and SPC

A very powerful feature of TrueChem is the built in statistical functions that are part of
the graphing features. TrueChem calculates a number of standard statistical parameters
such as mean, standard deviation, control limits and capability indices. However these
parameters are only as good as the data used to calculate them. Rules to help reduce data
entry errors improve data quality, however even these rules do not cover a few instances.
TrueChem has some ability to remove erroneous data points (Data Editing), hide specific
data points in lieu of editing, and mark particular data points as start up tests. Each of
these activities removes the data point form the SPC calculations

7.1 Data Editing

If the user has the proper rights, data in TrueChem can be edited. But the activity is time
consuming, so the TrueChem rights should normally be set to prevent this.

7.1.1 Changing a Data value

To change the value of a cell you must be in the Data Log. Right click on the cell and
select Edit Cell and the screen shown below will appear the current value is shown and

Figure 35: Editing a Cell in the Data Log

can be altered. However, a reason must be entered to exit the screen. The sample date
and Test date cannot be edited. If these are incorrect, the entire row must be deleted and
the date re-entered.

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 7.1.2 Deleting a Row of Data
This occasionally needs to done, particularly if the sample date and/or time are entered
incorrectly. The row is selected, and a right click brings up the menu that includes Delete
Row. A warning is displayed that deleting the row deletes everything related to the row of
data including any additions. Then a reason must be given to complete the deletion.

7.2 Hiding a Data Point from the SPC

To hide a data point from the SPC calculations and from graphing, right click column H
for a particular row and select Modify Hidden Status. A reason must be given and an
“X” appears in column H as shown. Everything in the row is hidden including
adjustments.

Figure 36: Hiding a Data Point

Should the data point be unhidden later, that change in hidden status will be recorded in
the notes with the original hiding.

7.3 Marking a Test as a Start up Test

When a new tank is made, often tests are done prior to placing the tank in service to
insure that the tank was made properly. In addition, with some additives several additions
can be necessary to bring the tank into specification. It makes sense not to include these
results in the SPC as the tank is not yet in production. Instead of hiding the test, marking
the test as a makeup test records the material used but does not use the results in SPC
calculations. To mark a test as a Start up Test, select the check box on the Output screen
after entering the data as shown

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 Figure 37: Marking a Test as Start up

The data associated with the test will show an X in the S column of the Data Log as
shown

Figure 38 Data Log Showing a Start up Test

8.0 Sign Off Requirements

The various sign off requirements that exist in TrueChem create more traceability and
assist the facility to complete actions that have been determined to be important to the
operation of the facility. In addition to Add Slip sign offs, the facility can decide to create
Corrective Actions and Events that may also require a sign-off. Sign-off conditions can
be made to require an explanation, which helps document the activities and in the case of
troubleshooting, can help prevent retracing steps.

8.1 Addslip sign off

When an Addslip is created by the Print/Save option, TrueChem adds that adjustment to
the Addslip Log. The facility can either print out the addslip immediately on Print/Save
or can go “paperless” and only print the Addslip when needed. In any case, the sign off
process begins after the addition has been completed. The user signing off the addition
goes to Addslip Log by clicking on the icon.

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The Addslip log is shown in Figure 39. The list shown can be sorted in a number of ways
to make finding the entry easier. The Addslip Log, by default, displays the current list of
outstanding add sheets. Addslips listed here have been issued from a test but not yet
signed off. Items appearing in red are overdue. Once the test generates the add sheet,
and the allotted time expires for sign off, the status indicator at the bottom of the screen
flashes “Past Due”.

Once the desired entry is selected, either right click on the entry and select the Sign Off
button or select the sign off icon from the button in the Add Sheet screen (yellow arrow).

Figure 39: Addslip Log

Figure 40: Addslip Sign Off

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The Addslip Signoff screen will appear. The list of add amounts that were called for in
the test are displayed with a check box to the left. If all of these boxes are checked and
the Sign Off button is pressed, then the add is signed off as issued.

If one of the adds needs to be modified, double click, or select, the item and press the
Modify button. The Modify adjustment dialogue will appear. The amount or units can be
modified and a comment must be given explaining why the modification occurred.

Note: The comment action is not optional and is required whenever the add amount
has been changed.

Figure 41: Modify Adjustment

8.2 Corrective Actions

What is a Corrective Action? Corrective Actions are defined by rules and are results that
the facility decides needs further investigation or documentation. An example might be
when a result is outside of its spec limits. By checking the Require corrective Action
Sign Off check box (Figure 42) in a Rule Setup, you are saying that this condition should
be flagged for sign off and tracked for sign off completion. In the Sign off section, the
exception type can be selected. These types are user defined. The exception can be
viewed and tracked by this type. A priority can be defined to assist in identifying the
importance of the exception. The description will help identify the details of the
exception. Allotted time is used to determine how much time should be allowed for the
signoff to occur. At the expiration of this time, an email could be sent to further raise the
awareness of the situation.

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 Figure 42: Defining a Corrective Action in a Rule

Once defined, conditions that create a corrective action will result in the Status bar
blinking “Exist” in the Corrective Action Field

Figure 43: Corrective Action in the Status Bar

If the Facility uses a Dashboard, the Exception column will show “signoff needed’

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 Figure 43: Corrective Action Indicated on the Dashboard

8.2.1 Completing a Corrective Action

To view the list of corrective actions, select the Corrective Action log button on the
graphical menu bar.

The Corrective Action Log screen will be displayed. The log is similar in format to the
Schedule Log or the Addslip Log. Items due are in black, those late are at the top of the
list in red. The initial view is always All Exceptions Not Signed Off. Like the Addslip

Figure 43: Corrective Action Sign Off

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Log, the sign off process begins by selecting the item from the list and clicking Sign Off.
As shown in Figure 44, details about the result that led to the corrective action are listed.
The sign off is completed by checking the boxes and filling in a cause description and
comments. The user also has the option of checking that there was an assignable cause.
For example, overflowing a tank could be and assignable cause to an out of spec
concentration resulting in a corrective action. When complete click OK.

Note: When complete, Corrective Actions disappear from TrueChem. If a

permanent record of the condition is needed, define the condition as an Event

Corrective actions are noted in the Data Log by color coding of the result. Orange
indicates a Corrective Action exists, blue a corrective action signed off with cause and
red a corrective action signed off without an assignable cause. When signing off, a reason
must be supplied and the user must have rights to sign off the corrective action.

Figure 45: Corrective Actions in the Data Log

Figure 45 indicates two corrective actions. One needs action (orange) and the other has
been signed off with a cause (blue).

8.3 Events
What is an Event? An Event is created when some action has occurred that TrueChem
was told to track. This includes changes to the data or the database set up. The tracking of
these actions is permanent and cannot be erased by anyone. Events, like Corrective
Actions, can also be created when a user defined rule condition creates a result that the
facility wishes to track permanently.

8.3.1 Events that TrueChem logs

There are several event types that TrueChem will automatically track. This tracking is
turned on in TrueChem’s System Setup under the Tracking tab.
o Track Add Sheet Status: This will cause TrueChem to require add sheets be
signed off.
o Track User Activity: This will cause TrueChem to log events related to user rights
such as invalid password attempts, changes to user rights or changes to user
status.

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 o Track Setup Changes: This option will cause TrueChem to log changes to the
setup of Processes (Groups), Tank (Objects) and Rules.
o Track Add Sheet Override: This causes a required reason be given for any
changes to add amounts.
o Track Schedule Override: This will log events describing changes when a
schedule has been overridden.
o Track Data Editing: This will cause TrueChem to log any editing or deleting of
test data from any Tank (Object).

Figure 46: Tracking Screen System Setup

8.3.2 Rule Driven Events

Events can be created and added to the event log by a rule. Figure 47 shows the set up
and it is very similar to setting up a corrective action. In this example, the log message
contains variables. This allows TrueChem to communicate about any tank because the
message draws the information to construct the message. The difference between the
Corrective Action and the Event is that events remain in the system even after being
resolved while Corrective Actions go away when resolved.

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 Figure 47: Rule Driven Events

8.3.3 Event Log

TrueChem’s Event Log is much like an audit log entry. However, it cannot be edited or
deleted. The event log can be viewed by selecting the Event Log button from the
graphical menu bar.

Since the event log is permanent, it will get large over time. As with the other logs, a date
range can be defined and then the columns sorted to facilitate navigation. The event log is
shown in Figure 48.

146
 Figure 48: Event Log

The Event Log serves as an audit log in TrueChem for events such as deleting of data,
editing of set ups and possible user defined events. The Event Log cannot be edited or

Figure 49: Event Log Detail

147
erased in any way. It only serves as an audit trail of what occurred. By double clicking
any item in the Event Log, the details of the event can be displayed.

The Event Log Details screen displays the following data: the event type, date, time, user
ID of the person who was logged into TrueChem, the work station (meaning the name of
the computer on the network that was used to perform this event), type, description, the
process that was involved, the tank that was involved and the subsequent message which
includes specific details of the event.

9.0 Reports
The Reports screen allows for running predefined reports. To access the report Screen,
click the icon in the graphic tool bar.

Several predefined reports are available in the pull down list. After selecting the report
type, select the scope. If the scope will be something you want regularly, add a scope
description. Selecting All will create a report run against all items on the TrueChem tree.
Using the Custom Scope allows the use of specific items. Adding and defining individual
scopes are then saved and become a part of the scope description list. The For Dates box
requires a date range the report will scan. The lower section of the report window
displays specific options for the selected report.

Figure 50: Available Reports Screen

148
10.0 The Placard System
The Placard System provides a way to print tank placards. Figure 51 is an example of an
8.5” x 5.5” placard. TrueLogic can customize your placards to suit your specific needs.

Figure 51: Example Of A Placard

To print one or more placards, click the Document Manager button at the top of the
screen (see arrow 1 in Figure 52). Then select Tank Placards from the View dropdown
list (arrow 2). Select one or more rows with the mouse, and click the print button or the
preview button located above the list (arrow 3).

Figure 52: The Document Manager

Required versus Not Required

If a placard is “required”, two things can happen:

149
 1. An expiration time for printing the placard can be set. Once that time has passed,
the “Needs Printing” column in Figure 2 will be set to “Yes” and an email can
optionally be sent to a user indicating that the placard needs to be printed.
2. A warning will be given at the close of Tank Setup if a parameter on the placard
was changed (e.g. tank volume or length). In such cases, the “Needs Printing”
column in Figure 2 will be set to “Yes”.

As of this writing, all placards use the same placard layout. And they will either be all
required or all not required. The default is not required, but contact TrueLogic technical
support if you’d like them to be required. Even if a placard is not required, it can still be
printed from the Document Manger. Non-required placards do not have an expiration
print date, and a warning will not be displayed when items on the placards are changed in
Tank Setup.

11.0 Lookup Tables

Users sometimes have two external lists of values. And there is often a need to
approximate a value from one list, given a value from the other list. The library of type
“Lookup Table” addresses this need.

Create A Lookup Table Library

To create a “Lookup Table”, click the System Setup button at the top of the screen, then
click the Library tab. Use the Add button to create a new library item of type “Lookup
Table”. As you add new XY pairs of values, a corresponding data point is added to the
graph. See Figure 53. The graph allows you to visualize your data – and spot trends and
outliers. The values for X and Y must all be either increasing or decreasing. But the lists
can go in opposite directions.

Figure 53: A ”Lookup Table” Library

150
lib.TableLookupX and lib.TableLookupY
Two variables return approximations from a “Lookup Table” library. The format for
them is: lib.TableLookupY (library name, givenX) and lib.TableLookupX(library name,
givenY). These variables require that the Lookup Table contains at least two data points.
In the above example, if you want to approximate X when Y is 0.29, you’d use:
lib.TableLookupX(Absorbance, 0.29)

Limit Error Codes

The Lookup variables make use of limit error codes as defined on the library creation
screen. See Figure 53. If your given value is either smaller or larger than all the values
in its list, we deem it “out of range”. There are two ways for the Lookup variables to
generate the return value when the given value is “out of range”:
1. the return value can be approximated, or
2. the return value can be a pre-defined limit error code. See Figure 53.

12.0 Selection Tables

The Input items on the Perform Test screen normally allow the user to type in values.
But if a library of type “Selection Table” has been created, then its values can be selected
for use on an Input item. In the below example, instead of typing “4” in the Input box, the
user simply selected it from the dropdown list box. The text to the right of the values will
be displayed in the Data Log.

Figure 54: A Dropdown List For An Input Item

Create A Selection Table Library

The first step in using a “Selection Table” as a dropdown list for a test Input is to create a
library item of type Selection Table. To do this, click the System Setup button at the top
of the screen, then click the Library tab. Use the Add button to create a new library item
of type “Selection Table”. As you add new Descriptions to the new library, the indices
are added automatically for you. You cannot change an index. Note that caution must be
taken before modifying an existing library because those changes will appear everywhere
that library was previously used.

151
 Figure 55: Create A Selection Table Library

Configure An Input Item To Use A Selection Table

Once a “Selection Table” library item has been created, you can instruct an Input item to
use it on the Perform Test screen. To do this, go to Tank Setup, select the Test tab, and
double click the Input item of interest. Place a checkmark next to “Select from Table,”
and use the dropdown box to select the desired library item. See Figure 56. If you were
to go to the Perform Test screen, clicking on this Input item will display the contents of
the “Selection Table”.

Figure 56: Configure An Input Item To Use A Selection Table

lib.TableSelect
A variable called lib.TableSelect returns the text Description from a “Selection Table”
library. Its format is lib.TableSelect (library name, index). In the example shown in
Figure 57, if the library name is “Pass Fail Library” then lib.TableSelect(Pass Fail
Library, 2) would return “Fail”.

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 Figure 57: Selection Table For Pass/Fail On An Input Item

13.0 Miscellaneous TrueChem Features

13.1 Printing, E-Mailing, and Exporting

Data from TrueChem is easily sent from the program. A few of those functions not
covered elsewhere are discussed.

Printing

The printer set up dialogue displays the specific details of the selected printer. The lower
section Printout Headings allows for customization of each heading that TrueChem will
use in various parts of the software, enabling report or printout customization by the user.
Note that TrueChem variables are being used in the Printout Heading section.

Figure 58: Printer Setup

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Clicking on the print button sends what is viewed in the working window to the printer.

Emailing

Clicking on the email button emails the information displayed in the working window to
a particular email address.

A pop up will appear asking for the recipient’s email address and the subject of the email.
An open area allows a message to be entered to go with the screen image.

Figure:59 Email Popup

Exporting Data

Running a report automatically exports the data to an Excel compatible format. Selecting
Export from the file pull down menu causes a popup to appear asking whether all rows of
data shown are to be exported or if only selected rows are desired.

154
After selection, the destination and file type must be defined. The file type choices are
shown in Figure 60.

Figure 60: Export File Type Choices

14.0 Getting Help

There are a variety of ways to get help with specific features of TrueChem. To access
TrueChem’s built-in help function, press the button at the right end of the graphic tool
bar.

The screen shown below will appear and the user can navigate to various topics.

155
 Figure 61: Online help

TrueChem’s Help functions were designed to be consistent with other widely used and
familiar software Help options.

TrueLogic’s Website
When TrueChem is initially opened or when the Home button is press in the graphic tool
bar, the screen below is shown

156
 Figure 62: TrueChem Home Screen

If the computer has access to the internet, clicking on either the web address or the logo
will take you to the TrueLogic Webpage.

Figure 63: TrueLogic’s Home Page

157
Additional assistance can be found at the TrueChem pull down on TrueLogic website.

If you still have unanswered questions, feel free to contact TrueChem directly.

Figure 64: FAQ’s

The FAQ contains the most up to date list of variables as well as answers to commonly
asked questions.

Finally, feel free to contact TrueLogic directly for additional assistance.

158
Appendix A: TrueChem Variable List

Categories:

Adjustment
Input Variables Result Variables Units
Variables
General Variables Library Variables Run Variables User Variables
Schedule User-Defined
GET Variables Name Variables
Variables Variables
{Group} Variables {Object} Variables Test Variables

Adjustment Item Variables – A test may contain multiple adjustment

items. To specify a specific adjustment item, you must include the item number
associated with the adjustment. If no item number is specified, TrueChem will
use the current adjustment item. Example: [ADJ4.VALUE] will return the value of
adjustment item number 4.

Name Description
The displayed adjustment amount (in the unit
ADJ
defined on the setup of the adjustment item)
The accumulated amount added since the last
ADJ.ACCUM remake not including the current adjustment
amount
The accumulated amount added since the last
ADJ.ACCUM(unit) remake (in the unit specified) not including the
current adjustment amount
The amount of additive to add to adjust
ADJ.ADDAMOUNT
[ADJ.BASEDON] by [ADJ.TOVARY]
ADJ.BASEDON The name of the test item the adjustment effects
Returns 1 if consumable is inventory controlled, 0
ADJ.CONSISINVENTORIED
otherwise
Returns balance of consumable's current active
inventory lot in consumable's defined stock unit, 0
ADJ.CONSLOTBALANCE
if no active lots are found or consumable is not
inventoried
Returns total balance of all consumable's current
active inventory lots in consumable's defined stock
ADJ.CONSTOTALBALANCE
unit, 0 if no active lots are found or consumable is
not inventoried
ADJ.DILUTEPOINT Point beyond which dilutions are calculated

159
ADJ.DILUTETO Target value of dilution
Displayed name of the additive for the adjustment
ADJ.DISPLAYAS
item based on advanced settings
Displayed text or number for the adjustment
ADJ.DISPLAYVALUE
amount
Percentage of current adjustment based on the
ADJ.FRACTIONOFMAKEUP additives makeup amount (as a decimal ie:
0.25=25%, 1.00=100%)
ADJ.ID Unique ID number
ADJ.LOTLABELS List of lot labels associated with this adjustment
Lot label associated with this adjustment. Replace
ADJ.LOTLABELS(#)
# with the number of lots you want to show
ADJ.MAKEUPAMOUNT Makeup amount of additive in defined makeup unit
ADJ.MAKEUPSHORTUNIT Short name for the additive's makeup unit
ADJ.MAKEUPUNIT Name for the additive's makeup unit
The maximum add amount. Adds will not be
ADJ.MAXADD
greater than [ADJ.MAXADD]
The minimum add amount. No adds will be given if
ADJ.MINADD
[ADJ.RAWVALUE] is less than [ADJ.MINADD]
ADJ.MSDS MSDS associated with this adjustment
ADJ.NAME Name of the additive
Notes assigned by a rule that are directly
ADJ.NOTES
associated with the adjustment item
ADJ.NUM Adjustment item number. ie ADJ1 number is 1
ADJ.PARTNUMBER Part number for this adjustment
The percentage added, since the last remake,
ADJ.PERCENTOFMAKEUP based on the additives makeup amount (as a
decimal)
Previous adjustment amount (in the unit defined
ADJ.PREVVALUE
on the setup of the adjustment item)
ADJ.PREVVALUE(unit) Previous adjustment amount (in the unit specified)
ADJ.PRICEPERSTOCKUNIT Price of additive
The calculated adjustment amount (in the unit
defined on the setup of the adjustment item)
ADJ.RAWVALUE
before rounding, applying the minimum and
maximum add amounts, and other adjustments
The calculated adjustment amount (in the unit
ADJ.RAWVALUE(unit) specified) before rounding, applying the minimum
and maximum add amounts, and other

160
 adjustments
The calculated adjustment amount (in the unit
specified) before rounding, applying the minimum
ADJ.REFERENCE
and maximum add amounts, and other
adjustments
ADJ.SHORTNAME Short chemical name
ADJ.SHORTSTOCKUNIT Short stock unit name
ADJ.SHORTUNIT Short unit name
ADJ.STOCKUNIT Stock unit name for additive
ADJ.TOOBTAIN The target value of [ADJ.BASEDON] item
Amount of change to [ADJ.BASEDON] item when
ADJ.TOVARY
[ADJ.ADDAMOUNT] is added
ADJ.UNIT Name of the additive unit
The displayed adjustment amount (in the unit
ADJ.VALUE
defined on the setup of the adjustment item)
ADJ.VALUE(unit) The displayed adjustment (in the unit specified)
ADJ.VENDOR Vendor of the additive
ADJ.VERB Verb that describes addition or removal action

General Variables
Name Description
COMPUTERNAME The current computer’s name
DATE The current date
DAY The current day
MONTH The current month
The current value of the result or adjustment item. You can
RESULT use this variable in a rule to reference the current item’s
value.
TIME The current time
YEAR The current year

GET Variables – GET variables are used to collect data from the end user.
Name Description
Replace PROMPT with the text the user will see when entering
GET.PROMPT
the variable’s value

{Group} Variables - {Group} is a user defined term in TrueChem. {Group}s

contain a collection of {Object}s.

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 Name Description
GRP.DATECREATED Date the {Group} was created
GRP.DESCP Name of the {Group}
GRP.DISTINFO Distribution information
GRP.DISTLIST Distribution list
The display message for the {Group} (on the {Group}
GRP.DSPMESSAGE
setup form)
GRP.FIELD1 User defined field in {Group} setup
GRP.FIELD2 User defined field in {Group} setup
GRP.ID Unique ID number
GRP.NAME Name of the {Group}
The print message for the {Group} (on the {Group} setup
GRP.PRTMESSAGE
form)
GRP.SELECT1 User defined list in {Group} setup
GRP.SELECT1SHORT User defined list in {Group} setup

Input Variables – A test may contain multiple input items. To specify a

specific input item, you must include the item number associated with the input. If
no item number is specified, TrueChem will use the current input item. Example:
[INP4] will return the value of input item number 4.

Name Description
INP The value of the input item

Inventory Variables – Inventory variables are used to obtain data related to

a particular lot when sending emails or other notifications. NOTE: These
variables are invalid in other areas of TrueChem.

Name Description
Maximum quantity defined for
INV.CONSMAXQTY
consumable
INV.CONSMINQTY Minimum quantity defined for consumable
INV.CONSQTYONORDER Current amount of consumable on order
INV.CONSQTYUNUSABLE Current unusable amount of consumable
INV.CONSQTYUSABLE Current usable amount of consumable
INV.CONSREORDERPOINT Reorder point defined for consumable
INV.CONSSHORTNAME Short name of consumable
INV.CONSSTOCKBALANCE Current balance of consumable

162
INV.CONSSTOCKUNITNAME Stock unit name of consumable
INV.CONSTYPEDESCRIPTION Type description of consumable
INV.CONSUMABLENAME Name of additive
INV.LOTBALANCE Current balance of lot
INV.LOTDATEORDERED Date lot was ordered
INV.LOTDATERECEIVED Date lot was received
INV.LOTDATERETIRED Date lot was retired
INV.LOTEXPIRATION Expiration date of lot
INV.LOTLABEL Lot label
INV.LOTLOCATIONDESCRIPTION Storage location description of lot
INV.LOTMANUFDATE Manufacture date of lot
INV.LOTPRICEPERUNIT Price per stock unit of lot
INV.LOTQTYRECEIVED Quantity received for lot
INV.MANUFLOTID Manufacturer lot identifier
INV.MANUFNAME Manufacturer name
INV.MANUFPRODDESCRIPTION Manufacturer product description
INV.MANUFPRODMSDS Manufacturer product MSDS
INV.POAMOUNT Quantity received for lot
INV.PODELIVERYDATE Requisition delivery date
INV.PONUMBER Requisition number
INV.TRANSAMOUNT Amount of transaction
INV.TRANSDATETIME Date/Time of transaction
Name of {Group} associated with
INV.TRANSGROUPNAME
transaction
Name of {Object} associated with
INV.TRANSOBJECTNAME
transaction
INV.TRANSTYPE Type of transaction
INV.TRANSUNITNAME Unit name of transaction amount
TrueChem user associated with
INV.TRANSUSERNAME
transaction
INV.VENADDRESS Vendor address
INV.VENCONTACT Vendor contact name
INV.VENDESCRIPTION Vendor description
INV.VENEMAIL Vendor e-mail address
INV.VENFAX Vendor fax number
INV.VENNAME Vendor name

163
INV.VENPHONE Vendor phone number
INV.VENPRODDESCRIPTION Vendor product description
INV.VENPRODPARTNUM Vendor part number
INV.VENWEBSITE Vendor website address

Library Variables – You can reference a user defined library using variables.
Library items can be custom documents or scripts.

Name Description
Replace Description with the
description of the library you want to
use. Example: [LIB.Safety
LIB.DESCRIPTION
Instructions] will return the library item
with a description of Safety
Instructions
Replace ID with the ID number of the
LIB.ID library you want to use. Example:
[LIB.12] will return library number 12
Returns a numeric value from a
LIB.TABLELOOKUPX (lib name, Y-value)
Lookup Table type library item.
Returns a numeric value from a
LIB.TABLELOOKUPY (lib name, X-value)
Lookup Table type library item.
Returns a text value from a Selection
LIB.TABLESELECT (lib name, index)
Table type library.

Name Variables – Name variables are used to return the user defined terms
in TrueChem.

Name Description
The word used to describe the action being performed
NAM.ACTION
on the current adjustment
The word used to describe an addition (On the Terms
NAM.ADD
Tab in SystemSetup)
The word used to describe a category (On the terms
NAM.CATEGORY
tab in System Setup)
NAM.COMPANY Your company’s name
The word used to describe item that are used within the
NAM.CONSUMABLE
company
The word used to describe exceptions (On the Terms
NAM.EXCEPT
Tab in SystemSetup)

164
 The word used to describe {Group}s (On the Terms tab
NAM.GROUP
in System Setup)
The description of the first user definable field in
NAM.GROUPFIELD1
{Group} setup
The description of the second user definable field in
NAM.GROUPFIELD2
{Group} setup
The description of the first user definable selection in
NAM.GROUPSELECT1
{Group} setup
The word used to describe items (On the Terms Tab in
NAM.ITEM
SystemSetup)
The word used to describe {Object}s (On the Terms
NAM.OBJECT
Tab in SystemSetup)
The description of the first user definable field in
NAM.OBJECTFIELD1
{Object} setup
The description of the second user definable field in
NAM.OBJECTFIELD2
{Object} setup
The description of the first user definable selection in
NAM.OBJECTSELECT1
{Object} setup
The word used to describe a partial remake (On the
NAM.PARTIAL
Terms Tab in SystemSetup)
The word used to describe a total remake (On the
NAM.REMAKE
Terms Tab in SystemSetup)
The word used to describe a remove (On the Terms
NAM.REMOVE
Tab in SystemSetup)
The word used to describe a test report (On the Terms
NAM.REPORT
Tab in SystemSetup)
The word used to describe sequence 1 (On the General
NAM.SEQUENCE1
Tab in [NAM.TREATMENT] System Setup)
The word used to describe sequence 2 (On the General
NAM.SEQUENCE2
Tab in [NAM.TREATMENT] System Setup)
NAM.SHIFT1NAME Name of the 1st shift
NAM.SHIFT2NAME Name of the 2nd shift
NAM.SHIFT3NAME Name of the 3rd shift
NAM.SHIFT4NAME Name of the 4th shift
NAM.SHIFT5NAME Name of the 5th shift
NAM.SHIFT6NAME Name of the 6th shift
Name of the primary date and time when performing a
NAM.TESTDATETIME1
test
NAM.TESTDATETIME2 Name of the secondary date and time when performing

165
 a test
NAM.TREATMENT The word used to describe products

{Object} Variables – {Object} is a user defined term in TrueChem. {Object}s

represent a single tank\bath\solution.

Name Description
OBJ.CURRVOLUME Volume of {Object} including the current level input
OBJ.DATECREATED Date {Object} was created
OBJ.DESCP Name of the {Object}
OBJ.DIMFT From top
OBJ.DIMUNIT Unit name for the dimensions of the {Object}
OBJ.DIMX Width
OBJ.DIMY Length
OBJ.DIMZ Height
OBJ.FIELD1 User defined field in {Object}
OBJ.FIELD2 User defined field in {Object}
OBJ.GROUPID The unique {Group} ID for this {Object}
OBJ.HMISHTMLIMAGE HTML to display the HMIS image for an {Object}
OBJ.ID Unique ID number
OBJ.LASTCHANGED Date {Object} was last changed
OBJ.LASTREMAKE Date of last {Remake}
The current operating level entered when performing a
OBJ.LEVELINPUT
test
OBJ.LOCATION Location of the {Object}
HTML for displaying the makeup information for an
OBJ.MAKEUPHTML
{Object}
OBJ.MANUFACTURER Manufacturer of {Object}
OBJ.NAME Name of the {Object}
Percentage of volume, as a decimal, of {Object} based
OBJ.PERCENTVOLUME
on the current level
HTML for displaying the PPE requirements for an
OBJ.PPEHTMLIMAGES
{Object}
OBJ.REMAKENOTES {Remake} notes for {Object}
OBJ.SELECT1 User defined list in {Object} setup
OBJ.SELECT1SHORT User defined list in {Object} setup

166
OBJ.VOLSHORTUNIT Short name of the volume unit
OBJ.VOLUME Volume of {Object}
OBJ.VOLUNIT Name of the volume unit

Result Variables – A test may contain multiple result items. To specify a

specific result item, you must include the item number associated with the result.
If no item number is specified, TrueChem will use the current result item.
Example: [RST4.VALUE] will return the value of result item number 4.

Name Description
RST.CALC Calculation or script text
RST.CP Calculated Cp of results
RST.CPK Calculated Cpk of results
RST.CURRENTVALUE The current or previous result value
RST.DESCP Description of the result
RST.DISPLAYVALUE Displayed value of result item (set by a rule action)
RST.ESTSTDDEV Estimated standard deviation of results
RST.ID Unique ID number
RST.LCL Lower control limit of result
RST.LSL Lower spec limit
RST.MCL Middle control limit
RST.MEAN Calculated Mean of results
RST.NAME Description of the result
Notes assigned by a rule that are directly
RST.NOTES
associated with the result item
RST.NUM Result number
RST.OPT Optimum spec limit
RST.PP Calculated Pp of results
RST.PPK Calculated Ppk of results
RST.PREVVALUE Previous result value
RST.RLL Range lower limit
RST.RML Range middle limit
RST.RUL Range upper limit
RST.SHORT Short description of the result
RST.SPCPOINTS Number of points used for SPC calculations
RST.STDDEV Standard deviation of results

167
 Returns 1 if downward trend is detected, 0
RST.TRENDDOWN(#) otherwise. Replace # with the number of points to
include in the trend analysis
Returns 1 if sawtooth trend (…>, <, >, <, etc) is
RST.TRENDSAWTOOTH(#) detected, 0 otherwise. Replace # with the number
of points to include in the trend analysis
Returns 1 if upward trend is detected, 0 otherwise.
RST.TRENDUP(#) Replace # with the number of points to include in
the trend analysis
RST.UCL Upper control limit of result
RST.USER1LOWER Lower other 1 limit
RST.USER1UPPER Upper other 1 limit
RST.USER2LOWER Lower other 2 limit
RST.USER2UPPER Upper other 2 limit
RST.USL Upper spec limit
RST.VALUE Calculated value of the result

Run Variables – Run variables are used to perform tasks within a script or
calculation.

Name Description
Returns the result of a simple one line calculation. Replace C
RUN.CALC(C)
with the calculation to be evaluated
Returns the result of a library script. Replace L with the ID or
RUN.LIB(L)
Description of the library script to be evaluated
Executes a simple script and can return a value if script
RUN.SCRIPT(S)
contains “result=”. Replace S with the script to be executed

Schedule Variables – Schedule variables are used to obtain data related to

a scheduled item when sending emails or other notifications. NOTE: These
variables are invalid in other areas of TrueChem.

Name Description
SCH.ALLOTTEDTIME The allotted time of the schedule
SCH.DESCP The name of the scheduled item
SCH.ENDDATETIME The end date and time of the schedule
SCH.FREQDESCP The schedule frequency
SCH.LASTDONE The date and time the schedule was last done
SCH.MISSED The number of times the schedule has been missed

168
SCH.NAME The name of the scheduled item
SCH.PRIORITY the priority of the schedule
SCH.STARTDATETIME The start date and time of the schedule

NOTE: The following variables are also valid schedule variables: [DATE], [TIME],
[OBJ.NAME], [OBJ.DESCP], [OBJ.LOCATION], [GRP.NAME], [GRP.DESCP]
and all Name variables.

System Variables
Name Description
SYS.APPPATH Path to TrueChem.exe
SYS.DATAPATH Path to TrueChem database or database connection file
SYS.TEMPPATH Path to TrueChem temporary directory

Test Variables – Test variables are used when performing a test.

Name Description
TST.DATE Primary test date
TST.DATE1 Primary test date
TST.DATE2 Secondary test date
Number of minutes between the current value of
TST.ELAPSEDDATE1
Date1 and the last saved value of Date1
Number of minutes between the current value of
TST.ELAPSEDDATE2
Date2 and the last saved value of Date2
Number of minutes between the current time and the
TST.ELAPSEDDATE3
last saved test
TST.ID Unique ID number
TST.NOTES Current test notes
TST.PARTIAL Current test partial percentage (as a decimal)
TST.REMAKE Current test remake (returns “True” or “False”)
TST.REPORTID Current test report ID
TST.SAMPLEDATE Sample date and time
TST.SAMPLENOTES Sample notes
TST.SAMPLENUMBER Sample number
TST.SAMPLERECVDATE Date and time sample was received
TST.TIME Current test time
TST.TIME1 Current test time 1

169
TST.TIME2 Current test time 2
TST.DATETIME1 Current test data time 1
TST.DATETIME2 Current test data time 2

User Variables – User variables are used to access information of the user
who is currently logged on to TrueChem.

Name Description
USR.ADDR The current users address
USR.DEPT The current users department
USR.EMAIL The current users Email address
USR.EXT The current users extension
USR.FAX The current users Fax number
USR.FNAME The current users first name
USR.ID The current users user ID
USR.LNAME The current users last name
USR.NAME The current users first and last name
USR.PHONE The current uses phone
USR.TITLE The current users Title

User-Defined Variables – User defined variables are used to store and

retrieve information.

Name Description
Replace NAME with the name of the variable.
VAR.GET(NAME) Returns the current value for the user defined
variables
Replace NAME with the name of the variable and
VAR.PUT(NAME=VALUE) VALUE with the value to store. Sets the value of the
user defined variable

Units – When using variables with a unit parameter, use the units short name
to specify which unit to return the value in.

For example, the following variables will work correctly:

[ADJ.VALUE(gal)]
[ADJ.VALUE(lt)]
[ADJ.VALUE(ml)]

170
[ADJ.ACCUM(gal)]
[ADJ.ACCUM(lt)]
[ADJ.ACCUM(ml)]

The following examples will NOT work:

[ADJ.VALUE(gallons)] :: uses unit long name instead of short name

[ADJ.VALUE (lt) ] :: space prior to first “(”
[ADJ.VALUE ml] :: missing parentheses around unit short name

Use the tables below to help identify a unit’s short name. NOTE: You cannot
convert units between tables.

Volume

barrel Fluid bbl

cubic centimeter cc
cubic foot f3
cubic inch in3
cubic kilometer km3
cubic millimeter mm3
cup c
drop gtt
gallon gal
imperial gallon imp gal
liter lt
fluid ounce floz
pint pt
quart qt
tablespoon tbsp
teaspoon tsp
milliliter ml
cubic meters m3
cubic yard yd3

Mass

grain gr
gram g
kilogram kg
milligram mg

171
ounce oz
troy ounce troz
pound lb

Length

centimeter cm
foot ft
inch in
kilometer km
meter m
millimeter mm
yard yd
Micron u

Time

day d
hour hr
minute min
month mon
second sec
year yr

Current

ampere hour Ah

Speed

miles per hour mph

feet per second fps
kilometer per hour km/h
meters per second mps

Temperature

British thermal unit Btu

Proportion

172
Molarity Mol
molality mo
normality N
part per million ppm
percent %

Area

square centimeter cm2

square foot f2
square inch in2
square kilometer km2
square mile mi2
square millimeter mm2
square yard y2
square Meter m2

173