One of the biggest problems with inventory control in a converter plant is how to account for the remaining material on butt-stock rolls.  Now more than ever, this is a major issue that can't be ignored if you have any hope of achieving the inventory levels associated with JIT manufacturing.  The KTC Butt-Stock Roll Control System keeps track of how much material has been used from a brand new roll.  If a roll change is needed and a butt-stock roll is created, KTC's system asks the operator simply, "Did you use the entire roll?"  If the operator chooses "No," a new barcode tag is generated and placed on the butt-stock roll.  The material that KTC's system has determined to be remaining on the butt roll is then added back to the physical inventory and the ERP inventory.  This assures that at all times, the ERP has a highly accurate accounting of all available inventory, including all butt-stock rolls. 

In some cases, the linear feet remaining on a butt-stock roll may require an over ride.  For instance, if a roll spins and the mounting chuck does not, the PLC will return bad data.  The KTC Butt-Stock Roll Control System allows the operator to over ride the calculation to accomodate this error.  Any over ride requests are instantly visable in the control room and can be set to require approval, based on plant, worker, or shift.