Automated Cycle Count Overview

Automated Cycle Count Overview


Amper's Automatic Cycle Count system is an add-on to the standard Amper system that allows accurate cycle counts to be automatically captured, instead of by operator input. This add-on does not currently unlock any new or different features in the Amper app, but instead focuses on accurately automating data collection of cycle counts. In most cases, the automatic cycle count system does NOT provide utilization data. Amper’s core factory hardware system is ALSO required.

Automatic Cycle Count Add-On Components:

  • Digital Aggregator (connected to Analog Aggregator’s 2nd CAT5 port via CAT5 cable, also powered via CAT5)
  • Accessories (CAT5 Cable, Wire, Wire Stripper, Micro Screwdriver, Wire Spades)


For more information on installation, see the
Pre-Install Checklist

The hardware captures up to two different digital signals from the machine. To install, wire is connected between the inputs on the Digital Counter and an interconnect in the machine where the desired signal passes through. Wire is also connected from the Digital Counter to the machine's PLC power output for reference (usually 24Vdc and 0Vdc).

The key aspect to the Hardware installation is picking the right signal to monitor. The chosen signal must correspond to a cycle / part or the resulting data will not be accurate. Because this is so key, it is important to carefully consider the best signal to install onto.

Where is the Data Displayed?

The Automated Cycle Count add-on replaces operator-logged counts via Tally sheets. These counts will be shown anywhere Tally sheet data is shown. For example, some of the places you will see this data include:

Operator Interface:

  • Menu → Tally sheets
    • Current Tally sheet will be updated with cycle time counts so far

Web App:

  • Reports → Paperless
    • Tally sheets will show cycle time counts determined via the auto cycle count add-on
    • Cycle time counts can be exported as CSVs via the Tally sheet CSV export
  • Timelines → Scoreboards
    • Machines show cycle time counts for current shift
    • Average cycle time will be shown for current shift

How Scrap/Bad Parts Are Handled

Machines Without Automatic QA (most common)

Most of the time (particularly with CNC or Injection Molding machines), the signal being monitored will correspond to TOTAL PARTS. This is because, in those cases, the machine itself does not know whether the parts were good or bad. So, given that scrap parts are determined outside of the machine (usually manually), SCRAP still need to be entered by the operator in the Operator Interface. Once the SCRAP number is entered, the system will automatically take the collected TOTAL CYCLES, subtract the SCRAP entered by the operator, and show the resulting, calculated, GOOD PARTS.

Machines With Good / Bad Part Sensing

In some cases, a machine may have a built-in QA that determines if a part is good or bad. This is usually the case with sorting or finishing machines, as well as many line-based systems. In this case, if any two of the three signal types (TOTAL CYCLES, GOOD, or SCRAP) can be automatically captured, then all three count types will automatically show in Amper.

Example Use Cases & Workflows

How many parts have been produced on a specific machine this shift?

Option 1: Scoreboards

  1. In the Amper web app, go to TimelinesScoreboards and select a group that contains the machine
  2. Look at the machine's Scoreboard card and see the cycle counts

Option 2: Operator Interface

  1. In the Operator Interface app, navigate to the machine's page
  2. In the upper right menu, click the Tallysheets button
  3. View the current Tallysheet and see the cycle counts

How many parts were produced for a specific job or part # this week?
  1. In the Amper web app, go to ReportsPaperless
  2. Set the time range to the days you care about
  3. Click Select All and then Download CSV
  4. In your preferred spreadsheet software, filter by the job or part # field and sum the counts

What is/was my average cycle time for a specific job over a shift?
  1. In the Amper web app, go to ReportsPaperless
  2. Set the time range to the day(s) you care about
  3. Note: To get this data in real time, make sure Ready Only and Submitted Only are NOT checked so that the in-progress Tallysheet is visible in the list and CSV. You may need to click Apply again.
  4. Click Select All and then Download CSV
  5. In your preferred spreadsheet software, filter by job or part # AND by the machine if necessary
  6. Look at either the Avg Cycle Time field for that entry or, if combining multiple entries, sum up the Total Parts and divide by the machine uptime

How can I track part counts / avg cycle times for a period of time that is shorter than a shift?

Auto cycle counts are tied to Tallysheets. You can evaluate shorter periods of time by submitting the current Tallysheet to automatically begin a new one. Use the start / end times of Tallysheets to break up periods of time when required. The Tallysheets will then show up as individual entries in the web app in ReportsPaperless