act te 335 corrected

TE-335Application of Computers in

Textile.

Chapter:1

Introduction to computer

Computer???

An electronic device which is capable of receiving information (data) in a particular form and of performing a sequence of operations in accordance with a predetermined but variable set of procedural instructions (program) to produce a result in the form of information or signals.

Computerization???

• Automation, mechanization: the act of implementing the control of equipment with advanced technology; usually involving electronic hardware like computer.

• To control, perform, process, or store (a system, operation, or information) by means of or in an electronic computer or computers.

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You may want to write letters to designers or manufacturers as part of your research. Addresses can be inserted for each manufacturer and then printed out without having to reproduce them again and again. Mail merge is an excellent tool to use as it will insert names and addresses at the touch of a button.

You could also use a word processor to produce a questionnaire to find out more about what your potential clients want.

Word processor

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Word processors like Microsoft Word enable you to perform multiple tasks, allowing you to cut, paste, move and resize images and text, change font, add bullet points, etc.

Spreadsheets are extremely useful for collecting and displaying a range of data.You can sort data by particular headings, enabling you to order information after it has been inputted.It is possible to manipulate data into different categories, complete tasks including calculations and mail merges and look up data from other spreadsheets.You can also filter information to print out specified data.This information shows whether manufacturers responded by sending samples.

Spreadsheets

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If you have completed a questionnaire in your coursework, graphs are a great way of presenting your findings.

Which age range would like your product?

Age Range

0

2

4

6

8

10

2-3 years 4-5years 6-7 years

Age

No

of c

hoic

es

Series1

Age Range

0

2

4

6

8

10

2-3 years 4-5years 6-7 years

Age

No o

f Cho

ices

Series1

Age Range

2-3 years

4-5years

6-7 years

Graphs

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You can collect and record information quickly using a digital camera. Digital photographs of existing products, or of places or objects that have inspired you, can be used to illustrate your design ideas.

Photo-editing software can be used to change the colour-ways and colour coordination of your product.

This will give you a good idea of what your garment or textile item may look like in different colours without making up samples.

Digital photographs

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Photos taken with a digital camera, or uploaded to a computer using a scanner, can be saved in a number of formats:

JPEG files are compressed images and can easily be inserted into documents for sending via e-mail or saving onto discs.

TIFF files have a very good resolution and can be used for computer presentation work and outputting transfer printed designs.

PICT files have a good resolution and can also be used for presentations.

Etc.

Digital photograph formats

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•Video conferencing allows designers, clients and manufacturers to talk to each other face to face. They are able to show each other ideas, share applications and even amend each other’s drawings on the other person’s computer.

Communication

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•E-mail is a quick and easy way of communicating with colleagues, clients and suppliers and can be a useful way of contacting manufacturers to gain knowledge and feedback.

•What advantages do you think video conferencing offers?

Saves time

Saves travelMore friendly than telephone

Can see what the other person is doing

The 5 main examples of computer systems used in the Textile Industry:

CAA: Computer Aided Administration

TechnologyCAM:

Computer Aided Manufacture

CAD: Computer Aided

Design

EPOS: Electronic Point

of Sale

CIM: Computer Integrated

Manufacture

This ICT system is used at every

stage of planning, designing and manufacturing.

Development of designs, creating and grading patterns

and lay planning.

ICT packages are used for marketing, sales order

processing and monitoring stock levels.

Computers are used for store design, lay planning and cutting, sewing and

pressing.

A system – computer based

which speeds up sales

transactions and keeps

account on stock levels.

Companies take advantage of other new technologies. Some examples are:

Other New Technology?

Skype

E-retail

BloggingInteractive Design

Instant Messaging

Video Conferencin

g

Virtual Imaging

Networking Sitese.g. Bebo, My Space and You

Tube

Technology

What is ICT???

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Stands for "Information and Communication Technologies." ICT refers to technologies that provide access to information through communications. It is similar to Information Technology (IT), but focuses primarily on communication technologies. This includes the Internet, wireless networks, cell phones, and other communication mediums.

How is ICT used?STAGE: PURPOSE: EXAMPLES:Research and Presenting • Collecting and recording

relevant facts• Using digital imagery

• Internet/email• Graphics Software•Digital Camera•Word Processing Software• Video Conferencing

Design • Creating visual designs• Developing a specification• Creating a prototype• Experimental work

• Graphics Software• Digital Camera• Scanner• Digital Printer • CAD Systems

Manufacturing/Production • Producing patterns• Producing end garments• Controlling machinery• Costings

• Lay planning• Digitisers / Digital Printers• 3D body scanning equipment• Computerised sewing, knitting and weaving ,machines• EDI (Electronic Data Interchange)

How is ICT used?Distribution • Stock control and

dispatch systems• Order processing

• Tagging (RFID)• Word Processing / Databases• Spreadsheets• Stock/asset tracking software

Sales • Promoting the product e.g. Advertising• Sales channels e.g. on TV, website/E-tailing• E-Commerce• Security Tagging

• Graphics Software• Word Processing Software• Digital Printer• Digital Camera• EPOS software• PDM Software

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Data and Information

i. Data is a plural of word Datum which means fact. Data is represented by symbols i.e. 1,4,5,9,0 or A,B,G,T,R or %, ?, $.

ii. Information -Data is a raw material for information. Information is knowledge that makes sense and produce meaning full results.

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The role of computer in manufacturing

Computer based information technology have been extensively used to help both designing and manufacturing industries manage their processes and information system to focus their efforts on increasing the overall efficiency and meet the customer’s requirements.

The role of computer in manufacturing may be broadly classified into following two groups:

1. Computer monitoring and control of the manufacturing process;2. Manufacturing support application, which deals essentially with

the preparation for actual manufacturing and post manufacturing process.

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What is CAD???

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Computer-aided design (CAD) is the use of computer systems to assist in the creation, modification, analysis, or optimization of a design. CAD software is used to

increase the productivity of the designer,improve the quality of design, improve communications through documentation, and to create a database for manufacturing.

CAD output is often in the form of electronic files for print, machining, or other manufacturing operations.

CAD is used to create or modify designs. The final design can then be digitally printed, or the information sent directly to cutting machines. Here, pattern pieces are designed on the computer and then printed.

CAD

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What is CAM???Computer-aided manufacturing (CAM) is the use of

computer software to control machine tools and related machinery in the manufacturing of workpieces/products. CAM may also refer to the use of a computer to assist in all operations of a manufacturing plant, including planning, management, transportation and storage.

Its primary purpose is to create a faster production process

and components and tooling with more precise dimensions and material consistency, which in some cases, uses only the required amount of raw material (thus minimizing waste), while simultaneously reducing energy consumption.

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Transfer printingAn image is produced using CAD (Computer Aided Design) and printed out onto the transfer paper. This image is then ironed face down onto the fabric. When it is cool you are able to remove the backing paper. There are many different papers on the market – some require reversing.

CAM in industry

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Embroidery machine

CAM in industry

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2. The embroidery machine can be linked directly to a PC or designs can be transferred on a disk.

3. The image is then downloaded onto the machine’s memory and output onto the machine bed, creating a machined logo or image.

1. A design is copied using a scanner or created using CAD software.

CIM Computer-Integrated Manufacturing (CIM) systems

integrate or link CAD and CAM systems.

These combined systems link design development, production planning and manufacturing systems together.

Companies that use CIM are able to design a product in one country and manufacture it overseas where labour costs are lower.

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AUTOMATION• Automation is the use of machines, control systems and

information technologies to optimize productivity in the production of goods and delivery of services.

• The word automation was originally coined by an engineering manager of Ford Motor Company in 1946 in order to describe the variety of feed device mechanism and automatic transfer devices.

“Automation is a technique of automatically controlledoperation of an apparatus, process or system by mechanical or

electronic devices that takes place of human organs of observation, efforts and decision.”

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Automation Tools

Computer-aided technologies (or CAx) now serve the basis for mathematical and organizational tools used to create complex systems. Notable examples of CAx include Computer-aided design (CAD software) and Computer-aided manufacturing (CAM software).

The improved design, analysis, and manufacture of products enabled by CAx has been beneficial for industry.

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Different types of automation tools

ANN - Artificial neural network BPM - Bonita Open Solution DCS - Distributed Control System HMI - Human Machine Interface SCADA - Supervisory Control and Data Acquisition PLC - Programmable Logic Controller PAC - Programmable automation controller Instrumentation Motion control Robotics

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The main advantages of automation

• The main advantages of automation are:– Increased throughput or productivity.– Improved quality or increased predictability of

quality.– Improved robustness (consistency), of processes

or product.– Increased consistency of output.– Reduced direct human labor costs and expenses.

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Product Life Cycle with Computer

• Product life cycle with computers can be divided in following main sections:1. Conceptual Design: Used from market needs to final

product. Computers can only help as an assistant for handling data or comparing ideas/ concepts.

2. CAD: Replaces all kind of prototype and testing with the use of virtual models and simulated analysis.

3. CAM: In part programming, machine control, inspection and packing jobs.

4. Selling and Follow-up: To generate new challenges and needs for the new product development.

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Chapter-2

Application of Computer in Textile sector


Application of Computer in Textile

In Processing

Production Machineries

Fibre processing/ Yarn Manufacturing

Fabric Manufacturing

Wet processing

Apparel Manufacturing

Quality Assurance

Testing Equipment

yarn Testing

Fabric Testing

Wet processing

Testing

Apparel Testing

Testing Calculation

Testing Software

Test Result Analysis

In Production Planning

Designing Software

Calculation Software

Record Keeping.

Data analysis software

In Management

Human Resource

Production data

Store data

Planning data

ERP

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Spinning sector/ Yarn Manufacturing sector

AAF, Lecturer-BUTex

USTER HVI 900:

1. It analyzes and classifies samples of cotton bales within seconds according to international trading standards.

2. It is also used for raw material purchasing and bale management in spg. mill.3. It measures the following important fibre bundle properties:

– Fibre length distribution – Strength & elongation – Micronaire– Color grade – Optical trash content – Short fibre content – Spinning consistency index(SCI)

4. Two versions are available:– Semi automatic system– Automatic system


USTER COLORIMETER 750:

To know the precise measurement of cotton color & grade.To determine Rd(Reflectance)+b(yellowness) with this

information:• Spinners, merchants and researchers can

determine acceptable standards for purchasing cotton.

• Controlling color variation in bale lay downs for producing quality yarn.


USTER MICRONAIRE 775:

1. It is used for precise measurement of micronaire of cotton fibres.

2. By using it bale lay downs will eliminate or reduce costly rejects from fabric barre.


USTER AFIS-N, L&D, Y:1. It is a single fibre testing installation. It is designed with

different modules-– Module N: For analyzing nep count & nep size.– Module L & D: To measure fibre length & diameter.– Module T: Determines the no. & sizes of foreign matter , dust and trash.– Multidata module: For simultaneous determination of neps, fibre length

& dia., trash, dust of sample.– Auto jet module: For automatic loading of test sample.

2. Unsuitable cotton types, incorrect machine setting as well as changes of quality can be recognized quickly & reliably.

3. Maintenance cost can be reduced, particularly with respect to card clothing.


USTER AUTOSORTER -3

1. It reduces the daily sorting expenditure in textile laboratory.

2. It determines-– Mean yarn count – Variation in yarn count(Std. deviation, Co-efficient of

variation, Frequency distribution)– The confidence limits


USTER CLASSIMAT 3:

1. It is yarn fault classifying installation.2. It automatically detects seldom occurring thick and thin place

faults in staple spun yarns.3. At the end of the test it converts the fault frequency to a

standard yarn length.4. The new USTER CLASSIMAT 3 displays the results in

various graphs and freely configurable reports.5. Ideal conditions are created to ensure the optimal setting of

the electronic yarn clearing installations.


USTER SLIVERDATA:

• It monitors the entire production process in the spg. preparation.

• At draw frames, cards, combers, the USTER PF sensor determines sliver count variations, evenness, spectrogram and thick places continuously and on line.

• If selected quality limits are exceeded, USTER SLIVERDATA triggers an alarm or stop the m/c concerned.

• The production & quality conditions of individual m/c, m/c groups, or the entire process are recorded in special reports.


USTER SLIVERDATA:

• Disturbance as well as their causes are quickly recognized and can be effectively eliminated.

• With little effort USTER SLIVERDATA can be integrated into networks via USTER POLYLINK.

• The USTER SLIVERVIEW application software allows an even quicker survey of events in the spg. preparation.

• USTER autolevelling& monitoring installations can be connected to USTER SLIVERDATA easily & without loss of investment.


Important characteristics, - supervised by SILVER DATA

• The most important characteristics, which can be supervised by SILVER DATA at card, comber and draw frame, are broadly of two types 1. Quality characteristics,&2. Production characteristics.


Quality characteristics.

• The data system continually monitors-Sliver court & variation,Evenness & periodicities,Co-efficient of variation at short length,Thick places,Spectrogram of above quality


Production characteristics

• The most important production data collection applied at all machines are-Production amount,Production speed,Efficiency,Frequency & length of interruption,Doffing,


The monitoring procedure of sliver data system:


The monitoring procedure of sliver data system:

1. The online data collection system is described by above fig. It performs its function by “Round the clock supervision”.

2. It provides an automatic alarm with any irregularity and automatic stopping of the m/c with serious fault.

3. The servo sensor motor determines the short wave length. 4. All the working device works simultaneously to show the

output on monitor.5. The controller sends the data to the central processing unit

of MILLDATA system.6. The sliverdata systems can be integrated into the networks

by polylink system.


USTER RING DATA :

1. It is the proven data system for quality and production monitoring in ring spg. mills.

2. It monitors every individual spindle with respect to end breakage and ring traveler speed.

3. End break frequency, rogue spindles, production, efficiency and stoppage are systematically monitored.

4. It allows to improve yarn quality and at the same time increase the productivity.

5. The special possibilities of USTER RINGVIEW include-– Long term evaluation.– ABC- analysis of end breaks.– Optimization of the ring spg. speed through evaluation of the end break

frequency for cops.


Ring data system: -characteristics data

• The characteristics data obtained from the RING DATA system can be categorized into two classes-1. Production characteristics ,&2. Quality characteristics.


Production characteristics

• Machine number ― Production quality• Date ― Efficiency• Time ― Doffing time• Interval monitored ― Number of doffing• Production period ― Code number of spindle• Spindle revolution ― Grams per spindle hour


Quality characteristics

• Yarn twist• End breakage rate• Mean period of each ends breakage• Yarn type.


The mechanism & working principle of ring data system.


The mechanism & working principle of ring data system.

1. A traveling sensor moves back and forth at about ring rail level on each side of one another or on all machines of the installation. It generates a magnetic field that is affected by the rapidly rotating traveler.

2. If a thread breaks, the sensor emits a pulse indicating an end down & identifies the code number of spindle.

3. Another sensor fitted to the front roller detects delivery speed and m/c downtime.

4. A further sensor registers the no. of doffs and the time taken for each doffing.

5. The computer evaluates the information and stores the result of the evolution over a given period.

6. The end breakage rate is identified by means of lamps.


USTER ROTORDATA:(Rotor spg.)

• It is used for the central controlled & monitoring of USTER POLYGURD yarn monitoring installations.

• The scope of performance includes among other features:1. Centralized overview of the entire rotor spg. department.2. Centralized setting of all USTER POLYGURD yarn

monitoring installations.3. Centralized acquisition of quality and production data of all

rotor spg. machines.4. Freely configurable reports with alarm function for limit

values.5. Graphical representation.


Characteristics Investigation

• The rotor data system displays following quality & production characteristics-

― Length measurement― Short & long thick places― Efficiency― Production quality― Twist of yarn― No of piecing― End breakage rate


USTER CONEDATA:(Cone winding)

1. It is the proven data system for efficient cone winding management.

2. With this system, the data collected by the yarn clearers USTER AUTOMATIC, USTER POLYMATIC and USTER POLYMATIC Q-PAC are made available at one central location.

3. Quality and productivity data are presented in clearly arranged graphics, surveys and exception reports.


Merits of using computerized control system in spinning:

• The SLIVERDATA, RINGDATA, MILLDATA system has made all mill conditions transparent & smooth.

• Computerized controlled system assist in planning of mtl. & personnel assignment.

• Computer control system has introduced bale management/ cotton mixing system eliminating manual mixing, removing faults and initiating a high production rate at the start of spg.


Merits in spinning:

• SLIVERDATA system ensures producing a quality final product.

• Computer based blending saves 5-12% cotton than traditional blending method.

• Possible to stop the m/c whenever a spg. m/c produces mtl. which is beyond its tolerance limits.

• In RINGDATA the sensor micro computer reduces the end breakage rate indicating the m/cs at which it occurs & helping in piecing it quickly.


Merits in spinning:

• Reduction of amount of testing of the product found from different m/c like sliver, rove, yarn in the mill laboratory.

• The computer control system offers to design the spg. department with more economic layout & structure.

• Continuous monitoring of the output has been used to control effects of mechanical failure.

• Computerized control system can restore the data for a long time to investigate the production of a spg. mill.


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Application of Computer in Fabric Manufacturing sector

AAF, Lecturer-BUTex

Computerized system in -weaving section.

• There is a huge application of computer in weaving sector.

• Now a days almost all types of weaving machines are automated and very high performance machine.

• There is no process left with conventional methods/ machine in today's factory.



Some of the most remarkable computer application is as below-• Weaving CAD: this software is vastly used to produce sample

fabric with required repeat size or repeat unit.• Dobby Tronic: Here lifting plan is manually input into this

software and it automatically select the heald frames as lifting plan. Weft-way color assembly is also executed by this application.

• Tex Tronic: Warp-assembly is executed by this application. For example, for any fabric of 15red+10blue stripe, this color way combination is input by this application as (15R+10B).



Merits of automation:Automation in weaving section provides various types of

advantages. As a result of automation we can know-• RPM, adjusting RPM.• on process tension,• production, production rate, productivity,• breakage rate of both warp and weft,• Breaking finger detector,• Machine temperature, different zone temp.• Auto pattern input,• Weft color assembly and so on.


Advantages of computerization in

-Weaving Section


The best computerization development in weaving section is integrating the creative and analytical aspects and actual control of the loom.Easy pegging plan & efficient dobby mechanism. Computer aided design in jacquard loom allowing frequent pattern change, elimination design error, increasing flexibility.Diversification in the design of woven fabric.Direct loom control as in SULZER RUTI loom.Display of all required value like weft insertion rate, loom speed, thread breakage rate, stoppage time etc.Improvement in yarn cleaning, fault dictation, length measuring unit, piecing as in CONEDATA system.

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Application of Computer in Wet Processing Sector

AAF, Lecturer-BUTex

Computerized system in -textile dyeing.

• Computerized Color Matching System (CCMS).1. CCMS is a system software used successfully in the field of

color measurement.2. The main objects of CCMS is the calculation of colorant

concentration necessary for matching.3. The CCM system can provide availability of multiple

choices of the predicted recipes.4. It is used to estimate the draft recipe.5. The basis of CCMS is relied on the use of Kubelk-Munk

theory which is demonstrated under controlled condition.



Advantages of using CCMS:• CCM provides optimum and economic recipe.• More attractive than conventional trial and error method.• A wide range of matching can be found with greater speed.



Super tex system:• It provides an automatic control on dyeing m/c.• The data exhibited by it :

– Batch weighting update.– Production quality & efficiency.– Color display- color simulation.

• It is used in dye house control & management system.



In discontinuous dyeing:• Computers are now be used in the discontinuous

dyeing of textiles to reduce energy and water and dyestuff consumption.

• Apple Lisa technology is used in this field.



Data color system:• Data color is a dyeing system which is based on color physics.• Firstly a light source is focused to a sample when the reflected light fall

on photo cell, it transfers the identified color to the memory of computer.• The shade% and required amount of color is previously accessed to the

computer.• If the shade% of sample is equal to the predetermined shade%, then

100% perfect shade is obtained.• The recipe can be obtained from the information/data system of desired

shade from computer or different recipe can be prepared by knowing the shade% of different color.

• The main function of the data color is to determine the shade% of a sample.



In monitoring devices:Micro computers are now used in different dyeing m/c to display

production data like production, efficiency, dyeing temp., time, M:L, dye concentration, amount of chemicals etc.

In finishing subsection:CP/M operating system is now used in finishing for its good

program portability to improve production planning & control.


Advantages of Computerization in

-Dyeing Section


Computerized color matching system provides optimum & economic colorant concentration necessary for matching.Data color system provides the measurement of required shade % and determination of color shade of a sample.BEACON controller provides uniform dyeing condition.Process data link chemical concentration, speed, temperature, shade % can be monitored & displayed from different computer system. Improved efficiency of discontinuous dyeing process.

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Application of Computer in Apparel Manufacturing Sector

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INTRODUCTION OF CADCAD means Computer Aided Design that is a project assisted by

a computer. CAD is the use of computer technology to aid in the design of a product.

• CAD actually encompasses all those activities of product design cycle with converts a workable concept into a ready to manufacture product specifications. The various sections are:

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CAD tool Elements

1. Geometrical Modelling and Computer Graphics: Helps in generation and visualizing models on which the analysis is done subsequently.

2. Analysis and Optimization tool: It predicts the behaviour of the model under the loading conditions when all constraints are simulated using boundary conditions.

3. Drafting and Documentation toolAAF, Lecturer-BUTex

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CAD SoftwareCAD software is used to increase the productivity of the designer, improve the quality of design, improve communications through documentation, and to create a database for manufacturing.

Auto CAD: Explore and visualise 2D/3D concepts with a powerful set of intuitive design tools.Real CAD Pro: It is all purpose 2D/3D CAD software for full 3D modelling, rendering, and 2D drafting in one inexpensive solution.Rhino3D: It is the best tool for opening, editing, fixing and converting 3D files of almost any type, as well as being a brilliant 3D modeller in its own right.

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CAD Software

• Iron CAD: It is the productivity leader when it comes to moving creative ideas into full 3D reality.

• PRISM: It allows the editing of shades of colours on the printer and makes a calibration according to the original colour & colour on the screen.

• COLOUR TEX: It creates realistic simulation of fabric created in colour weave. It is possible to create a wide variety of yarns of all material and types.

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CAD Software• MODARIS: Garment Sector• TUKACAD (TUKATECH): Garment Sector• LECTRA: Used in garment sector mostly for pattern

making, Grading and designing.• REACH CAD (REACH TECHNOLOGY INDIA): Garment

Sector• OPTITEX PDS (pattern design system) - Garment Sector• AUDACES APPAREL (VELCO GARMENT MACHINERY,

S.AMERICA): Garment Sector• GT RESOURCES: Garment Sector

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VARIOUS TYPES OF CAD SYSTEMS• Currently, the following are the different types of CAD systems

available in the market for the use of garment industry.i. Digitizing systemsii. Grading systemsiii. Marker making systemsiv. Pattern design software (PDS)v. Pattern generation software (PGS)vi. Body measurement softwarevii. Texture mappingviii. Embroidery systemsix. Specification & costing systems

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COMPUTER AIDED MANUFACTURING(CAM)

• CAM is the use of computer software to control machine tools and related machinery in the manufacturing of work pieces.

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CAM Tools

1. CAD Tool: Geometric information of model2. Manufacturing Tool: Fundamental of

manufacturing processes3. Networking Tool: Communication between

various machines and computers

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COMPUTERIZED EMBROIDERYMANUFACTURE (CEM)

Embroidery can be applied directly to piece goods and continuous fabrics.

The design philosophy for the embroidery CAD / CAM system was developed on the basis of an engineering CAD/CAM.

It is appropriate to call the system as CED/ CEM (Computer Embroidery Design/Computer Embroidery Manufacture).

CED is a multi user, multi-taking computer graphics system for the design of embroidery patterns.

CEM machine coding and the online electronic control of embroidery machines represent the embroidery pattern.

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CAD / CAM IN INDUSTRY

CAD/CAM system have greatly influenced in all kind of industries, but perhaps its effort can be appreciated more by those industries which used to invest a lot in prototype building and testing.

Basic conceptual model which can be used in Mechanical Industry are:

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ADVANTAGES OF CADi. Allows to shorten the time elapsing between the development of the

new fashion ideas and the collection presentationii. CAD reduce staff requirement in a given work as complex engineering

drawing can be easily done by use of CADiii. Quicker preparation of the collectionsiv. The degree of repetitiveness in the design part is more with the help of

CADv. The number of prototypes or samples to be physically produced prior to

acceptance by the customer is greatly reduced by use of CAD system, thus resulting in cost and timesaving.

vi. CAD system provides Quick Response (QR) capabilities to an enterprise by compressing the “design

- manufacturing - marketing" cycle time.

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vii. Cad system produce more logical pattern & improve concentration of designer to give optimum design

viii. Lower interference with the production activity.ix. CAD system can easily interface with CAM devicesx. (Computer Aided Manufacturing) for machine control

& Fabric production becomes practically automatic.xi. It gives fewer design errorxii. CAD system gives greater accuracy in design calculation

ADVANTAGES OF CAD

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ADVANTAGES OF CAD

xiii. The Designs can be stored in libraries, can be recalled, modified, and evaluated quickly

xiv. The CAD systems can directly download process information (e.g. machine settings, lifting plan) to the shop floor; designs can be quickly brought to production of woven fabric.

xv. Continuous monitoring & the control on the whole production cycle.

xvi. Offer a better service to the customer

AAF, Lecturer-BUTex

Advantages of computerization in

-Garment Section


Computerized interactive marker making by CAD system.Very accurate, efficient cutting & spreading of fabric.Different automatic like auto trimming, speed control, auto thread cutting mechanism of sewing machinery.Auto display of process data of the sewing m/c like model DDL 5550 JUKI.Introduction of CPD__ Computerized pattern design system.CED& CEM_ Computerized embroidery design and manufacturing system.Reduction in labor cost & high production from different stage of manufacturing.

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Application of Computer in Testing Sector

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Application of computer in Testing

• The incorporations of computers and microprocessors has brought great changes to the instrumentation used for testing textiles.

• Their use falls into two main categories:1. Recording and calculation of results and2. Automation of the test procedure.

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Recording of Results

• In these applications the computer is usually connected via an analogue to digital converter to an existing instrument from where it collects the data that would previously have been written down on paper by the operator. The advantages of such an installation are as follows:

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More Consistent Measurement: • In the case of a graphical output the whole of the curve is

recorded numerically so that results such as maxima, areas under the curve and slopes can be calculated directly without having to be read from a graph. This allows a more consistent measurement of features such as slopes which would previously have been measured by placing a rule on the graph by eye. However, it is important in such applications to be clear what criteria the computer is using to select turning points in the curve and at what point the slope is being measured. It is useful to have visual checks on these points in case the computer is making the wrong choice.

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Adjustment of Zero Level:

• The ability to adjust the zero level for the instrument automatically. This can be done, for instance, by taking the quiescent output as being the zero level and subtracting this from all other readings.

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Ability to Calculation:

• The ability to perform all the intermediate calculations together with any statistical calculations in the case of multiple tests.

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Printed Output:

• The ability to give a final neatly printed report which may be given directly to a customer.

It is important, however, to be aware of the fact that the precision of the basic instrument is unchanged and it depends on, among other things, the preparation and loading of the sample into the instrument by the operator and the setting of any instrumental parameters such as speed or range.

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Automation of the Test Procedure:

• Use of Electronic Processing Technology: In such applications use is made of electronic processing power to control

various aspects of the test rather than just to record the results. This means that steps such as setting ranges, speeds, tensions and zeroing the instrument can all be carried out without the intervention of an operator. The settings are usually derived from sample data entered at the keyboard. In the case of yarn-testing instruments can all be carried out without the intervention of an operator. The settings are usually derived from sample data entered at the keyboard. In the case of yarn-testing instruments the automation can be carried as far as loading the specimen. This enables the machinery to be presented with a number of yarn packages and left to carry out the required number of tests on each package.

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Automation of the Test Procedure:

• Repeatability of Test Results: The automation of steps in the tests procedure enables an

improvement to be made in the repeatability of test results owing to the reduction in operator intervention and a closer standardization of the test conditions. The precision of the instrument is then dependent on the quality of the sensors and the correctness of the sample data given to the machine. The accuracy of the results is, however, still dependent on the calibration of the instrument. This is a point that is easily overlooked in instruments with digital outputs as the numbers have lost their immediate connection with the physical world. If the machine fails in some way but is still giving a numerical output, the figures may still be accepted as being correct.

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Example of Computerized Textile Testing Instruments:

• Scanning Electron Microscopy• X-ray Photoelectron Spectroscopy(XPS)• Micro Glider• Gas Chromatography-mass Spectrometry (GC-MS)• Nuclear Magnetic Resonance (NMR) Analyzer• Rotawash Color Fastness Testers• Standard Reference Washing Machine• Standard Tumble Dryer

AAF, Lecturer-BUTex

Enterprise resource planning (ERP)


Enterprise resource planning (ERP)• Enterprise resource planning (ERP) systems integrate

internal and external management of information across an entire organization—embracing finance/accounting, manufacturing, sales and service, customer relationship management, etc

• ERP systems automate this activity with an integrated software application. ERP facilitates information flow between all business functions inside the organization, and manages connections to outside stakeholders.


Functional areas of ERP:

An ERP system covers the following common functional areas. In many ERP systems these are called and grouped together as ERP modules:

• Financial accountingGeneral ledger, fixed asset, payables, receivables, cash

management, financial consolidation• Management accountingBudgeting, costing, cost management, activity based costing• Human resourcesRecruiting, training, payroll, benefits, diversity management,

retirement, separation



• ManufacturingEngineering, bill of materials, work orders, scheduling, capacity,

workflow management, quality control, manufacturing process, manufacturing projects, manufacturing flow, product life cycle management

• Supply chain managementSupply chain planning, supplier scheduling, order to cash,

purchasing, inventory, product configurator, claim processing• Project managementProject planning, resource planning, project costing, work break

down structure, billing, time and expense, performance units, activity management



• Customer relationship management (CRM)Sales and marketing, commissions, service, customer contact,

call center support - CRM systems are not always considered part of ERP systems but rather BSS(Business support systems)systems . Specifically in telecom scenario

• Data services Various "self–service" interfaces for customers, suppliers and/or

employees


CharacteristicsERP (Enterprise Resource Planning) systems typically include

the following characteristics:• An integrated system that operates in real time (or next to real-

time), without relying on periodic updates• A common database, which supports all applications• A consistent look and feel throughout each module• Installation of the system without elaborate application/data

integration by the Information Technology (IT) department.


ERP software packages

• 1C:Enterprise from 1C Company• 24SevenOffice Start, Premium, Professional and Custom from

24SevenOffice• A1.iO from Alliance Technologies • A1 Academia from Alliance Technologies • abas Business Software from ABAS Software AG • Access SupplyChain from the Access Group • Accpac from The Sage Group• Activant acquired by Epicor• Acumatica Cloud ERP from Acumatica• AddonSoftware from BASIS International• Agresso Business World from Unit4• AIVA 9001 from AIVA SISTEMA


Types of softwares for textile industries

Software Name Website

ACS Optima www.cgsinc.com/softwaresoultions/index.html

Bann www.bann.com

BPCS www.ssagt.com

Datatex www.datatex-tim.com

InteniaMovexFashion www.intenia.com/w2000.nsf/index

JD Edwards www.jdedwards.com

Pointman www.pivotpoint.co.uk

SAP www.sap.com


Development of ERP package for textiles:

• ERP facilitates a company wide integrated information systems covering all functional areas such as manufacturing, sales and distribution, accounts, payables, receivables, inventory ,human resources etc. ERP solution includes manufacturing, marketing as well as finance sectors. The main steps in development of such a software package are:

1. Defining the problem.2. Designing the programme.3. Debugging.4. Testing5. Documentation.6. Maintenance.7. Redesign.



DEFINING THE PROBLEMIt includes feeding of data (i.e. specifications of input and output processing

requirements).Thus to design such a system one requires to know various parameters of textile.

Fibre Module: - It consists of market price of fibres as well as technical specifications like grade, fineness, strength, moisture regain, etc should be included.

Yarn Module: - It includes various technical, process as well as commercial details.

i. Technical parameters like yarn count, strength, weight, CV%, twist, quality ratio, breaking strength and irregularity.ii. Production details like lot number, shift production, efficiency and wastage.

iii. Process parameters like carding, drawing, spinning.iv. Commercial details like end use, market price etc.


Fabric Module: - It includes Technical specifications like yarn count for warp and weft, reed count, ends and picks per inch, process specification at winding.ii. Process details like weight and fabric width, no. of knots, sizing paste, size take up, ends and picks, fabric faults etc.

Marketing Module:-This deal with store section and various parameters like stock.

Finance Module: - It deals with HR cell and includes various parameters like database on HR, performance rating, HR allocation and selection and recruitment.



Designing the programme:1. First Step: The first step is to input incoming orders, check the

feasibility of requested dates for delivery, suggest possible delivery, manage the entire order cycle from acceptance and entry to packing list, shipping and invoicing, manage the price list, allow orders to be accepted via internet, order taking, booking of stocks.

2. Second Step: Second step is article coding (giving codes to different end products).The code structure of each article type may be named and defined as per software developer or user and parameters required.

3. Third Step: Planning is next step. It means working from given budget and production plan and calculating material and capacity requirements, laundering production orders.



• Fourth Step: Next step is checking of product manufacturing. It allows planning, laundering and tracking of production activities across whole cycle and to handle fault reporting and mapping, optimizing cutting of pieces at each inspection cycle. Inventory and purchasing should be taken care of defining purchasing and stock policies by specifying minimum inventory levels, re-order quantities and replenishment times.



• DEBUGGING: - it is the procedure of correcting the errors.• TESTING: - it is the checking of correction of individual

programme as well as complete system.• DOCUMENTATION: - it gives full description of package

and details for executing the system.• MAINTENANCE: - it is the preservation of complete

package.• REDESIGN: - it is the extension and changes as per the

requirements of individual situation.


LEADING ERP GIANTS:

• MICROSOFTThis software holds a promising segment in the small and medium enterprises market. They have been constantly upgrading the versions and are expert in manufacturing the products from the vendor's point of view (who knows all the practical difficulties of the stakeholders). The biggest advantage of this software is that many companies will prefer them for one reason that they can be easily run in Microsoft application and platforms.


LEADING ERP GIANTS:

• ORACLEThey have been in the limelight ever since they have purchased People Soft ERP software. Another encouraging fact for them is the mass campaign carried by UNDP (United Nations Development Program) to create an awareness of their products. They have also satisfied the customers (of both people soft and oracle) by offering many competitive features.


LEADING ERP GIANTS:

• SAP ERPSAP ERP, a specialized ERP product meant to solve technical

and managerial issue continues to be the choice of many companies around the world. It helps companies to redefine their business operations. Some of the features and advantages of this software program are at par with industry standards though some others require to be improved in order to make it compatible to the end user.


LEADING ERP GIANTS:

• UPS ERPThis ERP software has an important feature. They can work in

combination with other applications like SAP, Oracle etc. This will enable him or she to get the best features from each software and put them in use as may be demanded. This has also hogged the limelight due to this advantage.


LEADING ERP GIANTS:

• PEOPLE SOFT ERPPeople Soft ERP software program helps the companies to

streamline their H.R. functions in an easy and effective manner. This software continues to be the undisputed leader in the market when it comes to H.R. operations anywhere in the globe. Oracles recent takeover of People Soft has only been a boon to its customers who are now able to access the e-services of Oracle also as a result of this merger.


Use of ERP in Textiles


Limitations of ERP include:

• Though ERP has lots of benefits but it has some limitations too. Some limitations of ERP can be summarized as below:

1. Customization of the ERP software is limited. Some customization may involve changing of the ERP software structure which is usually not allowed.

2. ERP systems can be very expensive to install.3. ERP vendors can charge sums of money for annual license

renewal that is unrelated to the size of the company using the ERP or its profitability.

4. Systems can be difficult to use training must needed for user.


RFID (Radio Frequency Identification Device)


What is RFID?• RFID stands for Radio Frequency Identification Device. It is

an automatic identification technology whereby digital data encoded in an RFID tag or Smart label is captured by a reader using radio waves.

• RFID is a wireless communication technology that is used in physical markers (RFID tags) to mark products.

• In simpler terms, it is similar to bar code technology but uses radio waves to capture data from tags, rather than optically scanning the bar codes on a label.

• It does not require the tag or label to be seen to read its stored data. It is one of the key characteristics of RFID system.


RFID consists of ???

• RFID systems consist of three basic components: A tag (also called a transponder),An interrogator (a reader or a read/write device)

and A controller (a host).


RFID consists of ???


How RFID works?• RFID tags consist of an integrated circuit (IC) attached to an

antenna, i.e. typically a small coil of wires covered with some protective packaging (like a plastic card) as determined by the application requirements.

• Data is stored in the IC and transmitted through the antenna to a reader.

• RFID tags are either Passive(no battery) or Active(self-powered by a battery). Tags also can be read-only(i.e. stored data can be read but not changed) or read/write (stored data can be altered or rewritten), or a combination, in which some data is permanently stored while other memory is left accessible for later encoding and updates.


How RFID works?• A reader is basically a Radio Frequency (RF) transmitter and

receiver, controlled by a microprocessor or digital signal processor.

• The reader captures the data from tags with help of antenna, and then transfers the data to computer for processing.

• Readers can be affixed in a stationary position (for example, beside a conveyor belt in a factory or dock doors in a warehouse) or portable (integrated into a mobile computer that also might be used for scanning bar codes).

• The reader in turn sends the data to the processor and determines the actions to be performed.

• Once the process is over, the processor sends an acknowledgment signal to the tag stating the completion of the operation.


The applications of RFID in textile and apparel industries

• Product Tracking System• Tracking of Labor Movement• Fabric Lot Storage and Retrieval• Garment Washing and Laundering• Merchandise Leveling Across Stores• Easy Product Accessibility in Retail Stores• Exchange Goods Inventory Control• Customer-Specific Shopping Reminders and Promotions• Re-Stocking Alerts and Replenishment



• Product Tracking SystemIn spinning industry it is used to avoid product mix, which is one

of the prevailing problems faced in the quality control department. The areas such as carding, drawing and combing (sliver can hank mix-up), simplex (bobbin mix-up), ring spinning (cop mix-up) can be avoided by placing the tag in the corresponding semi-finished materials.



• Tracking of Labor MovementKnowing where an employee is at a particular time would allow the

management to dispatch the closest-qualified employee to a location requiring assistance. If an RFID reader detects an RFID-tagged employee approaching a security door, the door could be designed to open automatically. This would allow employees carrying packages or carts to move more efficiently. Additionally, if store management could verify through an automated system that an employee was at the appropriate station at the start of the shift or end of a break, some aspects of labour management could be automated, requiring less effort by employees and the management. This type of monitoring would also allow the management to know, for instance, if an employee spends excessive time in the break room or if he/she is not getting enough break time. Reports could be generated automatically to flag exceptions for management attention.



• Fabric Lot Storage and RetrievalDue to limited machine capacity in a wet processing unit, a fabric order may

require many number of lots, each lot will be having their own shades. In this process, it is mandatory to bring each lot up to the garment stitching process in order to control the shade variations and product mix up. An Italian textile manufacturer, Griva, has applied RFID tags as a part of a new system to control production units and stock-rooms. The tags are attached to the outside parts of cores of rolls with fabric. This has several advantages.

Firstly, the process of fabric stock-taking in stockrooms is much more effective.

Secondly, the effectiveness of all production and storage processes is higher. Moreover, it enables tracking a given object at every stage of its production process.

Finally, Griva achieved a return on its RFID investment within nine months.



• Garment Washing and LaunderingThe normal RFID tags are not launderable and also it is not possible to tag the

garment using barcodes in the process of washing and laundering. For this purpose, a German company which makes RFID tags, KSW Microtec, has unveiled two new labels. One can be ironed or sewn directly onto the fabric of a garment. The other is mounted on a polyester substrate and sewn onto a garment. The new flexible 13.56 MHz labels can withstand temperatures of up to 40C. They have a life-expectancy of 10 years and are not affected by tumble-drying, ironing processes. KSW is also working on a label that can withstand temperatures of up to 60C. The company wants to apply its technology to tag uniforms for the US army. Texas Instruments plans to offer its customers an RFID tagging system in a form of plastic rings that can be sewn or stuck onto a garment cleaned in factory laundries.



• Merchandise Leveling Across StoresSome stores require customers to leave merchandise that they are

carrying at a desk or provide evidence of purchase. However, if a store has RFID readers and RFID-tagged merchandise, shoppers could avoid this step. Instead, at checkout, the readers would charge customers only for items with tags that indicate that they were not already paid for.



• Easy Product Accessibility in Retail StoresBy using RFID, shop sellers can identify the exact location of any retail item at any time. Customer requests can be handled quickly and easily by your customer service team through access to a centralised database. RFID-tagged items offer store-to-store visibility, so items can be located immediately with the touch of a button. This level of product accessibility results in shorter wait times for customers and offers a better shopping experience. Improving overall store efficiencies ultimately results in greater savings to customers.



• Exchange Goods Inventory ControlWhen any apparel product is returned or exchanged, its RFID tag

could be read and automatically added to the inventory database. Employees who do re-stocking could read the RFID for returned items; they could be given information about where to place them (that is, the appropriate shelf if the item is not defective, or a particular area in shipping for returning to the vendor if the item is defective). An application could automatically compare the RFID code of the returned item against recall notifications.



• Customer-Specific Shopping Reminders and PromotionsWith RFID on loyalty cards to identify the customer, and a customer shopping-history database, items could be priced differently depending on the characteristics of the shopper (eg, special promotions for first-time shoppers and rewards for frequent shoppers). Different promotions could be offered to different customers via their personal digital assistants or cell phone displays, at kiosks (Information Booth), and by employees receiving price on their point-of-sale terminals. Additionally, if customers have submitted their profiles to the store, they could be reminded of upcoming events such as birthdays, and have purchases suggested to them. These can be added on to the loyalty cards which already exist at places like Shopper’s Stop, Wills Lifestyle, etc, and it can be centralised to all the stores in different cities so that customers get similar welcome whether they are in dhaka or london or new york.



• Re-Stocking Alerts and ReplenishmentProducts are monitored to ensure that they remain stocked at appropriate levels. When they fall below that level, an alert is sent to the stockroom or office to bring out or order more merchandise. For stores with stockrooms, RFID monitoring alerts employees when stock levels reach the threshold. For example, if many black trousers of waist 32-size are being sold and are getting out of stock, RFID can send an alarm to order more such trousers from the storeroom.



• Accurate data: The use of RFID helps in maintaining up-to-date data regarding various products, spare parts, and processes. Highly accurate data is available as and when required. RFID enables one to obtain the necessary data about a person, product or asset, as and when required.



• Efficient decision making: A study of the processes of production and the pattern of sales can be done using the data collected by employing RFID. Unnecessary processes can be identified and eliminated. If any process is taking more time than it should, the reasons behind it can be determined and problems, if any, can be eliminated. Similarly, if the demand for any product is very less, a decision might be taken not to stock it at all or to stock it in a lesser quantity. Hence, RFID is also helpful in making efficient decisions, ultimately saving cost and increasing the profitability of the organization.



• Ease in inventory control: Accurate data about all the material that comes into a warehouse and goes out of is available through the use of RFID. Similar is the case with a retail outlet. Hence, stock can be replenished as soon as it is exhausted. Out-of-stock situations can be reduced, thereby increasing customer satisfaction and trust on the outlet.

Similarly, keeping track of capital assets also becomes simpler, and their management also becomes easier and more effective.



• Reduction in supply chain errors: RFID can be used to track the movement of the goods that go out of warehouses. In this case, as soon as a certain goods item goes astray on the way from the warehouse to the place of production, information about the same can immediately be obtained at the point of control. Wastage and theft can thus be minimized, and the possibility of errors in the supply chain can be brought down drastically. This, in turn, would lead to timely completion of the production process and savings in cost.



• Lesser human intervention: When RFID is incorporated in an organization, the necessary data can be collected as and when required using a reader. The number of people required for locating lost goods, for finding a certain product, as well as in inventory control and management can be reduced. RFID leads to lesser requirement of human intervention, which, in turn, leads to considerable savings in manpower costs.



• Efficient quality control: RFID helps in obtaining data about the exact time when each component of the process of production passed on to the next stage. In case of any defect in a certain batch at a later stage, it would be possible to trace it back to a particular worker or group of workers. Quality control thus becomes more efficient.

Similarly, good work done can also be traced back to the concerned worker or group of workers. They can be rewarded accordingly. This would, in turn, boost the morale of the workers.


Thanks for your patience
