OrgaTEX_E

OrgaTEXs c h e r m u l y t e x t i l e c o m p u t e r Production and performance management software for textile finishing 2 OrgaTEX – sustained improvement of your competitiveness Changes in the textile industry are gaining momentum. Effec- tive measures ensure the future competitiveness of a company: Shortening “Time-to-Market” of the products Increasing the product transparency and flexibility Planning optimization Reduction of downtimes Lowering production costs At the same time it should safeguard High quality standards Optimal production efficiency across all production facilities at the lowest costs possible. • • • • • • • In order to reach these challenging goals it is essential to have an integrated vertical and horizontal IT infrastructure that helps to coordi- nate the production in real time. OrgaTEX – today’s standard in finishing OrgaTEX is a production management system for textile finishing. Various software modules allow an efficient integration of the production processes and enterprise resource planning (e.g. SAP) and provide highest transparency on all levels. The unique scalability of Orga- TEX within a widely diversified standard allows to react fast and flexible to new market situations and ensures an expeditious return of your investment (ROI). 3 Benefit from our global experi- ences Besides the world’s largest manufacturers of T-shirts, towels, home textiles and sewing thread OrgaTEX is also firmly implemented into the value-added chain of the leading manufacturers of technical textiles and high end products. Benefits and advantages OrgaTEX stands for a high product- and production quality with adherence to schedules up to shipping the goods. Transpar- ency, consistent documenta- tion and traceability make every company secure and profitable. Planning takes place under real- time conditions and can so increase the productivity up to a maximum. … for the management Aligns the organization to- wards a central data platform Effective resource management Reduction of production costs Safeguard company know- how … for the production administration Access to all relevant information from one computer Utilization of integrated reports and information presen- tations Analysis of production, efficiency, down times, shifts, … Standardization • • • • • • • • … Production and process engineers Creating reports incl. alarms and historical logs Temporary supervision of weak spots Copy and paste data into analysis applications Fast familiarization by using a universal platform on all loca- tions … Energy and environment Efficient use of energy resources (steam, fuel oil, gas) Reduction of environmental impact … in global competition Fast reaction Optimized processes Lasting investments Protecting existing competitive advantages • • • • • • • • • • 44 Program editor The creation and administration of various complex dye processes is considerably easier and more efficient if done on a PC. Recurring process sections (pre- wash, bleaching, soaping, after treatments) are created as treatments and can so be combined without difficulty into dyeing procedures. In this way standards are created automatically that enhance the optimization, reproducibility and savings of dye processes. Features Graphical and tabular forms Temperature-/time curve Variable function parameter with formula integration • • • Production dye house Centralized tools for the daily production work Batch scheduler Dye program editor Function selection Automatically generated temperature curve/time curve Batch scheduler The online batch scheduler is an optimal tool to reduce the daily routine work in a dye house office to a minimum. Features Electronic planning board Batch scheduling Use of templates Batch can be moved per drag and drop Deadline monitoring Preparation and addition treatment processing Selection and display of production downtime (optional) • • • • • • • 55 Process data Online status Online supervision of the processes Fault and process information display or performing necessary interventions during batch runtime; all centrally from a workstation in the office – with Or- gaTEX you have your dye house under control. Features Display of actual process and machine data (tabular and graphical) Correction of process parameters Interventions during unfore- seen incidents Online analysis of the process data • • • • Online editor Scope of services Dye program administration Batch scheduling and planning Online supervision Alarm management Process analysis Production calendar Report system Advantages and benefits Standardizing processes Flexible production Detect discrepancies Fast reaction to unexpected events Lowering production costs Higher machine utilization (PDA) Management information system • • • • • • • • • • • • • • Transform your reports into significant business information Information becomes more and more important as production and competition factor. By processing this information with the OrgaTEX analysis and report management system, data becomes a valuable company asset that can help to get fast and reliable information about production costs and efficiency. 6 Report Real time analysis and report management Scope of services Machine report Batch report Alarm report Dosing report Benefits and advantages Easy and individually configurable report documents Manual, cyclic or event orien- tated reporting Access to all articles, product and process data Data transfer to MS-Office programs • • • • • • • • Costs per dye process Operative figures Operative figures are an important instrument to ensure the lasting success of your company: Evaluation of variances and their causes Identification of target varia- tions Checking the effectiveness of measures • • • 7 Report examples Daily production/capacity Target setting total production x-t/day Comparison of the machine performance Production costs/standard procedures Total production costs x-u/kg product Cost distribution Right First Time/additions Objective of x-% Detailed analysis of processes (problems with dosing, liquor ratio etc.) Analysis regarding irregulari- ties of procedures, recipes • • • • • • • Shift comparison/operator Assessment of the produc tion output up to gathering data for additional pay Weak spot analysis/target dis- crepancy Process runtimes Alarm messages Consumption of water, chemicals, dyestuff • • • • Production overview Runtime deviation Right first time quote (%) Trend diagrams History of energy costs History of production costs Utilization of the production Dosing system Utilization Transfer times • • • • • Scope of services Up to 64 stop reasons per machine group Operator administration Display and correction facilities in batch scheduler Simple time selection between batches Integrated into the OrgaTEX report system Advantages and benefits Objective data acquisition Increase in production PDA terminal = machine controller • • • • • • • • 8 PDA Production data acquisition of downtimes With the Widows CE.NET based controller generation SETEX provides an “all-in-one” solution for the acquisition of production downtimes: The controller of the OrgaTEX down time reasons production machine is also used as terminal for the production data acquisition. In combination with the OrgaTEX module “PDA” a flexible and fully integrated system is available. With similar machinery and with the help of an objective data acquisition, using the corresponding reports and by ensuing measures an increase in production of 15 – 30 % can be achieved. Displaying downtime reasons SECOM CE controller 9 This module looks at the production from a completely new perspective and provides additionally online information of process states. It also provides intervention facilities directly from the workstation in the office. With the plant navigator, machines und installations can be graphically shown according to the floor plan of the production area. Features Graphical user interface Departments can be separat- ed (e.g. piece/yarn dye house, finishing, dye kitchen, heat recovery) Machine status Online batch and process information Batch status display (next batch) • • • • • Plant navigator All machines at a glance Overview plant navigator Next to the new presentation also “active intelligence features” are implemented. The intercon- nection of all machines and the combination of process values, OrgaTEX database and “active intelligence” provides an alter- native of information, monitoring and control. Active intelligence features HT drain interlock (additional extension) Repeated use of bleaching bath Energy management (sequential startup of the machines) Alarm notification via SMS or e-mail By focusing on the energy management cost reductions will be achieved, expensing energy peaks will be avoided and gov- ernmental requirements will be met. • • • • • Machine details plant navigator 10 10 Recipes are an important instrument for the internal commu- nication in order to achieve a reproducible procedural finishing. This applies to the production personnel as well as to the machine controllers and dye kitchen systems. In combination with the optional formula management the Orga- TEX recipe module is a powerful system to save costs and to optimize quality and flexibility. OrgaTEX has the tool to save available process know-how and to introduce it automatically into the daily production: It covers all requirements. Recipe The central origin for the procedural communi Dyestuff library Recipe editor Features Recipe management Simple and efficient operation Integrated dye program or preparation data set Generation of preparations with automatic numbering Sub-recipe technology Different liquor rations depending on treatment Configurable input editor Integration of formula management (option) Scalable printouts Variable recipe search Product exchange with recal- culation facilities Cost calculation • • • • • • • • • • • Scope of services Creation of base recipes Chemical and dyestuff administration Article and customer management Calculation of production and addition recipes Advantages and benefits Enhance the process reliability Enhance the production flexibility Shorten the “time-to-market” Integration with dye kitchen systems Storage and use of process know-how Cost calculation and data transfer to controlling • • • • • • • • • • 11 11 cation Stock management … for chemicals and dyestuff The stock management is a helpful instrument for a cost conscious production which gives always a clear overview over the stock inventory, reserved quantities and consumptions. Every product that is ordered too late will create substantial problems in the everyday production. Stock management Features Automatic inventory management with variable feedback (set / actual values) Input of stock management terms Assignment of consumed product quantities to the particular batches Generation of order-recommendation lists Creation of consumption reports with flexible criteria’s Cost calculation of the stock quantities • • • • • • Product management Product specifications Check for incompatibility Barcode support Dyestuff class assignment Substrate affinity Assignment of dispensing stations Display and input of stock data (option) • • • • • • • Article/customer management Article definition Integrated substrate management Mixed fibers definition Assignment of production parameters Assignment article – customer Parameter for CSD optimization • • • • • • Production recipe Flexible selection of base recipes Interaction via batch parameter Configurable, automatic recipe printout Display and printout of recipe costs Addition generation • • • • • 12 With the formula management a universal tool has been created that can be used in several Or- gaTEX programs. The manifold possibilities allow for an easy implementation of gathered experi- ences and logical dependencies into so-called formulas for the optimization of existing proce- dure and recipe data. Formula management Automatic process and recipe optimization … in reports Analyses are performed to the specific requirements of a company therefore it is difficult to define certain standards. Report management in combination with formulas enable the user to create his own, customer specific reports which permit companies to create their own “standard“ reports for certain user or user groups. Examples Calculation of operating figures Evaluation of performances Comparison of processing time Machinery availability • • • • Formula use in step editor Formula editor Formula use in preparation sets Formula management … in dye programs and preparation sets By using formulas the number of dye programs or preparation sets will considerably be reduced and the administration effort mini- mized. Examples from practical experience Number of rinse cycles in rela- tion to the salt concentration Dosing time dependent on the number of circulations Width adjustment depending on the fabric width • • • 13 … in recipe Use of available know-how and automatic application it to the daily work – using formulas in recipes contributes to reach this target. The efficiency and the savings potential of this functionality guarantees a fast ROI (return on investment). Batch runtimes will be shortened, dyestuff, chemicals and energy will be saved. Flexible use Depending on the dye procedures, color depth, article, and machine type etc. formulas can flexibly be used in the recipes: Calculation of chemical quantities (salt, alkali) Automatically activating / de- activating pre and after treatments in the production recipe (bleaching, rinsing, soaping) • • Assignment of function parameters, e.g. temperature, gradient, hold time Usable for various requirements (unit conversions, print safety records) Access to all data of the Orga- TEX database (article, quality, dyestuff records etc.) Decision-making aids Pre-calculation of the production costs by accessing dye programs and recipe data Pre-calculation of the total process time Cost comparison of the different processes • • • • • • Formula use in recipes Weighing Correct amounts are essential 14 Weighing For a qualitative high grade and cost-conscious production the correct weighing of the specified recipe quantities is indispens- able. With the OrgaTEX system module “Weighing” an easy to operate user interface is available. Complemented with a suitable PC and connected scales SETEX provides a powerful weighing terminal for the daily routine work in the dye kitchen. In order to minimize errors the connection of a barcode scanner, paternoster and label printer is supported. Features Adaptable batch and machine selection Graphical display of set and actual values during the weighing process • • Adjustable tolerances Optional barcode scanner for product identification Weighing process can be interrupted and continued at any time Printout of labels for the clear identification of preparations Automatic feedback to the optional stock management Weighing of products outside of batches Reweighing from full contain- ers Paternoster control via SECOM controller • • • • • • • • Paternoster controller SECOM 626 TC Dye stuff weighing Weighing terminal WT 2000 Paternoster If a paternoster with a SECOM controller is available then automatically, after selection of the product, the paternoster moves to the corresponding position. Only after the product position is reached the weighing process will be started. Scale 3 kg Scale 32 kg IND690 Barcodes canner Label printer 15 Dye kitchen systems Connection assure the synchronization with production Preparation requests are realized via the connection between OrgaTEX and the central dye kitchen system using: SECOM control system on the production machine (discontinuous, continuous) Request terminal next to the production machine Manual activation via the OrgaTEX batch scheduler • • • More and more textile finishing companies are using centralized dye kitchen systems in their production in order to save chemicals and dyestuff as well as to enhance the reproducibility. If these dye kitchen systems are used as isolated application then most likely the expectations will not be fulfilled because of the extended time and effort that is used for recipe administration and faults created during manual operation. The connection to OrgaTEX considerably simplifies the operation of dye kitchen system as recipe or preparation data is managed and calculated centrally in Or- gaTEX. Additionally synchronization between the preparation calls on the machines controllers and on the dye kitchen system takes place. The connection of dye kitchen systems to OrgaTEX is used in dye houses and on continuous machines. Features Provision of preparation data (product, quantity, target tank and request time) for the dye kitchen system Taking over the actual data from the dye kitchen system to the stock control Taking over error messages of the dye kitchen system to be recognized and displayed on the production machines. • • • Integration central dye kitchen system to SECOM controllers Connection central dye kitchen system to third party control system Central dye kitchen with SECOM control systems can nowadays be found in many textile finishing plants. In combination with the CDC module the degree of efficiency of the dye kitchen system can be substantially increased as CDC possesses of an automatic, integrated capacity utilization control. Priorities in the preparation processing, e.g. for additions and continuous machines, are controlled by the CDC module. In connection with a dyestuff dissolving station the CDC automatically calculates the dissolving process depending on the dyestuff to be dissolved. If problems occur during the daily operation or if manual interventions are necessary for the preparation processing then an appropriate user interface will 16 CDC – Central dye … for dispensing, dissolving and weighing statio Dispensing calls Emergency processing be important. CDC shows the status of all preparations online and provides various solutions to avoid delays of the production should a problem occur. Features Automatic calculation of the dissolving program Capacity utilization control Priority assignment of preparation processes Automatically preferring additions Signaling of error conditions Configurable emergency handling Tank administration Dosing history/reports • • • • • • • • 17 kitchen control ns equipped with SECOM control systems Dispensing and dissolving systems PROBLEM: Preparation addition all-in-one for 100% Tank w i t h o u t C D C The recipe contains three different preparations for li- quids, powder and dyestuff that can only be handled sequentially. w i t h C D C The recipe contains one “mixed” preparation with all three kinds of chemicals. The CDC sends the related calls to the corresponding dye kitchen systems. d i s a d v a n t a g e By processing the preparation calls sequentially time delays may occur depending on the utilization of the dye kitchen systems. a d v a n t a g e Simple and according to dyeing technology logical- recipe creation No time delay because of parallelprocessing • • Example of use Dyestuff dissolving system PROBLEM: Dyestuff quantity cannot be processed in one dissolving cycle w i t h o u t C D C Dissolving programs for all possible variants must be created. The selection of the dissolving program must be coordinated with the dyeing process and the dyestuff quantity. w i t h C D C Flexible, automatic creation of dissolving programs Automatic calculation of the temperature, time and water quantity. Automatic calculation of the necessarydissolving cycles. Automatic dosing of solvents fromthe recipe, e.g. acetic acid for alkaline dyestuff. • • • • d i s a d v a n t a g e Increased possibility for errors and often manual interventions necessary. a d v a n t a g e Flexible solution for any quantity of dyestuff without manual intervention. Liquid chemical dispensing system PROBLEM: Defective valve on the dispensing system w i t h o u t C D C First machine waits for the confirmation of a preparation call. All other machines that have sent calls to the dispensing system are waiting for their calls to be processed until the valve is fixed. w i t h C D C Via CDC the tank will manually be disabled. CDC automatically sends a user info to the operators of the other machines so that they can add the product manually and then quit the function via the machine controller. d i s a d v a n t a g e Downtimes and manual interventions on the controller of the dispensing system and on the dye machine controller. a d v a n t a g e Flexible solution without manual intervention on the dispensing and dye machine controller. 18 18 Program editor The creation and administration of preparation data sets for a large number of article specific machine setting and various different machine types can easily be realized with the program editor. Depending on the machine type different input screens are available. By using the module “Formula Management” variable parameters (e.g. fabric width) can be created that will considerably reduce the number of data sets. Features Graphical and tabular editor Variable function parameter with formula integration Freely creatable organization structure (tree control) • • • Continuous production Transparency in the continuous machinery area Batch scheduler The assignment of correct machine settings or preparation data sets for all batches of the continuous machines can easily be realized by using the batch scheduler. This electronic online planning board shows transpar- ently the actual situation of all production batches. Batch scheduler Preparation data set Features Electronic planning board Batch disposition Automatic set time calculation Batch can be moved per drag and drop Deadline monitoring Preparation call to central dispensing system Selection and display of production downtime (optional) • • • • • • • 19 19 Online status Via the Online Status program the central control of all connected machines takes place. With the help of configurable templates the user dependent display of all process values and batch data will be realized. Features Display of actual process and machine data (tabular and graphically) Correct process parameter Intervention during unfore- seen events Alarm information Online-analysis of process data • • • • • Process analyzer Batch related process data can be displayed and printed with the process analyzer. The software is used for company internal information as well as for the proof of certain standards to third parties according to the quality standard EN ISO 9000 ff. Features Display of analog process data Set/act values Display of digital machine information Alarm list Batch information • • • • • Process data Online visualization Scope of services Preparation data set administration Batch scheduling an planning Online supervision Alarm management Process analysis Production calendar Report system Advantages and benefits Article specific standardization of processes Transparency of the production Detect discrepancies Fast reaction to unexpected events Lowering production costs Higher machine utilization (PDA) Management information system • • • • • • • • • • • • • • 20 Interfaces … for integrated solutions 20 Interface recipe systems A number of dye houses are already using recipe systems. By connecting those systems to OrgaTEX the recipes can further be used in the production process. The transfer of procedures to the recipe system allows link- ing the recipes with the dye program. From the transferred recipes OrgaTEX creates the necessary preparation data for the connected scaling stations and dosing systems. If an external stock management system is available then the actual consumption data is automatically fed back to this system. Interface ERP/PPS A large number of companies are using various computer systems for order management and production control. In order to transfer this data directly to Or- gaTEX an ODBC interface to an integration database can be provided by OrgaTEX. In this way different data like batch information etc. can be transferred to OrgaTEX. On the other side OrgaTEX provides a large number of data that can be made available in the database once the batch is finished. This data then can be used by the production planning system for calculations and evaluations. 21 Interface Dye kitchen systems The currently very popular automatic chemical and dyestuff dosing systems are especially effective if they are intercon nected to OrgaTEX. The necessary data is available in the batch recipe. Preparation calls from the machine controller synchro- nize the dosing system and the process. The actual dispensed quantities are fed back to the stock management. OrgaTEX provides programs to display the requested and processed preparation calls. In exceptional cases the preparations can also be requested or deleted manually. The chronological logging and display of all historical preparation processes allows a state- ment about the utilization of the connected dosing system. Interface continuous Via a database interface continuous machines can be connected to OrgaTEX. This results into a functionality that is comparable to the SETEX continuous controller. Management of all machine settings (sets of preparation data), batch scheduling, online information and data feedback after batch end are possible with these continuous machines. Interface handling/transport systems For package dye houses there are some manufacturers that offer automatic handling and transport systems. In connection with SETEX controller and an OrgaTEX system the handling system can receive automatically loading/unloading orders for the particular machines. 22 OrgaTEX – fail-safe and alw … in connection with standard IT solutions 22 How much system downtime and loss of data can you afford? How fast can you restart the production after a server crash? High availability systems HAS MS Cluster Server – 2003 Enterprise Server High availability of the company based IT systems under eco- nomical aspects are a central issue in every company. If company and production critical applications like the connection to a production planning system or an automatic dye kitchen are not available then this can cause immense costs. Fail-safe and redundant Advantages Completely redundant server hardware platform Eliminating non-planable fail- ures Automatic transfer of the tasks in case of a problem from one server to the other in less than 2 minutes No loss of data by switching over the server Performance enhancement of the system Simple backup solution • • • • • • 23 ays online Independent from server hardware VMware infrastructure By using server virtualization a physical server will be divided into several virtual servers. These “apparently available” servers share the main resources like main memory, hard disks and network connections. Advantages Provision of new servers in minutes without the need to invest in new hardware. Increasing the capacity utilization of physical servers Moving a virtual machine from one server to another without reconfiguration Simple migration of virtual machines to the VMware infrastructure Simple backup solution • • • • • OrgaTEX on the go The WEB interface Citrix access essentials – Access via Intranet or Internet Wherever your employees are currently located – be it in the office, in a field office, travelling or in a home office – the centrally provided applications by Citrix Access Essentials are available for all users within and outside of the LAN with the same functionality, actuality and performance. Advantages Fast and simple access via Internet or Intranet Every terminal can be used Immediate availability of new applications and information for travelling employees or staff in subsidiaries and home offices Protection of sensible data by limitation of the information access Encryption of the communica- tion Time saving administration by using a centralized concept • • • • • • 23 24 OrgaTEX service contract OrgaTEX Service and support Activate your potential An important element of our business activities are the introduction and realization of optimization features in the textile finishing plants. Use your existing machinery and infrastructure within your company efficiently and benefit from our long-time experience. Conducting workshops and training courses Performing process and performance analysis Identification of optimization potential • • • Recommendation for treatment and process changes Implementation of optimization formulas or software Implementation coordination or introduction • • • Assistance by our Support Center within normal office hours Remote diagnosis and remote service (online service) All necessary actions will im- mediately be taken to solve a problems Upgrade service On-site service Option Premium service contract: 24 h hotline on 365 days • • • • • • SETEX training room 25 Overview OrgaTEX basic – entry – professional OrgaTEX modules basic entry professional Production Program editor • • • Process analyzer • • • Online status • • • Batch scheduler • • Alarm monitor • • Production calendar • • Batch report • • Machine report • • Service- and configuration tool • • • Optional OrgaTEX professional modules PDA production downtimes Plant navigator Recipe Recipe editor Product data management Article management/customer management Stock control Formula management CSD – Computer Supported Dyeing Weighing Paternoster Integration of dye kitchen systems (SECOM controller) CDC – Central Dye kitchen Control Interface to recipe systems (3 rd party) Interface to dye kitchen systems (3 rd party) Interface ERP/PPS Interface continuous Interface handling/transport systems Web interface OrgaTEX extensions basic entry professional Number of connected controllers 25 1 – 10 not limited** Number of workstations 1 1 5 – ∞* ** limited by Microsoft System licenses 26 OrgaTEX – the information Interface between ERP and production 27 carousel OrgaTEX: scope of services Modules Production PDA production downtimes Plant navigator Recipe Stock control Formula management CSD – Computer Supported Dyeing Weighing Paternoster Integration of dye kitchen systems (SECOM controller) CDC – Central Dye kitchen Control Interface to recipe systems (3 rd party) Interface to dye kitchen systems (3 rd party) Interface ERP/PPS Interface continuous Interface handling/ transport systems Web interface • • • • • • • • • • • • • • • • • 28 Headquarter Agencies Service stations s c h e r m u l y t e x t i l e c o m p u t e r SETEX Schermuly textile computer GmbH Hauptstraße 23–25 35794 Mengerskirchen Germany Phone: +49 6476 9147-0 Fax: +49 6476 9147-31 www.setex-germany.com [email protected] Technical modifications reserved. All brand and product names are trademarks or registered trademarks of their respective owners. Printed in Germany. Your Distributor 01.10.2007 ∙ SD1400501 ∙ OT-KEA-010-0005-2 SETEX America www.setex-america.com SETEX Asia www.setex-asia.com SETEX Brasil www.setex-brasil.com SETEX China www.setex-china.com SETEX Far East www.setex-fareast.com SETEX France www.setex-france.com SETEX Honduras www.setex-honduras.com SETEX India www.setex-india.com SETEX Taiwan www.setex-taiwan.com

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