ACT AHM DIU application of Computer in TE.pptx

TE-335
Application 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.
4

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
5
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
6

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
choices
Series1
Age Range
0
2
4
6
8
10
2-3 years 4-5years 6-7 years
Age
No
of
Choices
Series1
Age Range
2-3 years
4-5years
6-7 years
Graphs
7

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
8

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
9

•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
10
•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 travel
More 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
Technology
CAM:
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
Blogging
Interactive
Design
Instant
Messaging
Video
Conferencing
Virtual
Imaging
Networking Sites
e.g. Bebo, My Space and You Tube
Technology

What is ICT???
13
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
• 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
• Word Processing
Software
• Digital Printer
• Digital Camera
• EPOS software
• PDM Software
15

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.
16

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.
17

What is CAD???
18
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
19

What is CAM???
Computer-aided manufacturing (CAM) is the use of
computer software to control machine tools and related
machinery in the manufacturing of work pieces/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.
20

Transfer printing
An 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
21

Embroidery machine
CAM in industry
22
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.
23

24
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 controlled
operation of an apparatus, process or system by mechanical or
electronic devices that takes place of human organs of
observation, efforts and decision.”

25
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.

26
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

27
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.

28
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.

29
Chapter-2
Application of Computer in Textile
sector

30
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

31
Spinning sector/ Yarn Manufacturing sector

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
32

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.
34

USTER MICRONAIRE 775:
1. It is used for precise measurement of micronaire of
cotton fibres. Micronaire value or Mic. Value
determines the number of fibre in the cross(x)
section of a yarn.
2. By using it bale lay downs will eliminate or reduce
costly rejects from fabric barre.
35

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.
36

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
37

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.
38

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.
39

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.
40

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.
41

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
42

Production characteristics
• The most important production data collection
applied at all machines are-
Production amount,
Production speed,
Efficiency,
Frequency & length of interruption,
Doffing,
43

The monitoring procedure of sliver data
system:
44

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.
45

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.
46

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.
47

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
48

Quality characteristics
• Yarn twist
• End breakage rate
• Mean period of each ends breakage
• Yarn type.
49

The mechanism & working principle of
ring data system.
50

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.
51

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.
52

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
53

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.
54

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.
55

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.
56

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.
57

58
Application of Computer in Fabric
Manufacturing sector

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.
59

-weaving section.
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).
60

-weaving section.
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.
61

Advantages of computerization in
-Weaving Section
62
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.

63
Application of Computer in Wet Processing
Sector

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.
64

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.
65

Computerized system in dyeing
Super tex system:
• It provides an automatic control on dyeing m/c.
• Provides control and supervision in virtually every dyeing area.
Thanks to non-proprietary software designs, this complete, integrated
management system offers the industry's highest level of machine
control, procedure management, performance measurement,
inventory control and drug room supervision. Super Tex consists of a
number of modular packages, each designed to provide management
and control functions in specific areas of the dye house. It is designed
to interface with computer-integrated manufacturing (CIM) systems
within the plant, not only to exchange information but to offer
supervisory downloading to other areas..
• It is used in dye house control & management system.
66

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.
67

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.
68

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.
69

Advantages of Computerization in
-Dyeing Section
70
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.

71
Application of Computer in Apparel
Manufacturing Sector

72
INTRODUCTION OF CAD
CAD 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:

73
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 tool

74
CAD Software
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.
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.

75
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.

76
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

77
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 systems
ii. Grading systems
iii. Marker making systems
iv. Pattern design software (PDS)
v. Pattern generation software (PGS)
vi. Body measurement software
vii. Texture mapping
viii. Embroidery systems
ix. Specification & costing systems

78
COMPUTER AIDED MANUFACTURING
(CAM)
• CAM is the use of computer software to
control machine tools and related machinery
in the manufacturing of work pieces.

79
CAM Tools
1. CAD Tool: Geometric information of model
2. Manufacturing Tool: Fundamental of
manufacturing processes
3. Networking Tool: Communication between
various machines and computers

80
COMPUTERIZED EMBROIDERY
MANUFACTURE (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.

81
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:

83
ADVANTAGES OF CAD
i. Allows to shorten the time elapsing between the development of the
new fashion ideas and the collection presentation
ii. CAD reduce staff requirement in a given work as complex engineering
drawing can be easily done by use of CAD
iii. Quicker preparation of the collections
iv. The degree of repetitiveness in the design part is more with the help of
CAD
v. 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.

84
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 devices
x. (Computer Aided Manufacturing) for machine control
& Fabric production becomes practically automatic.
xi. It gives fewer design error
xii. CAD system gives greater accuracy in design calculation
ADVANTAGES OF CAD

85
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

Advantages of computerization in
-Garment Section
86
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.

87
Application of Computer in Testing Sector

88
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 and
2. Automation of the test procedure.

89
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:

90
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.

91
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.

92
Ability to Calculation:
• The ability to perform all the intermediate
calculations together with any statistical
calculations in the case of multiple tests.

93
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.

94
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.

95
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.

96
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

Enterprise resource planning (ERP)
97

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.
98

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 accounting
General ledger, fixed asset, payables, receivables, cash
management, financial consolidation
• Management accounting
Budgeting, costing, cost management, activity based costing
• Human resources
Recruiting, training, payroll, benefits, diversity management,
retirement, separation
99

• Manufacturing
Engineering, bill of materials, work orders, scheduling, capacity,
workflow management, quality control, manufacturing
process, manufacturing projects, manufacturing flow, product
life cycle management
• Supply chain management
Supply chain planning, supplier scheduling, order to cash,
purchasing, inventory, product configurator, claim processing
• Project management
Project planning, resource planning, project costing, work break
down structure, billing, time and expense, performance units,
activity management
100

• 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
101

Characteristics
ERP (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.
102

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
103

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
104

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. Testing
5. Documentation.
6. Maintenance.
7. Redesign.
105

DEFINING THE PROBLEM
It 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.
106

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.
107

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.
108

• 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.
109

• 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.
110

LEADING ERP GIANTS:
• MICROSOFT
This 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.
111

LEADING ERP GIANTS:
• ORACLE
They 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.
112

LEADING ERP GIANTS:
• SAP ERP
SAP 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.
113

LEADING ERP GIANTS:
• UPS ERP
This 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.
114

LEADING ERP GIANTS:
• PEOPLE SOFT ERP
People 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.
115

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.
117

RFID
(Radio Frequency Identification Device)
118

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.
119

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).
120

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.
122

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.
123

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
124

apparel industries
• Product Tracking System
In 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.
125

apparel industries
• Tracking of Labor Movement
Knowing 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.
127

The applications of RFID in textile and apparel
industries
• Fabric Lot Storage and Retrieval
Due 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.
128

apparel industries
• Garment Washing and Laundering
The 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.
129

apparel industries
• Merchandise Leveling Across Stores
Some 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.
130

apparel industries
• Easy Product Accessibility in Retail Stores
By 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.
131

apparel industries
• Exchange Goods Inventory Control
When 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.
132

The applications of RFID in textile and apparel
industries
• Customer-Specific Shopping Reminders and Promotions
With 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.
133

apparel industries
• Re-Stocking Alerts and Replenishment
Products 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.
134

apparel industries
• 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.
135

apparel industries
• 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.
136

apparel industries
• 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.
137

apparel industries
• 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.
138

apparel industries
• 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.
139

apparel industries
• 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.
140

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