OrgaTEX. Machine management software for the textile finishing. Textile Finishing. Control Systems for

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1 OrgaTEX Machine management software for the textile finishing s c h e r m u l y t e x t i l e c o m p u t e r Control Systems for Textile Finishing

2 OrgaTEX the information In times of difficult market situations and strong competition the textile industry demands more and more integrated solutions. The target is a continuous flow of information starting from the machine level via the plant manager up to the administrative management. Vertical integration interface between PPS and production The data based connection between the three levels provides the possibility to quickly take the right measures and to optimize processes. OrgaTEX hereby has a key function as it acquires process and operational data and makes it available to the higher company levels. In the other direction disposition data and data for the process optimization are transferred via OrgaTEX to the machine level. This makes OrgaTEX to a turntable in the vertical integration. OrgaTEX provides a number of software modules to the textile finisher that can gradually be build into an integrated solution. 2

3 carousel Ensure quality In order to have the necessary data of all articles awailable for the dyeing and finishing process OrgaTEX provides editors for the creation and the management of dye programs, machine settings (preparation data) and recipes. The integrated link between recipe data and related dye program or set of preparation data ensures that for all stages of the finishing processes the quality is assured. Decide quicker Detailed information is the requirement for quick decisions. With OrgaTEX you always have immediate access to all acquired data. By utilizing filter and sort functions every desired information can directly be found and accessed. Via the ODBC database interface the information can be transferred and processed in MS Excel or similar programs. 'Process Curves' and 'Alarm Report' you can control your quality standards. Anomalies, failures and manual interventions are displayed immediately. Plan more accurate To keep you delivery dates OrgaTEX supports you during planning and by following up all processes. For the disposition OrgaTEX provides an electronic planning board and automatically calculates all set runtimes for every single batch. Every time deviation of the current production is immediately recognized and will be displayed. Everything under control The permanent online connection to the production machines allows for the supervision and control of quality, times, consumption values, costs, personnel also in connection with subsystems like scale and do- Ensure quality Decide quicker Plan accurate Recognize problems Recognize problems immediately Reduce costs OrgaTEX is online connected to all processes. The automatically acquired measurement data of every production segment is constantly stored in the database. By using the programs 3

4 OrgaTEX dye house prod OrgaTEX dye house production The editor The dye program is an important part of the process know how in the dye house. With the editor we provide a flexible tool to easily and fast describe even complex control sequences. Variable parameters reduce considerably the number of dye programs for various articles. Batch overlapping and 'look Dye program editor ahead functionality allow for time optimized dye programs, especially in combination with automatic dye kitchen. Automatically generated time/temperature curves Function selection Batch scheduler 4 The online batch scheduler is a powerful tool to reduce the daily routine work in the dye house office to a minimum. An electronic planning board always informs about the current state and progress of the batches. Batches can easily be moved by simply using drag and drop procedures. Paperless preparation and addition processing, from the weighing station to the automatic dispenser, is part of our concept of a modern dye house. Electronic planning board

5 uction Online process control Error messages, process information and necessary manual interventions to running batches, everything centrally from the workstation in the office, with OrgaTEX you have the dye house under control. Reports Data for consumptions, costs, times, alarms, deviations etc. are automatically collected for every batch and every machine. Time evaluation Batch information Kostenverteilung Färberei Machine status Cost evaluation Process data logging Operator calls Production calendar By using the report generators you can create flexible reports for daily, weekly or monthly information. Productivity data is available due to an integrated production calendar. 5

6 OrgaTEX continuous pro OrgaTEX continuous production The editor The continuous editor is used to manage a large number of article related machine settings for various continuous machines. Set of preparation data Batch scheduler In combination with the batch scheduler the correct sets of preparation data will be assigned to every batch and then automatically transferred to the SECOM controller or to third party PC's via optional interfaces. The electronic online planning board provides assistance for an efficient and economical operation. The observance of production and delivery dates is controlled and any transgression will be conspicuously indicated. Electronic planning board 6

7 duction Quality control The automatic logging of process data, first of all quality data like width, square weight, temperatures, dwell time, shrinking etc., allows a continuous monitoring with clear indication of the quality. Reports Data for consumptions, costs, times, alarms, deviations etc. are automatically collected for every batch and every machine. Kosten Spannrahmen 2 Stenter costs Quality data Produktion Spannrahmen 3 Alarm list Production efficiency State of operation Process visualization Production calendar By using the report generators you can create flexible reports for daily, weekly or monthly information. Productivity data is available due to an integrated production calendar. Online-Informations 7

8 OrgaTEX recipe At the time a batch is scheduled the batch recipe will be calculated. The necessary a- mounts of dyestuff and chemicals will be reserved in the stock control module. OrgaTEX recipe/stock control Recipe management Recipes are in the center of the finishing process. This makes it necessary to have a fast and versatile organization of all data like base recipes, products etc. Automatic stock control, order lists, cost calculation and a definite assignment of consumed products to their particular batch are features of the stock control module for dyestuff and chemicals. Dyestuff library Chemical library By using the easy to handle recipe editor chemicals and dyestuffs for the finishing process are put together. A special feature is the possibility to link the recipe with the machine program or with machine settings to combine the two elements that basically form a finishing process. To mark preparations for manual or automatic calls is easy but important. In combination with automatic dye kitchen it ensures a correct dispensing process. Recipe editor Recipe selection 8

9 weighing dyestuffs that can be identified by barcodes will be weighed to their adjustable tolerances. The actual values are fed back to the stock control module. OrgaTEX weighing/paternoster Weighing The various preparations with their products are displayed on a special PC that is suitable for the drug room environment. With the help of connected scales the chemicals and Paternoster If a paternoster with a SETEX controller is connected then after selection of the product the system will lead to the related storage position. Paternoster automation Dyestuff weighing 9

10 OrgaTEX the interfaces OrgaTEX connection to ITM-Process OrgaTEX connection dosing systems OrgaTEX connection recipe systems 10 Connection ITM-Process The integration of ITM-Process with OrgaTEX is currently the highest degree of flexible creation of dye programs for every single batch. With the help of dye-technical experience build into ITM-Process the batch data with the necessary treatment sections and parameters for the dye process as well as the complete recipe will be transferred to OrgaTEX. This results into a reproducible abundance of dye procedures for every kind of articles, dyestuffs and machines etc. that cannot be achieved by conventional means. Based on this method the dye programs are automatically generated by OrgaTEX from the transferred treatments and parameters. The transferred batch itself will be shown in the batch scheduler. The recipe data is available for further processing in a manual or automatic dye kitchen. Connection dosing systems The currently very popular automatic chemical and dyestuff dosing systems are especially effective if they are interconnected to OrgaTEX. The necessary data is available in the batch recipe. Preparation calls from the machine controller synchronize 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 statement about the utilization of the connected dosing system. Connection 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 linking 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.

11 OrgaTEX connection main frame/ order data OrgaTEX connection third party continuous controller OrgaTEX connection handling/ transport systems Connection main frame/ order data A large number of companies are using various computer systems for order management and production control. In order to transfer this data directly to OrgaTEX an ODBC interface to an integration database can be provided by OrgaTEX. In this way different data like batch information, recipes 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. Connection third party continuous controller Via a database interface third party controller 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 third party controllers. Connection 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. 11

12 Entry package Operating System: Windows Server Software Network: Ethernet Workstation Colorprinter Single user system Entry package with full performance for maximum 10 machines. Can later be upgraded to a Multi user system. 737 Machine Machine TC Machine 10 12

13 Multi user package Production package Server Multi-user package for an unlimited number of machines. Can be connected to third party systems (see OrgaTEX interfaces) Workstation Colorprinter 737 Machine Machine 2 Option, additional Workstations 838 Machine TC Machine 4 Option, connection to external computer systems 848 TC Machine n 13

14 14 Integrated Production Man

15 agement The OrgaTEX modules Dye house production Continuous production Recipe/stock control Weighing/paternoster Connection ITM-Process Connection dosing systems Connection recipe systems Connection main frame/ order data Connection third party continuous controller Connection handling/ transport systems 15

16 SETEX Schermuly textile computer GmbH Hauptstraße Mengerskirchen Germany Phone: + (49) / Fax: + (49) / info@setex-germany.com SETEX America SETEX Asia SETEX Brasil SETEX China Your distributor SETEX Honduras 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 Taiwan Technical modifications reserved. All brand and product names are trademarks or registered trademarks of their respective owners. Printed in Germany. 10/2004 SD OT-KEA