Process Overview

• Laying

Laying the fabric on the Lay Table as per Cutting Requirements.

• Cutting

Cutting the Laid Fabric according to the pattern

• Bundling

The System Generates series of Unique ply numbers for every layer of fabric laid. The System Generates a unique bundle number for every bundle based on the bundle size specified.

• Sorting

The Bundles are sorted and grouped to have respective parts based on the Group/ Operation and operation sequence

• Assigning Tags to Employees / Operators

For Employees’ identification purpose, each employee is assigned and given an iButton tag. Which they use to login and logout at their assigned workstations prior to start and leave

• Assigning Tags to Bundles

An ibutton tag is mapped and assigned to every bundle with their respective bundle numbers. Then the same tag is physically tied with the bundle and sent to sewing line. Every bundle carries one tag.

• Resource assignments

Assigning and mapping of available resources (man and machine) to the operations defined for a style.

Operation – Operator - Machine

Possible combinations of resource assignments are:

1 Operation – 1 machine
1 Operation – N machines
N Operations – 1 machines
N Operations – M machines

• Sorting

The Bundles are sorted and grouped to have respective parts based on the Group/ Operation and operation sequence

• Issue to Sewing

The bundles along with the iButton tag are issued to sewing line for production.

• Sewing

Every piece of garment goes through different operations in production line. A bundle may have N pieces of garments of same style where the individual pieces undergo the same process repeatedly till the bundle is finished.

Each operator will do the designated operation in the sequence.

• Start Punch

On receiving the bundle, the operator will punch the tag, which is tied with the bundle, on the iButton Probe of the reader unit to indicate the start of the operation

• End Punch

On completion of the bundle, the operator will once again punch the tag on the iButton Probe of the reader unit to indicate the end of the operation.

The time difference between the start and end punch is calculated as the production time for a particular bundle.

When a tag is punched, the reader unit captures the following data:

• Workstation ID
• Tag ID
• Date and Time

Punches Captured in the reader units are sent to the central database server over a network. This is continued till the last operation in the sewing line. After completion of the final operation, the tag is removed from the bundle / finished garment and sent back to re-use.

The software calculates production qty and production time for every bundle.

Production Time - Difference between the start time and end time
Production Qty - After an end punch is received, the software takes the Bundle pieces as production qty.

The system will provide real time production status on a Bundle / Operation / Operator basis.