ProCon is a revolutionary technology tool to monitor apparel manufacturing process in real-time basis. The objective of the system is to gather and distribute information to the production management team to respond instantaneously and to solve any problems that may arise.

By and Large, garment-manufacturing process is based on progressive bundle movement. Every bundle goes through different stages of operations in the production line. Finally when all the operations are completed, the finished garment will come out of the line.
Procon is Electronic Coded Tag and Reader Unit Based System.
The Reader Units are attached to every sewing machine in the production line and Networked and connected to the central database server.
The Coded Tag is attached to every bundle and sent in the sewing line for Production.Every operator will do his or her designated operation(s) in the sequence in the line.
By doing so, operators are expected to punch the tag on to the reader unit for start and completion (i,e twice for each bundle) of the bundle.The punches captured at each reader unit are sent to the central database server instantaneously. So the bundle’s presence / status are captured at all workstations as and when it passes there by providing real time data.

No, the coded tags are re-usable; once the final operation for a garment is completed the tag is removed from the bundle and can be re-used for another bundle for same style or different style.

Please refer our booklet.

HardWare: Reader Unit ,Coded tag, Networking Accessories
Controller PC(s), Server
Software : Data Acquisition Software
Production Management Software

All the reader units are connected to the Controller PC thru RS485 Multi-drop full duplex network.

No, We use CAT 5 Cable (24 AWG) for networking with RJ45 Connector

Reader Units - One reader Unit is required for every sewing machine.
Tags - Approx. Minimum 20 Tags required for each reader units. (1:20)
This calculation is based on the estimated WIP at each workstation, Ready to issue (bundles in stock) and Tags in stock.

Coded Tag (ibutton) is a product of DALLAS SEMICONDUCTORS.
As Per their data sheet, the life of coded tag is approx 1 million punches. (Half million bundles)

We have two models, 1) Procon Reader Unit 2) QC Unit

QC Units are Procon reader units with numeric keypad attached to it.
These units are connected in the sewing line along with the procon reader units at various QC Check points.
Bundles are checked for quality at various stages of operations. On identifying the rejections the bundle is sent back to the concerned operator for correction / rectification.
For the operator to know which particular operator has done the operation, the operator will tag in the bundle on to the QC unit and should enter the operation code which is found faulty, then the system will display the operator name of the concerned operator who had done the bundle, then the QC executive will send the bundle to that operator and updates the no. of faulty pieces in the qc unit.
Order qty depends on the no. of QC check points you have.

Yes, Based on your applications requirement we can provide data from procon.

As we mentioned earlier, like each bundle is identified with the use of coded tag, every employee is also identified with unique set of tags. The same kinds of tags are used for employee but with different color.
Prior to start work, every employee is expected to tag in his or her respective reader units.
The system will authenticate the employee for validity and allow them to continue their work, once logged on; all the production count on that reader unit is accounted for that particular employee.
An Operator can log on to any workstation, but at any given point of time he / she can log on to only one workstation.

Every product carrier has its own identity therefore it is possible to rout different styles through various paths of the manufacturing process. A part of the concept is to reduce Work In Process (WIP). To be able to maintain and improve WIP you must be able to change styles, manufacture to costumers orders etc. Low WIP has a positive impact on the throughput time for finished products and in it self it reduces the number of styles in the system at one time.

Please refer our booklet.

Prior to issuing bundles to sewing line, a tag is attached to the bundle.
This tag should be assigned to a particular bundle. This assignment is done thru PMS application software. The system will store all the bundle details with their respective tags that are assigned.

In the production management software, there is an option called line setting,Where, for every style, you need to say which operation is done on which workstation (physical workstation).
The details of reader units attached to these workstations are pre-stored in the system.

Please refer comparison chart in booklet

Future updates of PMS application software will be informed thru newsletters and will be available on our web site. You can download the same keep yourself updated.
Hardware up gradation, if any, will be done at nominal cost.

Support will be given directly by us or by our authorized channel partners.

ProCon System is solely Designed and Developed by Crystal Consultancy Services Pvt.Ltd. and Marketed by our authorized Distributors.

ProCon Unit is so designed to attack these kinds of problems.
Every Reader Unit has a backup memory inside which stores the data in it, When the server is up, the data is automatically updated in the server.

Procon reader unit has a 16x2 LCD at the top.
All response messages are displayed on the LCD.
Any message from the server is displayed.
There are 3 buttons present on the reader unit.
Button 1 – when pressed, style / operation’s target qty set for the day is displayed
Button 2 – when pressed, Actual achieved pcs by the operator is displayed
Button 3 – When Pressed, Earnings for the pieces produced is displayed

The system has got the option of assignment of resources
Operation -> workstation -> machine
possible assignments are
1 operation-> 1 workstation
1 operation -> 2 or more workstations
n Operation-> 1 workstation
n operation-> m workstations

When start punch is made, the current tag id is displayed in the LCD And when the end punch is made, the tag id will vanish from the LCD