Zünd Connect – a way to optimize productivity
Zünd Connect compiles production data from integrated Zünd cutting systems into meaningful key performance indicators, such as cutter capacity, availability, and overall equipment effectiveness. Zünd Connect creates transparency and identifies areas in the digital cutting workflow with potential for optimization.
There are many ways to optimize digital cutting and ensure maximum productivity, which is the reason why Zünd now offers Zünd Connect, a monitoring tool that helps the user recognize this potential and increase productivity. Using Zünd Connect, the user can see at a glance when and, more importantly, why machine interruptions occur, how much time is spent in setup, and what the availability of each machine is.
The most successful companies are the ones that produce the most saleable products per hour. High machine availability and productivity are essential for profitable cutting and finishing. As simple as this may sound, it is no small thing in the day-to-day production environment. Where do the relevant key performance indicators come from? Is data available that enables monitoring? And last but not least, how is the data compiled so that it can be interpreted accurately and reliably?
This is where Zünd Connect comes in. The web-based monitoring tool gives the user access to cutter- performance data at a glance, any time of day. Reliable key performance indicators are available at all times to help users maximize productivity. The system records productivity levels over a freely definable period using Zünd Cut Center – ZCC (Version 3.4 or later) as data source. Data monitoring provides information users need in order to make informed decisions. This comprehensive overview of production data reveals connections that are often overlooked. Zünd Connect supplies valuable key performance indicators for assessing how efficiently cutting systems are working. To be able to improve cutter efficiency, potential areas of improvement must be uncovered and recognized. This potential lies primarily in the technology but also in the way it is being used. Zünd Connect consists of multiple dashboards with specific options for evaluating data:
Overview – This dashboard provides past production data and indicates, for example, fluctuations in machine utilization. The user can select various views and switch between indices for overall equipment effectiveness (OEE), availability, and capacity. In addition, a filter function can be used to compare performance across different shifts.
Job list – This shows a list of processed jobs, what they entailed, the time it took to produce them, and the cutting distance travelled per job. Diagrams show the time spent by each individual material/substrate, processing method, tool, and module. In reference to materials, for example, bar graphs show the processing time for each material used during a specified time frame.
Loss detection – This view visualizes losses in terms of time. It shows, for example, when process interruptions tend to occur most often. Loss detection enables the user to evaluate factors such as the specific time frames, materials, or tools most likely to be associated with interruptions.
Interruption statistics – This lists the reasons for such interruptions. The user can filter for time of day, material, method, tool, or module. The statistical representation shows the user how many hours the cutters were unable to produce during a specified period because of machine interruptions.
Zünd Connect is available in a “Monitor” or an “Analyzer” version. As the name suggests, “Monitor” consists of a graphical display of overall equipment effectiveness and is available to all ZCC users for free. “Analyzer”, on the other hand, makes it possible to perform subsequent analysis and pinpoint productivity losses. “Analyzer” provides the necessary tools for the user to be able to evaluate the production process and recommend improvements.
Twine Solutions announces partnership with Gerber Technology
The TS-1800 machine by Twine will be installed at the Gerber Innovation center in New York City in early September. This machine is the world’s first on-demand digital thread and yarn dyeing solution. The system can dye various types of filament and spun polyster. It is designed to be implemented in any production environment and can be operated by anyone.
Twine Solutions is a technology start-up in Israel which was founded in 2105. The company has developed a proprietary and revolutionary digital on-demand thread dyeing system and a digital dye-to-match colour application. Gerber Technology is a USA-based company founded in 1968. In June 2021, it was acquired by Lectra. Gerber Technology develops software and automation solutions for fashion, automotive, furniture and other businesses across the globe.
The best rapier technology for technical textile applications
Technical textiles are textiles that are engineered with a definite functionality. The sector of such functional textiles is regarded as a sunrise sector as it has varied and growing applications across multiple industries such as healthcare, construction, automobile, aerospace, sports, defense, and agriculture. Indian textile mills have realised that the wide-ranging uses of technical textiles represent a huge opportunity and are enhancing their capabilities to create a greater variety of technical textiles. India is becoming a key player in the global technical textile scene.
In the past few years, woven fabrics manufactured on rapier looms have comprised a significant part of the total production of technical textiles, especially for applications such as agro textiles, airbags, canvas fabrics, car seats, coating fabrics, conveyor belts, gauze, geo grids, filter fabric, fiberglass fabric, tire cord, etc.
SMIT srl, a globally renowned weaving machine manufacturing company from Italy with more than 80 years of history, has been supplying advanced rapier looms for technical textile applications. A.T.E. – committed to supporting the Indian textile industry with the latest technology solutions –has recently joined hands with SMIT for the promotion of their rapier looms in India. A.T.E. is a one window solution provider in textile engineering across the textile value chain, with 80+ years of experience. The partnership between these two textile engineering leaders is expected to provide a fillip to the Indian technical textile segment.
SMIT was recognised for the development of the well-known dynamically controlled rapier ribbon system in the late 80s, which was the most significant development of the guideless carbon punched tape technology. The philosophy of innovation at SMIT is evident in its new, revolutionary weaving machine – the SMIT-ONE– a patented single rapier weft transfer weaving machine for the manufacture of technical textiles.
Key features of the SMIT-ONE:
SMIT-ONE gripper system has a smaller cross section that complies with the warp shed geometry, which is narrower compared to a traditional double gripper machine
- Weft insertion at low weft tension, resulting in higher insertion efficiency
- Reduced warp shed amplitude, thus increasing efficiency
- Easy to adjust machine during article change, reducing machine downtime
- Can use all yarn types that were so far not weavable on traditional rapier systems – such as delicate yarns, fancy yarns, carbon yarns, etc.
- Special pliers that perfectly hold any weft shape, weight, and consistency
- Laser stop motion, or full-width temple can be offered
- PosiLeno® system: positively controlled leno system which ensures perfect leno binding; is applicable for all fabric constructions including technical fabrics
- Reinforced backrest structure increases warp tension by more than 50%, thus enabling the production of heavy density technical fabrics
- Special type of pressure rollers prevents slippage of cloth on take-up roller
- Stronger sley bar enables production of dense fabrics on the machine
- Take-up designed for ultra-high warp tension
- Working width – 1700 mm to 2200 mm
- Weaver beams up to 1100 mm and fancy beam can be used
Benefits:
Fabrics for technical, fashion, furnishing applications, as well as classic fabrics with exclusive yarns and patterns, can be woven with excellent quality and high efficiency on the SMIT-ONE
SMIT’s “dynamically controlled” flexible free-flight tape rapiers system, combined with the development of advanced solutions enhances the weft insertion
The highest versatility and efficiency in terms of weft insertion allows the use of a wide range of yarns, and unparalleled simplicity in the article change, as well as minimum maintenance costs
- Free flight technology – no friction on the warp yarn
- Minimum stress on warp
- Consistent fabric properties from full to empty warp beams
- Laser warp stop motion to avoid friction on the warp ends
- Special type of full width temple for low cloth recoiling or high weft density
The SMIT-ONE can be used in the manufacture of:
Fashion fabrics
- Safety gear
- Glass fabrics
- Carbon fabrics
- Filter fabrics
- Sportswear
- Sophisticated clothing and furnishing
- Suitable to produce fabrics in which complicated yarns are used
Mono-rapier system has been tested mainly in fashion fabrics with different and complicated weft.
Carbon fabrics
Fibre glass fabrics
Filter fabrics
Further, SMIT-ONE offers highest versatility, efficiency in terms of weft insertion, flexibility with the widest range of fabrics, and energy savings. Due to these numerous benefits, SMIT-ONE is emerging as a preferred choice for weavers around the world to meet the rising demand for technical textiles.
Stäubli at Techtextil North America 2021
One-piece woven airbags (opw), or individual fabrics for lightweight construction, whatever the technical textile need and requirements, Techtextil North America (August 23-25) will be an inspiring platform for its visitors. Weaving mill managers, weavers, or investors will have the great occasion to learn more aboutadapted production solutions among the broad Stäubli machinery range dedicated to technical textiles. Visitors to Techtextil North America are invited to meet the Stäubliteam at the German Pavilion booth n° 1315.
Because technical fabrics are subject to the highest quality standard requirements, weaving requires more than ordinary production means. To fulfill high-end standards, each step in the weaving process is crucial and has to be operated with utmost precision. In addition, to stay competitive, at optimized weaving speeds.
Continued R&D resulting in ingenious technologies, premium construction materials, and services before, during, and after the machinery installation, make the sustainable reputation of long-lasting quality Stäubli machinery, as well as its capability of running durably at highest production speeds.
Techtextil North America is the ideal opportunity to find out more about Stäubli solutions, including weaving preparation solutions, such as the MAGMA tying or SAFIR automatic drawing-in machines, the renowned S3000/S3200 rotary dobbies, or the LXXL and UNIVAL 100 Jacquard machines, and the TF weaving system.
With its local US team, the Stäubli textile division provides the weaving mills speedy support and a wide range of services, with one key objective: to keep customers agile and competitive in the challenging textile industry. Weavers being concerned about any weaving project or the productivity of their mill should take the chance to schedule a talk with the Stäubli team at Techtextil North America in Raleigh.
ColorJet Launches SubliXpress Plus – 9000 Sq.Meters Daily Production Industrial Sublimation Printer
Dye sublimation printing is dominant in the digital textile printing sector accounting for almost 50% of all digital textile prints across the polyester & apparel domain. The dye sublimation textile printing market which was valued at USD 8.1 billion in 2019 is facing a CAGR of 10.7% during the forecast period of 2020-2025 and is expected to reach a value of USD 14.2 billion by 2025. Considering the need for a high production sublimation printer to mitigate this high demand, ColorJet has launched SubliXpress Plus.
The SubliXpress Plus comes with 8 staggered Kyocera heads that can print variable drop sizes of 5,7, and12 pL as demanded to produce exceptionally sharp lines and create smooth gradients in color tones. The high-speed, high-quality printing with minimal ink consumption is a result of decades of experience in manufacturing digital inkjet printers. ColorJet’s proprietary AST™ and HSTR™ technology are inherent features of the machine.
The ColorJet SubliXpress Plus is ideally positioned for existing high-volume dye sublimation printers & first-time investors looking to upgrade their business with high production machine. The company also foresees a good potential for this zero water-consuming printing technology that would add a fillip to sustainable garment manufacturing as it would work very well on fabrics made with recycled polyester– knit and woven. Despite the adverse impact of the pandemic, ColorJet has continued to work and develop the next ground-breaking technology for the sublimation printing market.
Trailblazing technology to suit all kinds of paper
On its 1.8 m printing width, the machine can handle a wide range of paper starting from 18 gsm and above.
The Leaf clamp is yet another ingenious improvisation to prevent the paper from curving up at the edges when printing. Being able to use low gsm paper and the ability to print on a less than ideal paper roll with ease, it addresses some major practical shop floor concerns. The vacuum bed which holds the paper in place is wider and the suction pressure can be varied.
The two-stage drying system provided immediately after the printing zone stops the paper from puckering even when printing large patches of solid color. HSTR™ or High Sense Paper Tension Regulator detects fluctuation in paper tension and corrects it almost instantly to ensure error-free printing.
Increased machine up-time, uninterrupted production
The printer includes features for enhanced productivity including a 900 mm diameter feed roll, high precision servo motor, and large rubber roller with pneumatic shafts for a firm grip of the paper roll core. The machine is also equipped with multiple brush rollers to continuously smoothen out the paper as it moves from feed roll to re-winding of printed paper
Superior print quality
The new SubliXpress Plus is equipped with gold plated metal encoder to give more precise ink jetting at high speeds, effectively leading to longer service life. In addition to this, the AST™ or Active Seaming Technology is used for producing superior quality at high speed. In short, the SubliXpress Plus is a high production, high-quality printing solution for sublimation inks on paper that are low on printing costs.
Thailand’s leading garment manufacturer selects FastReactPlan for digital transformation
As the industry emerges from the Covid-19 pandemic, Thailand’s leading garment manufacturer, Hi-Tech Apparel ensures business stability and boosts profitability by digitizing its production planning and control processes with FastReactPlan from Coats Digital. FastReactPlan, Coats Digital’s market-leading solution, will support Hi-Tech with effective master planning across multiple factories, as well as detailed and accurate scheduling of manufacturing lines, providing a firm foundation for a faster, more efficient and agile production and delivery process.
Established in 1991, Hi-Tech Apparel Co Ltd is one of the leading garment manufacturers of Thailand, with production facilities in 10 different locations including cities in Thailand, as well as in Cambodia, Vietnam, and Laos. They manufacture a wide range of sportswear and formal wear and caters to leading brands, including Nike, Target, Warrix Sports and Joe Boxer.
The Hi-Tech team was faced with numerous challenges in their planning process which was having a huge impact on the profitability of their business. There was a lack of a centralized planning mechanism, which meant it was difficult for the team to monitor planning across multiple factories at the same time. Unanticipated issues related to critical path and material availability meant that the team had to spend a lot of time and effort firefighting, which affected the on-time start of production, delivery performance and increased air freight costs.
Hi-Tech recognised that the digital transformation of its business was essential to respond to these challenges and gain a competitive advantage in a market that is rapidly changing. In December 2020, Hi-Tech selected Coats Digital’s FastReactPlan solution to enhance control and visibility in its planning process to optimise efficiency, lead time and delivery performance.
“The Covid-19 crisis has brought unprecedented changes in the industry which affected our business as well. There is increased uncertainty and a high level of competition in the industry. So it was important for us to carefully prioritise business initiatives that provide firm foundations for a faster, more efficient and agile production and delivery process.
FastReactPlan was the answer to all our critical business needs. We wanted to quickly adapt to the best-practice planning process and improve communication and coordination across departments without wasting any time. We’re confident that FastReactPlan will enable us with sustainable improvements in our performance which is really essential, particularly in the current situation.” said Wason Vitanakorn, CEO of Hi-Tech Apparel.
The project at Hi-Tech Apparel will include detailed planning of the sewing factories using FastReactPlan’s highly visual planning board, scheduling and visualisation of load on secondary processes such as cutting and printing, dynamic planning of material requirements (MRP) as well as third party integration to a wide range of in-house business systems.
Kholchapol Chuensawang, Director (IT), Hi-Tech further commented, “Considering the rapidly changing consumer demands and increasing competition in the industry, we realised it was important to take a step forward to streamline and digitize planning, communication and coordination in and across our factories. We found that Coats Digital was the perfect partner to enable us best practice processes and digitization of production planning and control (PPC) through their solution FastReactPlan.
Earlier it was difficult for us to have visibility of planning boards of multiple factories in one place. We’re confident that FastReactPlan will enable fast, detailed and accurate planning and order confirmation process, with informed order allocation and management across our multiple factories. FastReactPlan’s master planner will allow us to manage total demand and capacity and have a consolidated picture of materials and pre-production activities across the business.”
Before FastReactPlan, the Hi-Tech team had to spend a huge amount of time and effort to solve unforeseen problems either related to material availability or pre-production critical path activities. This directly impacted the on-time start of production and the delivery performance.
FastReactPlan will help Hi-Tech to ensure that all departments have shared priorities and clear visibility of key tasks that they need to complete to achieve an on-time start of production. Alerts highlighting late events will help them take proactive actions and reduce firefighting and ultimately achieve the date of delivery as committed to the customers.
