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About RealTime System


A Real-time system is a technology tool, which gathers and distributes information to everyone in the factory as events are happening. Real-time System is well proven technology to achieve realistic production goals, at reduced cost and increased profit and meets customer needs at on-time delivery.

Need for RealTime System

The real time production monitoring system in manufacturing industries enables users to continually monitor production process and collect real time information with regard to reliability,accesibility and maintainability of the equipement.Information must be collected and disseminated quickly and accurately in order to meet the production goals.

Production monitoring system provides centralized production monitoring and counting for use with any industrial or mass production environment.

The key objective of a real-time system would be its ability to collect production information on real time basis which would enabable the production management team to respond in a timely manner to solve any production related issues that may arise.

RealTime Production Monitoring System is a revolutionary technology desined to provide real time information to production management team to effectively manage the complex requirements of apparel manufacturing processes.


About ProCon

Crystal’s ProCon is a revolutionary digital technology tool for achieving real time goals in the Garment and Apparel manufacturing Process. ProCon is a digital assistant in the quest for maximizing enterprise productivity.

Global market and technology are forcing tremendous changes in the Textile and Apparel industries. ProCon system is focused on the issues, complexities and opportunities for Apparel and Textile companies and their suppliers. ProCon system is fully interactive and integrates with the complete range of distribution, material and capacity planning, manufacturing and financial systems which makes it the most comprehensive real-time system.

The key objective of ProCon system is to collect production information on a real time basis to enable the production management team to respond instantaneously and to solve any problems that may arise within the line. ProCon system operates without requiring any changes or placing unreasonable demands on the way your business operates. ProCon system yields returns with cost savings to pay for your system, right from the first day it is installed. ProCon system has the capability of making almost every apparel manufacturer more competitive and better supplier.

ProCon System can be Implemented for Cutting, Sewing, Checking,AQL, Washing, Finishing and Packing.

ProCon system works on following Identification Technologies commonly termed as i-Tags.

Crystal ProCon Real Time System can be termed as

ProCon system comprises of i-Tag reader and i-Tag. An i-Tag is used to identify Operators, Supervisors , Mechanics, Qas and Bundles with unique color holders. This i-Tag will have a polythene pouch attached to it. This pouch will carry the printed information of the bundle/Operator details.

A reader is attached to every workstation in the production line.

All readers in the line are networked and connected to a Data Capturing PC which captures the Data for Log-In, Log-out, Bundle Start and Bundle End made by the operators and updates the information in central repository in real time.

How ProCon works?


Benefits of Installing Real Time System

The benefits of installing effective and efficient real time system is seen at following levels due to immediate on screen access to all informations.

Production

Work-in-Progress

Supervisors

Operators

Quality Control

Management

Customer Care

ProCon Data Readers

i-Tag Reader (iButton) (Sewing)

The reader displays the Operator’s name, Target, Actual production, Efficiency, Idle Time and Excess Time.

Reader Configuration

  • 2 x 16 Liquid Crystal Display
  • Tx / Rx Indicator LEDs
  • Tag Read Indicator LED
  • iButton Contact Probe
  • 64 K Backup Memory
  • Real Time Clock
  • Numeric KeyPad with Functional Buttons
  • Tag or Keypad inputs
  • 0-9 - Enter Operator No or Bundle No.
  • Info - To view the production details
  • NW - To record Operator No Work time
  • BD - To record Machine BreakDown time
  • RW - To record ReWork time
  • Sngl - To account Single Piece Movement
  • Alrt - Sends an alert as SMS to the concerned person
  • CB - Cancel or Close Bundle
  • LO - LogOut current logged in Operator

i-Tag Reader (iButton) (QC)

This reader can be configured as Loading / Inline checking / End line / AQL / Finishing checking.

Reader Configuration

  • 2 x 16 Liquid Crystal Display
  • Tx / Rx Indicator LEDs
  • Tag Read Indicator LED
  • iButton Contact Probe
  • 5 x 4 Matrix Keypad
  • Qc Passed Pieces Button
  • Rejection Pieces Button
  • Rework Pieces Button
  • Alert Button
  • Function Buttons
  • PS - Enter Passed pieces
  • RW - Enter ReWork pieces
  • RJ - Enter Rejection pieces
  • NW - To record Operator No Work time
  • MS - Clears the current state.
  • Alrt - Sends an alert as SMS to the concerned person
  • CB - Cancel or Close Bundle

RFID Reader (LF / HF) (Sewing)

The reader displays the Operator’s name, Target, Actual production, Efficiency, Idle Time and Excess Time.

Reader Configuration

  • 2 x 16 Liquid Crystal Display
  • Tx / Rx Indicator LEDs
  • Tag Read Indicator LED
  • 64 K Backup Memory
  • Real Time Clock
  • Numeric KeyPad with Functional Buttons
  • Tag or Keypad inputs
  • 0-9 - Enter Operator No or Bundle No.
  • Info - To view the production details
  • NW - To record Operator No Work time
  • BD - To record Machine BreakDown time
  • RW - To record ReWork time
  • Sngl - To account Single Piece Movement
  • Alrt - Sends an alert as SMS to the concerned person
  • CB - Cancel or Close Bundle
  • LO - LogOut current logged in Operator

RFID Reader (LF / HF) (QC)

This reader can be configured as Loading / Inline checking / End line / AQL / Finishing checking.

Reader Configuration

  • 2 x 16 Liquid Crystal Display
  • Tx / Rx Indicator LEDs
  • Tag Read Indicator LED
  • 5 x 4 Matrix Keypad
  • Qc Passed Pieces Button
  • Rejection Pieces Button
  • Rework Pieces Button
  • Alert Button
  • Function Buttons
  • PS - Enter Passed pieces
  • RW - Enter ReWork pieces
  • RJ - Enter Rejection pieces
  • NW - To record Operator No Work time
  • MS - Clears the current state.
  • Alrt - Sends an alert as SMS to the concerned person
  • CB - Cancel or Close Bundle

ProCon Tag Assigning Reader

This reader is used to assign tags for operators and bundles

HR Department : This reader will be connected to the PC in the HR Department. The operator name and token no details are printed for the operators. The operator cards are inserted in the i-Tag’s pouch and assigned to this reader for every operator / supervisor.

Cutting Department : This reader will be connected to the PC in the cutting department. The bundles are generated in the application software and bundle cards are printed For the bundles. The bundle cards are inserted in the i-tag’s pouch and assigned in this reader for every bundle prior to issue to the Production floor.


ProCon Line Display Board (LED TV)

An LED TV can be installed for every line / section. The Following information with Graphs can be shown on the LED TV of the respective line / section.

  • Consolidated information as shown in the picture
  • Supervisor Dashboard with hourly production
  • Line / Operator Performance
  • Line production with W.I.P
  • Quality information (Rework / Rejection Defects)
  • Lost Time information (Operator / Line)
  • Bottleneck Operations in a Line
  • Style / Order status

In Addition to the above, any other information to be shown can be Customized according to the requirements.


ProCon Workstation Status Indicator

  • A ProCon Workstation Status Indicator is attached to every workstation to indicate the current status of the workstation / operator.
  • The Status indicator has 3 different color LED lights, each of which can glow or blink. A maximum of 6 status variables can be configured.
  • The Status Indicator can be configured to indicate the Machine Breakdown, Idle Time, Rework Time, Work-In-Progress, Efficiencies, Batch Setting, Non Productive Time, Excess Time etc.

Identification Technologies


i-Tags

i-Tag for bundle identification
An i-Tag is physically attached to every individual bundle and sent to sewing line for production. This Tag travels along with the bundle in the sewing line from start to end. As each operator starts his/her bundle he/she will tag onto his/her reader ,which will denotes the start of the bundle.On completion of the bundle the operator will again tag onto the reader to indicate the end of the bundle.
i-Tag for Operator identification
An i-Tag is provided to every Operator for his or her identification purpose. Operator uses this tag to login at the workstation before starting work and logout while leaving the workstation.

i-Tag (iButton)

The i-Tag is a computer chip enclosed in a stainless steel can that proves its identity by a globally unique serial number. This i-Tag is used to identify Operators, Supervisors , Mechanics, QA s and Bundles with unique color holders. This i-Tag will have a polythene pouch attached to it. This pouch will carry the printed information of the bundle/employee details.


i-Tag (RFID) - Low Frequency

Typically LF RFID systems operate at 125 KHz. This frequency band provides a short read range of 10 cm, and has slower read speed than the higher frequencies, but is not very sensitive to radio wave interference.


i-Tag (RFID) - High Frequency

Most HF RFID systems operate at 13.56 MHz with read ranges between 10 cm and 1 m. HF systems experience moderate sensitivity to interference.


i-Tag (RFID) - High Frequency Washable Laundry Tag

Most HF RFID systems operate at 13.56 MHz with read ranges between 10 cm and 1 m. HF systems experience moderate sensitivity to interference.


Input through Reader Keypad

Operator can use the Reader keypad to Log-In themselves as well as Bundles by entering their Token Nos and Bundle Nos.

ProCon Softwares


Data Capturing Software :

This software is installed in the Data Capturing PC in the production floor which captures the punches from all the readers and updates the central database instantaneously.

Production Management System : (PMS) Application Software

This application software is installed in all the client machines. All Masters and Transaction details are entered in this application. Style Order details, Laying, Cutting, Bundle Generation, Tag Assigning to Bundles, Operation Bulletin, Line layout etc., are entered in this application

Dashboard :

ProCon DashBoard is a Business Intelligence (BI) tool that displays the Macro level information in real time of all the Production lines graphically. Micro level information can be viewed by drilling down the respective cells. Provides various types of graphs at all levels for analysis and comparison for better decision making.

Web based MIS Reports :

This software is installed in the central server. This software collects all the production information from all the PROCON installed factories automatically and produces the following MIS reports.

All the above reports are cross tab with drill down feature that has 5 levels i,e factory – line – buyer- style – day and so on.
You can compare and analyze multiple factory / line across months /weeks etc.

ProCon System Networking


State-of-the-art Networking based on SCADA principles ensures 100% Data reliability

Readers from sewing lines are connected to Controller PC which captures the Data from the Readers and Updates the Central Database in Real-time.

One Controller PC can handle a maximum of 300 Readers.

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Pre-requisite hardware and software for installing ProCon

Hardware

Server

Intel Hexa Core processor or higher, 32 GB RAM, 1 TB HDD, USB Ports, 100 Mbps network connection, DVD Drive, Color Monitor, Keyboard, Mouse.

Controller PC

Intel i5 Processor or higher, 16 GB RAM, 250 GB HDD, Network Card, USB Ports, Monitor, Keyboard, Mouse .

Controller Computer

All Reader units are connected to Controller computer through Network. Controller computer is connected to the Database Server.
The Interface software installed in this Controller PC collects the data from the reader units and stores in the database server.One Controller PC can handle upto 300 Readers connected to it.

Software

  • Server Operating System – Windows 2012 or higher.
  • Clients Operating System – Windows 7 Pro or higher.
  • Database – Microsoft SQL Server 2012 or higher.

Key benefits of ProCon

ProCon System provides efficient and effective real time information for the performance of the company to implement business strategy successfully.

Instant Reports at all levels.
ProCon system reveals real time information and reports at all levels.
On-Line Production Status
ProCon system provides on screen access to production order and their progress, to eye production status.
Improvements in effective and efficient usage of man & machine
Efficient Line Balancing
ProCon system furnishes accurate information of line balancing
Reduction of Work In Progress Time
ProCon system makes production tracking more transparent and this removes the need for checking the work-in-progress every two hours.Workforce analysis on who is working under each section of workflow and the cost of their performance against the project can be monitored whenever needed
Reduction in Downtime
ProCon system reduces unproductive downtime by 20% by providing downtime reports which will enable management to initiate corrective action
Improved In-Line Quality Control
Eliminating the need for Supervisory Checks
Accurate time keeping
ProCon system ensures that the operators check-in directly in time at their workstation. This ensures considerable reduction in queuing time per operator.
Accurate Payment to Operators
ProCon system prevents unnecessary waste of labor time in maintaining their own records and resolves disputes among operators in calculating the cost of the work done by each Operator. The operators are paid only for perfectly completed work and appropriate reductions are applied for faulty pieces before payment. ProCon system eliminates holding back of work tickets and paying twice for the same work. Errors in payroll claims are also reduced to great extent. ProCon system calculates the gross payroll faster than the traditional book keeping system.
Reduction in Overtime Working with maximum utilization of HR
Absence of key workers adds on to the overhead charges and affects the productivity. ProCon system highlights the problem immediately and eliminates unnecessary overtime. An efficiently implemented real time system would reduce the overtime expenses by 50%. Future production planning is made easier.
Reduced Administration Costs
ProCon system reduces paperwork and clerical errors.
Accurate MIS Reports
ROI In Less than 2 Years
By installing ProCon system, you will reap return of investment within two years. You can also benefit from the ProCon hardware depreciation over a period of time.

Salient Features of Crystal ProCon