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.

• iButton Tags
• RFID - Low frequency (125 Khz)
• RFID - High Frequency (13.56 Mhz)
• RFID - Laundry Tags(13.56 Mhz)
• KeyPad Input

Crystal ProCon Real Time System can be termed as

• Online Production Monitoring System
• Process Control System
• Work In Progress Tracking System

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?

• Operator should Log-in in their workstations with the Operator tag.
• An i-Tag is programmed and tied to every bundle at cutting section and issued to sewing line for production.
• This i-Tag travels along with the bundle in the sewing line from start operation to final operation.
• Operators prior to start the operation for the bundle, will Log-in the bundle’s i-Tag in the reader to record the operation Start time.
• Operators on completion of all the pieces in the bundle, will Log-out the same bundle’s i-Tag in the reader to record the operation End time and the bundle is moved along with i-Tag to the next operator.
• All the subsequent operators will Log-in and Log-out the bundle’s i-Tag for their respective operation to record the production
• Operator should Log-out from their workstations during break-times, moving to other workstations or leaving End of the day.

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 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.
The Readers are attached to every sewing machine in the production line and Networked and connected to the Data Capturing PC.
The i-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 for start and completion (i,e twice for each bundle) of the bundle.The punches captured at each reader are sent to the central database server instantaneously. So the bundle’s presence / status are captured at all workstations as and when it passes thereby providing real time data.

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

Please refer our pre-requisite menu

HardWare: Reader ,i-Tag, Networking Accessories
Controller PC(s), Server
Software : Data Acquisition Software
Production Management Software

All the readers 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

Readers - One reader is required for every sewing machine.
i-Tags - 10 Tags required for each reader. (1:10)
This calculation is based on the estimated WIP at each workstation, Ready to issue (bundles in stock) and i-Tags in stock.

The life of i-Tag (iButton) is around 10 years

We have two models,
1) Procon Reader for Sewing
2) ProCon Reader for Quality Checking

Qc readers used to record rework and rejection pieces.
Qc Readers can be installed for capturing data at Loading, In-line, End-line, AQL, Finishing and packing sections.
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 reader 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 reader.
Order qty depends on the no. of QC check points you have.

Yes, can be seamlessly integrated with your ERP systems.

• Operator should Log-in in their workstations with the Operator tag.
• An i-Tag is programmed and tied to every bundle at cutting section and issued to sewing line for production.
• This i-Tag travels along with the bundle in the sewing line from start operation to final operation.
• Operators prior to start the operation for the bundle, will Log-in the bundle’s i-Tag in the reader to record the operation Start time.
• Operators on completion of all the pieces in the bundle, will Log-out the same bundle’s i-Tag in the reader to record the operation End time and the bundle is moved along with i-Tag to the next operator.
• All the subsequent operators will Log-in and Log-out the bundle’s i-Tag for their respective operation to record the production
• The captuerd Data is instantaneously updated in the Central Database Server
• Operator should Log-out from their workstations during break-times, moving to other workstations or leaving End of the day.

Yes, Every Style 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.

refer Dashboard Presentation

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.

The following are Production Methods supported by ProCon either Fully or Partially.

• Progressive Bundle Movement
• Piece-by-Piece Movement
• Unit Production System (Hanger Movement)
• Bundle Sharing

In the production management software, there is a process called Line Setting, Where, for every style, you need to assign Operations to WorkStations in the Line.
The details of readers attached to these workstations are pre-stored in the system.

New versions of ProCon Applications will be provided to customers as and when launched.

Online Support will be provided by our team from our Office through Remote Access.
Onsite Support will be provided by our Support Engineers

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

Procon reader has a 16x2 LCD at the top.
All response messages are displayed on the LCD.
Any message from the server is displayed.
Operator's Target, Actual,Efficiency values are displayed. On pressing the Info button , style / operation’s target qty set for the day 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 iTag id is displayed in the LCD And when the end punch is made, the i-Tag id will vanish from the LCD

Yes ProCon Supports 3 Models of Incentive Methods.

• Piece Rate Method
• Individual Operator Performance based
• Line / Section Performace based

• Operators idle Time
• Operators Non Productiove Time
• Operators Rework Time
• Operators Nowork Time
• Machine Breakdown Time
• Lines Non Productiove Time

ProCon System Captures the Cycle Time of all the Pieces Produced by the Operators and generates the Pitch Diagram Graph showing the Operation Cycle Time.
The Production Team continuously monitor this Pitch Diagram to take corrective actions for the weaker Processes / Operators / Operations and balance the Line to get the Optimal Output from the Line.