Looms and knitting machines: beams, shift production, doffed rolls
Keep each loom and knitting machine with its speed, the beams loaded on it and its production per shift with efficiency. Doff a roll from the shift rows and it goes into stock with its yarn used, roll number and metres, with an inspection waiting.
PLANSScale only
The problem it solves
- Shift production is written in a register and reaches the office days later.
- Nobody knows how many metres are left on the beam on loom 14 until it runs out.
- Woven rolls go into the godown without a roll number, so their yarn cost and quality are guessed.
How it works
- On each machine set its type (air-jet, rapier, power or water-jet loom, circular or flat knitting), RPM, width and picks per inch.
- Under Textile > Beams, record each beam: number, warp yarn, ends, length, warp kg, the loom and the fabric woven. Press Load on Loom; a beam already running there is marked finished.
- Each shift, add a row in Loom Production: date, shift, loom, beam, weaver, fabric, picks, metres, kg, minutes run and yarn used. Efficiency works itself out.
- When a roll comes off, select its production rows and choose Doff a Roll. Give the roll number; the metres and kg add up from the rows.
- The roll goes into stock with its yarn taken by the fabric's BOM, or from the beam's warp by the metres woven. An inspection waits for it.
Everything it does
Machines and beams
- Loom / Knitting Machine: Air-jet, Rapier, Power, Water-jet Loom, Circular or Flat Knitting; RPM, Width (inches), Picks per Inch
- Beam: Beam No., Warp Yarn, Ends, Length (m), Warp Weight (kg), On Loom, Fabric Woven, Loaded On
- Beam stages: Ready, On Loom, Finished; Metres Woven and Metres Left from the shift rows
- Filter On Looms
Production per shift
- Shift A, B, C or General; Minutes Run 480 to start with
- Picks, metres, kg, yarn used (kg), weaver or operator
- Efficiency (%) = picks / (RPM x minutes run); blank when no picks are typed
- Filters Today (on to start with) and Not Doffed; group by loom or shift
- Pivot: metres and average efficiency by loom and day
Doff a roll
- Select rows of one fabric; rows of two fabrics are refused
- Roll No., Metres and Kg (added up from the rows), Inspection Waits (on to start with)
- Makes and finishes a production order for the fabric, in metres or kg by the fabric's unit
- Yarn by the fabric's BOM; with no BOM, the beam's warp yarn by warp kg x metres / beam length
- Makes the roll with its roll number, metres and kg; rows are marked doffed
- With inspection on, a 4-point inspection is made for the roll with its length in yards and the fabric's width
Who uses it
Weaving supervisorLoads beams, keeps shift production and doffs rolls.
Production managerReads efficiency by loom and day and metres left on each beam.
Quality inspectorPicks up the inspection waiting for each doffed roll.
Where you use it
- Web: Manufacturing > Textile > Loom Production, Beams; Doff a Roll from the Action menu of Loom Production
- Web: the Loom tab on a machine
- Not on the shop floor terminal: weavers do not enter shift production there
- Not in the SmartMy Manufacturing app: the textile screens are on the web only
What you control
Settings
- Textile screens: Settings > Manufacturing > Industry: Textile, per Entity (off to start with)
- Per machine: type, RPM, width, picks per inch
- Minutes run per shift: 480 to start with, per row
- Inspection Waits when doffing: on to start with
Questions
How is loom efficiency worked out?
Picks woven against what the loom could weave: RPM times minutes run. If you type no picks, efficiency stays blank.Do knitting machines work the same way?
Yes. Choose circular or flat knitting as the type and keep kg and metres per shift. Efficiency needs a count in Picks against the RPM.Is the yarn taken out of stock when we doff?
Yes. By the fabric's BOM, or with no BOM, the beam's warp yarn by the metres woven. Weft yarn is taken only through a BOM.Can a machine feed the counts by itself?
No. Machine data from PLCs is not offered; shift rows are entered by the supervisor.Which plan has looms?
Scale, with fabric inspection and style costing.Related features
TEXTILE AND GARMENTS4-point fabric inspectionInspect each roll by the 4-point system: defects with their points and points per 100 square yards. Each gets a grade A, B or Rejected by your limits. A rejected roll is put on quality hold until a quality manager releases it.TEXTILE AND GARMENTSTextile: fabric data, rolls and style orders by ratioKeep yarn and fabric details on your items and every roll with its metres, kg, shade and dye lot. Take a buyer's style order by colour and size ratio and make one production order per colour and size in one step.LINES AND SCHEDULINGOEE per machine and day, and the machine board on a TVOEE is worked out every hour for each machine and day from its running time and the pieces counted at the terminal. It is split into availability, performance and quality. A machine board on a TV shows every machine as working, stopped or idle.PRODUCTION AND JOB WORKBills of materials, production orders and work ordersKeep each item's bill of materials with its components and the steps on your machines. A production order reserves the material, lays out the work orders step by step and puts the finished goods into stock at cost.PLANNING, QUALITY AND COSTPreventive maintenance by days, hours or cyclesEach machine gets maintenance plans that fall due by the calendar, by its running hours or by the pieces it has made. A due plan raises a maintenance request with its checklist and spares, and closing the request costs it and moves the plan on.
See your shop floor on it.
Tell us what you make, how many machines and people you run, and how production is recorded today. We will set up a line with you and run a job on the terminal.