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In today’s competitive marketplace, with continuously increasing cost for raw materials, shorter time-to-market,
tight tolerances from retailors, restricted substance lists from brands – while supporting sustainability goals
and higher quality – effective production management is essential. OrgaTEX provides technological advanced
methods in planning, controlling, supervision and analysis of manufacturing processes.
OrgaTEX
rti
ve
PRODUCTION FLOOR
horizontal integration
With SETEX you have one supplier for MES software and machine control hardware.
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Enables operational intelligence Management key-numbers
The OrgaTEX Recipe module provides awe-inspiring • Know-how protection
features to simplify complex production steps, to • Lasting investment
save expert know-how systematically and to opti- • Production performance
mize resource efficiency. A wizard is implemented • Resource productivity
to provide highly dynamic process optimization. The • Target and plan
operational intelligence of this module can empower
everyone to prepare individual, specifically optimized
production orders that previously would have taken Administration key-numbers
a specialist several hours. • Central multi-source information
• Wide variety of reports and visualization
possibilities
Knowing each step • Analysis of production, efficiency, downtimes,
Addressing every single parameter of a dyeing or shifts, …
finishing machine allows smart data handling in the • Standardization
OrgaTEX supervisor and MES software.
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Dyeing Manufacturing
Manufacturing runs and production processes
Online status
Process info
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Production order analyzing Process, treatment and step
Ecological and economic reasons may require new Regardless whether “teaching-in” the local machine
products, but innovative and sustainable solutions programs or preparing new procedures, the OrgaTEX
require measures of the involved production process. Program Editor leads to visualize process information,
The communication of machine automation and discovers anomalies and enables to systematically
OrgaTEX background processes enables automatic optimize production processes for the existing
process data recording for every batch. machinery.
The OrgaTEX Process Analyzer displays every The possibility to split-up processes visually in
production batch, descriptive and graphically, in different parallel tracks, simplifies every complex
width and depths. The visualization is configurable to production procedure. Such structuring enables
show the essential items of the production process operators to avoid countless similar dyeing programs
straight to you – down to every sensor signal. Different and leads to few Standard Operation Procedures
options for rapid interaction with the info-graphic (SOP), which makes everyday optimization easier,
assist to focus on the desired data. increases reproducibility and savings.
Features
• Graphical and tabular forms
• Temperature/time curve
• Variable function parameter with formula integration
OEE R
epo rt
Product
ion (h)
Batche
s
Batch/m
achine
84%
83%
77%
Time-win
dow of 2
knitted q 4/7
uality with week. Reaktive
5:18 ho dye
urs averag ing process of
e process
Plan time
hours Result
5019 (h
)
P o te n tial
batches 4208 (h
)
946 (b) 811 (h)
batches 784(b)
machine/d
ay 4,8 (b) 162(b)
3,7 (b)
Downtimes displayed in batch scheduler 1,1 (b)
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Real-time Batch Scheduler
Production planning and scheduling
OrgaTEX Batch Scheduler is the central platform where all dye lots can be composed, planned and supervised
from one vantage point.
The graphical planning board delivers an authentic real-time planning and available at one mouse-klick,
situation of the entire production by synchronizing e.g. production recipe, dye lot cost, dye lot history…
business data (e.g. products and delivery time) with
production operations (e.g. machine status, mainte- To visualize, control and optimize complex facilities,
nance) and real-time communication. it is possible to configure several different planning
boards for each department e.g. preparation, dyeing,
The company business logistic department is able finishing and inspection.
to experience a precise medium and short-term
outlook. A dynamic real-time planning visualizes real Summary
production time and duration for every batch. The OrgaTEX Batch Scheduler brings planning
online visible and accessible. It allows easy planning
The production department is able to adapt and for a maximum machine utilization.
respond to changes instantly based on real-time • Electronic planning board
production progress monitoring and “on-klick” detail • Batch scheduling
information (e.g. chemical call, sampling, queuing • Drag and drop batch arrangement
error). • Deadline monitoring
• Processing preparations, additions and repairs
For informed decisions in day-to-day activities, all • Optional: production downtimes visualization
processes in the production chain are linked with the
Textile finishing is a competitive and unsteady industry. There is no doubt that there are no two identical companies.
Key performance indicators (KPIs) help to position the company, develop key figures for benchmarking and
increase margin.
Duration of downtimes
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Product analysis To improve the operational performance it needs
Resource or process related reporting provides infor- information on lead times, maintenance, additions
mation about the machines which have been used and color corrections, uptimes, planned and un-
to produce a product. planned downtimes, etc. In short: OEE adapted to
• Machine and production utilization including main- the manufacturing assets.
tenance
• Reduction of stock (Work In Process) By monitoring the performance of every single
• Production transparency increase machine in the production floor, adding shared
• Comparison of machine performance with the target recipe and process information (e.g. alarms) and
• Comparison between machines collecting information of unplanned downtimes, the
OrgaTEX Reporting tool provides robust informa-
Weak point analysis tion on these grounds.
A fault related analysis in combination with the online
status module is providing the basic data for a weak • Reducing efforts to collect real-time production
spot analysis. information
• Process runtimes • Preventing unscheduled downtime
• Alarm messages, reports • Maximization of production equipment utilization
• Consumption of water, chemicals, dyestuff • Reducing maintenance costs by optimizing
• Problems with dispensing, liquor ratio etc. planning activities
• Comparison of current with history data • Improving process performance
• Easy export to Excel worksheets through “grid to file”
Overall Equipment Effectiveness (OEE) • Easily create presentation-quality reports based
Availability against planned times, performance on the latest data
against target values and process quality against
additions are the key factors to obtain the real
Equipment Effectiveness.
Consumption of electricity
Merging a recipe of colorants and chemicals with a production process, containing every single item for a perfect
batch and communicating with machines and dye kitchen systems, has never been easier. The OrgaTEX Recipe
modules provide awe-inspiring features to simplify complex production steps, to save expert know-how system-
atically and to optimize resource efficiency.
Ease of use
The powerful all-new user interface has the following • Modern editor
objectives: Firstly, to develop an intuitive and practi- • Drag and drop
cal interface, which represents considerable savings • Tabbed forms, instant switch
in time for the user. Secondly, to provide the per- • Perfect overview
formers of production processes with an optimized
workflow by means of visual clarity. Search and list
grid of recipes is configurable to customer’s needs.
Process recipe
Stock management
Lab2Bulk
Integrating with laboratory software (e.g. color
matching and QC) with the OrgaTEX Lab2Bulk
module, has a markedly favorable effect of better
processes for maintaining accuracy, transparency
and standards from lab to production.
Online production correction
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OptiWeigh
Integrated system for reliable weighing
In order to achieve reliable, high level processes, the OrgaTEX.module “Weighing” provides a constant data
stream from scheduling up to the dye kitchen. In combination with the SETEX OptiWeigh components the
software guides the operator through the dye kitchen weighing process: precise, reproducible and documented.
It provides quick and easy access to the information needed to ensure the right amounts are prepared. It reduces
production cost with increasing “right first time”.
Fully integrated
• Scheduled batches are immediately available on
the WT2010 weighing station
• Fast selection of priority jobs with a barcode scanner
• Batch/product status synchronized with OrgaTEX
• Product consumption feedback to the OrgaTEX
stock control module
The phrase "savings on chemicals" is often used with centralized dye kitchen systems. Most likely these systems
will not fulfill the expectations if they are used as isolated applications. Extended time and efforts for recipe
administration, supply disruption and manual operation cause inefficiency and bad reproducibility.
The OrgaTEX CDC module perfects automatic capacity utilization control, individual generated dissolving
procedures and a close connection to dyeing machine programs. This simplifies day-to-day business and
increases the throughput.
Tolerance band
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Finishing Department
From traditional finishing to automatic guided and controlled manufacturing
Grouping the experience of SETEX and textile finishing machines manufacturers together, optimizes the throughput,
records and reports production and saves know-how.
Batch scheduler
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Features
• Batch management
• Automatic set time calculation
• Drag and drop batch arrangement
• Deadline monitoring
• Preparation call to central dispensing system
• Optional: production downtimes visualization
Production monitoring
OrgaTEX Online Supervision is the real-time in-
formation of your running production, presented Online visualization
Process analyzer
Traditional energy management systems support textile finishing companies in reporting consumptions and assist
for consideration about investments.
The OrgaTEX Energy Management system goes far beyond the simple logging of energy consumption. More-
over, several applications permit an immediate adaption of the production related energy demand, related with the
availability of electricity, gas, compressed air and steam. In short: It makes active process adjustments to balance
energy loads.
3 degrees of influence
SETEX has comprehensive knowledge in controlling
relevant energy influencing factors in production. To
Energy control terminal
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Avoiding electricity and gas peaks critical steps”) according to priority and importance of
An energy management system is efficient, when action. The deeply integrated connection down to the
electricity and gas peaks are reported before they machine PLC level permits interventions that cannot
happen. OrgaTEX monitors individual and total be realized manually.
energy consumption in real-time, and arranges
alternative processes at the same moment, as the Water management
anticipating algorithm predicts an upcoming energy In times of dyeing machines with very low liquor ratio
peak. and other water saving challenges, OrgaTEX assists
to run processes that require less thermal energy, less
Alarm messages will be shown, energy intensive electrical energy and less cooling water.
program steps will be modified, the start of additional
machines will be prevented. Keeping fill-levels and temperatures of machines and
tanks controlled, the SETEX solution provides optimi-
Steam management zation features for various scenarios:
The highest efficiency of steam-generators is at a • Precise temperature of supplied stock water is
specific steam pressure rate. The OrgaTEX steam synchronized with machine heating actions.
management solution allows balancing the steam • Automatic selection of water type depending on
consumption to avoid generator ups and downs. availability and priority management
The SETEX solution adjusts process parameters (e.g. • Cooling with warm water depending on customer
heating a stock tank, avoid machine heating in “non rules (with process adjustments)
Steam consumption/utilities
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System Landscape
ERP
MES
OrgaTEX basic
• Program Editor
• Process Analyzer
• Online Supervision
Server Workstations
PRODUCTION
FLOOR
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LABORATORY DYE KITCHEN SYSTEMS
Datacolor • Paternoster
Lab recipe • Weighing
• Quality • Dissolving
• Colorants • Dispensing
• Process •…
Service adapter
Material flow
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OrgaTEX – IT strategies
Clustering, virtualization and terminal services architecture –
OrgaTEX supports useful performance and safety environments.
Expensive production downtimes require preventive methods to bridge system failures (failover), to generally
improve the IT service (virtualization) and to simplify the management of applications and computers (terminal server).
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Overview
OrgaTEX basic – OrgaTEX professional
Temperature Control
Dyehouse Production
95 70 m/min
0.8
30 60 %
No 0998 EXAMPLE
011 Sample 10.0 min
012 Temperature Control 95 °C
98
65
33
0
10:00 11:00 12:00 13:00 14:00
575
Program Editor
Process Analyzer
Online Supervision
Batch Scheduler –
Production Calendar –
Batch Report –
Machine Report –
Product
Strategy
Product
Development
Product
Management
Product
Marketing
Root Data Management –
Production Recipe –
Stock Management –
Formula Wizard –
Energy Management –
Weighing –
98
65
33
0
012
10:00
86
Temperature Control
No 0998 EXAMPLE
011 Sample
RUN
95
0.8
30
Temperature Control
60 %
30
10.0 min
95 °C
14:00
Paternoster –
575
ERP
Interface ERP/PPS –
848TCE
Continuous Production
– = not available, = included in OrgaTEX basic, when used as single PC setup, = included in OrgaTEX professional, = optional
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Headquarter
Subsidiaries