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s c h e r m u l y t e x t i l e c o m p u t e r
Production and performance
management software
for textile finishing
2
OrgaTEX
sustained improvement of your competitiveness
Changes in the textile industry
are gaining momentum. Effec-
tive measures ensure the future
competitiveness of a company:
Shortening Time-to-Market
of the products
Increasing the product trans-
parency and flexibility
Planning optimization
Reduction of downtimes
Lowering production costs
At the same time it should safe-
guard
High quality standards
Optimal production efficiency
across all production facilities at
the lowest costs possible.
44
Program editor
The creation and administration
of various complex dye process-
es is considerably easier and
more efficient if done on a PC.
Recurring process sections (pre-
wash, bleaching, soaping, after
treatments) are created as treat-
ments and can so be combined
without difficulty into dyeing pro-
cedures. In this way standards
are created automatically that
enhance the optimization, re-
producibility and savings of dye
processes.
Features
Graphical and tabular forms
Temperature-/time curve
Variable function parameter
with formula integration
55
Process data
Online status
Online supervision of the processes
Fault and process information
display or performing necessary
interventions during batch run-
time; all centrally from a work-
station in the office with Or-
gaTEX you have your dye house
under control.
Features
Display of actual process and
machine data (tabular and
graphical)
Correction of process para-
meters
Interventions during unfore-
seen incidents
Online analysis of the process
data
Online editor
Scope of services
Dye program administration
Batch scheduling and plan-
ning
Online supervision
Alarm management
Process analysis
Production calendar
Report system
Advantages and benefits
Standardizing processes
Flexible production
Detect discrepancies
Fast reaction to unexpected
events
Lowering production costs
Higher machine utilization
(PDA)
Management information
system
7
Report examples
Daily production/capacity
Target setting total production
x-t/day
Comparison of the machine
performance
Production costs/standard
procedures
Total production costs
x-u/kg product
Cost distribution
Right First Time/additions
Objective of x-%
Detailed analysis of processes
(problems with dosing, liquor
ratio etc.)
Analysis regarding irregulari-
ties of procedures, recipes
Shift comparison/operator
Assessment of the produc tion
output up to gathering data
for additional pay
Weak spot analysis/target dis-
crepancy
Process runtimes
Alarm messages
Consumption of water, chemi-
cals, dyestuff
Production
overview
Runtime deviation
Right first time quote (%)
Trend diagrams
History of energy costs
History of production costs
Utilization of the production
Dosing system
Utilization
Transfer times
Scope of services
Up to 64 stop reasons per
machine group
Operator administration
Display and correction
facilities in batch scheduler
Simple time selection between
batches
Integrated into the OrgaTEX
report system
Advantages and benefits
Objective data acquisition
Increase in production
PDA terminal =
machine controller
8
PDA
Production data acquisition of downtimes
With the Widows CE.NET based
controller generation SETEX pro-
vides an all-in-one solution
for the acquisition of production
downtimes: The controller of the
OrgaTEX down time reasons
production machine is also used
as terminal for the production
data acquisition. In combination
with the OrgaTEX module PDA
a flexible and fully integrated
system is available.
With similar machinery and with
the help of an objective data ac-
quisition, using the correspond-
ing reports and by ensuing mea-
sures an increase in production
of 15 30 % can be achieved.
Displaying downtime reasons
SECOM CE controller
9
This module looks at the pro-
duction from a completely new
perspective and provides ad-
ditionally online information of
process states. It also provides
intervention facilities directly
from the workstation in the office.
With the plant navigator, ma-
chines und installations can be
graphically shown according to
the floor plan of the production
area.
Features
Graphical user interface
Departments can be separat-
ed (e.g. piece/yarn dye house,
finishing, dye kitchen, heat
recovery)
Machine status
Online batch and process in-
formation
Batch status display
(next batch)
Plant navigator
All machines at a glance
Overview plant navigator
Next to the new presentation al-
so active intelligence features
are implemented. The intercon-
nection of all machines and the
combination of process values,
OrgaTEX database and active
intelligence provides an alter-
native of information, monitor-
ing and control.
Active intelligence features
HT drain interlock
(additional extension)
Repeated use of bleaching
bath
Energy management
(sequential startup of the
machines)
Alarm notification via SMS or
e-mail
By focusing on the energy man-
agement cost reductions will
be achieved, expensing energy
peaks will be avoided and gov-
ernmental requirements will be
met.
Scope of services
Creation of base recipes
Chemical and dyestuff admin-
istration
Article and customer manage-
ment
Calculation of production and
addition recipes
Advantages and benefits
Enhance the process reliability
Enhance the production
flexibility
Shorten the time-to-market
Integration with dye kitchen
systems
Storage and use of process
know-how
Cost calculation and data
transfer to controlling
11 11
cation
Stock management
for chemicals and dyestuff
The stock management is a
helpful instrument for a cost con-
scious production which gives
always a clear overview over the
stock inventory, reserved quanti-
ties and consumptions. Every
product that is ordered too late
will create substantial problems
in the everyday production.
Stock management
Features
Automatic inventory manage-
ment with variable feedback
(set / actual values)
Input of stock management
terms
Assignment of consumed
product quantities to the par-
ticular batches
Generation of order-recom-
mendation lists
Creation of consumption re-
ports with flexible criterias
Cost calculation of the stock
quantities
Product management
Product specifications
Check for incompatibility
Barcode support
Dyestuff class assignment
Substrate affinity
Assignment of dispensing
stations
Display and input of stock
data (option)
Article/customer management
Article definition
Integrated substrate manage-
ment
Mixed fibers definition
Assignment of production
parameters
Assignment article customer
Parameter for CSD optimization
Production recipe
Flexible selection of base
recipes
Interaction via batch parameter
Configurable, automatic
recipe printout
Display and printout of recipe
costs
Addition generation
12
With the formula management a
universal tool has been created
that can be used in several Or-
gaTEX programs. The manifold
possibilities allow for an easy im-
plementation of gathered experi-
ences and logical dependencies
into so-called formulas for the
optimization of existing proce-
dure and recipe data.
Formula management
Automatic process and recipe optimization
in reports
Analyses are performed to the
specific requirements of a com-
pany therefore it is difficult to
define certain standards.
Report management in combi-
nation with formulas enable the
user to create his own, customer
specific reports which permit
companies to create their own
standard reports for certain
user or user groups.
Examples
Calculation of operating figures
Evaluation of performances
Comparison of processing
time
Machinery availability
13
in recipe
Use of available know-how and
automatic application it to the
daily work using formulas in
recipes contributes to reach this
target. The efficiency and the
savings potential of this func-
tionality guarantees a fast ROI
(return on investment). Batch
runtimes will be shortened, dye-
stuff, chemicals and energy will
be saved.
Flexible use
Depending on the dye proce-
dures, color depth, article, and
machine type etc. formulas can
flexibly be used in the recipes:
Calculation of chemical quan-
tities (salt, alkali)
Automatically activating / de-
activating pre and after treat-
ments in the production recipe
(bleaching, rinsing, soaping)
Adjustable tolerances
Optional barcode scanner for
product identification
Weighing process can be
interrupted and continued at
any time
Printout of labels for the clear
identification of preparations
Automatic feedback to the op-
tional stock management
Weighing of products outside
of batches
Reweighing from full contain-
ers
Paternoster control via
SECOM controller
17
kitchen control
ns equipped with SECOM control systems
Dispensing and dissolving systems
PROBLEM: Preparation addition all-in-one for 100% Tank
w
i
t
h
o
u
t
C
D
C
The recipe contains three different preparations for li-
quids, powder and dyestuff that can only be handled
sequentially.
w
i
t
h
C
D
C
The recipe contains one mixed preparation with all
three kinds of chemicals. The CDC sends the related
calls to the corresponding dye kitchen systems.
d
i
s
a
d
v
a
n
t
a
g
e
By processing the preparation calls sequentially time
delays may occur depending on the utilization of the
dye kitchen systems.
a
d
v
a
n
t
a
g
e
Simple and according to dyeing technology logical-
recipe creation
No time delay because of parallelprocessing
Example of use
Dyestuff dissolving system
PROBLEM: Dyestuff quantity cannot be processed in one dissolving cycle
w
i
t
h
o
u
t
C
D
C
Dissolving programs for all possible variants must
be created. The selection of the dissolving program
must be coordinated with the dyeing process and the
dyestuff quantity.
w
i
t
h
C
D
C
Flexible, automatic creation of dissolving programs
Automatic calculation of the temperature, time and
water quantity.
Automatic calculation of the necessarydissolving
cycles.
Automatic dosing of solvents fromthe recipe, e.g.
acetic acid for alkaline dyestuff.
d
i
s
a
d
v
a
n
t
a
g
e
Increased possibility for errors and often manual in-
terventions necessary.
a
d
v
a
n
t
a
g
e
Flexible solution for any quantity of dyestuff without
manual intervention.
Liquid chemical dispensing system
PROBLEM: Defective valve on the dispensing system
w
i
t
h
o
u
t
C
D
C
First machine waits for the confirmation of a prepa-
ration call. All other machines that have sent calls to
the dispensing system are waiting for their calls to be
processed until the valve is fixed.
w
i
t
h
C
D
C
Via CDC the tank will manually be disabled. CDC
automatically sends a user info to the operators of
the other machines so that they can add the product
manually and then quit the function via the machine
controller.
d
i
s
a
d
v
a
n
t
a
g
e
Downtimes and manual interventions on the control-
ler of the dispensing system and on the dye machine
controller.
a
d
v
a
n
t
a
g
e
Flexible solution without manual intervention on the
dispensing and dye machine controller.
18 18
Program editor
The creation and administration
of preparation data sets for a
large number of article specific
machine setting and various dif-
ferent machine types can easily
be realized with the program ed-
itor. Depending on the machine
type different input screens are
available.
By using the module Formula
Management variable param-
eters (e.g. fabric width) can be
created that will considerably
reduce the number of data sets.
Features
Graphical and tabular editor
Variable function parameter
with formula integration
Freely creatable organization
structure (tree control)
Continuous production
Transparency in the continuous machinery area
Batch scheduler
The assignment of correct ma-
chine settings or preparation
data sets for all batches of the
continuous machines can easily
be realized by using the batch
scheduler. This electronic online
planning board shows transpar-
ently the actual situation of all
production batches.
Batch scheduler
Preparation data set
Features
Electronic planning board
Batch disposition
Automatic set time calculation
Batch can be moved per
drag and drop
Deadline monitoring
Preparation call to central
dispensing system
Selection and display of pro-
duction downtime (optional)
19 19
Online status
Via the Online Status program
the central control of all con-
nected machines takes place.
With the help of configurable
templates the user dependent
display of all process values and
batch data will be realized.
Features
Display of actual process and
machine data (tabular and
graphically)
Correct process parameter
Intervention during unfore-
seen events
Alarm information
Online-analysis of process data
Process analyzer
Batch related process data can
be displayed and printed with
the process analyzer. The soft-
ware is used for company in-
ternal information as well as for
the proof of certain standards
to third parties according to the
quality standard EN ISO 9000 ff.
Features
Display of analog process data
Set/act values
Display of digital machine in-
formation
Alarm list
Batch information
Process data
Online visualization
Scope of services
Preparation data set adminis-
tration
Batch scheduling an planning
Online supervision
Alarm management
Process analysis
Production calendar
Report system
Advantages and benefits
Article specific standardization
of processes
Transparency of the pro-
duction
Detect discrepancies
Fast reaction to unexpected
events
Lowering production costs
Higher machine utilization
(PDA)
Management information
system
20
Interfaces
for integrated solutions
20
Interface
recipe systems
A number of dye houses are
already using recipe systems.
By connecting those systems to
OrgaTEX the recipes can further
be used in the production pro-
cess. The transfer of procedures
to the recipe system allows link-
ing the recipes with the dye pro-
gram.
From the transferred recipes
OrgaTEX creates the necessary
preparation data for the con-
nected scaling stations and dos-
ing systems. If an external stock
management system is available
then the actual consumption
data is automatically fed back to
this system.
Interface
ERP/PPS
A large number of companies
are using various computer sys-
tems for order management and
production control. In order to
transfer this data directly to Or-
gaTEX an ODBC interface to an
integration database can be pro-
vided by OrgaTEX.
In this way different data like
batch information etc. can be
transferred to OrgaTEX. On the
other side OrgaTEX provides a
large number of data that can be
made available in the database
once the batch is finished. This
data then can be used by the
production planning system for
calculations and evaluations.
21
Interface
Dye kitchen systems
The currently very popular au-
tomatic chemical and dyestuff
dosing systems are especially
effective if they are intercon
nected to OrgaTEX. The neces-
sary data is available in the batch
recipe. Preparation calls from
the machine controller synchro-
nize the dosing system and the
process. The actual dispensed
quantities are fed back to the
stock management. OrgaTEX
provides programs to display the
requested and processed prepa-
ration calls. In exceptional cases
the preparations can also be
requested or deleted manually.
The chronological logging and
display of all historical prepara-
tion processes allows a state-
ment about the utilization of the
connected dosing system.
Interface
continuous
Via a database interface continu-
ous machines can be connected
to OrgaTEX. This results into a
functionality that is comparable
to the SETEX continuous control-
ler. Management of all machine
settings (sets of preparation
data), batch scheduling, online
information and data feedback
after batch end are possible with
these continuous machines.
Interface
handling/transport
systems
For package dye houses there
are some manufacturers that
offer automatic handling and
transport systems. In connec-
tion with SETEX controller and
an OrgaTEX system the handling
system can receive automati-
cally loading/unloading orders
for the particular machines.
22
OrgaTEX fail-safe and alw
in connection with standard IT solutions
22
How much system downtime
and loss of data can you afford?
How fast can you restart the pro-
duction after a server crash?
High availability systems HAS
MS Cluster Server
2003 Enterprise Server
High availability of the company
based IT systems under eco-
nomical aspects are a central
issue in every company. If com-
pany and production critical ap-
plications like the connection to
a production planning system
or an automatic dye kitchen are
not available then this can cause
immense costs.
Fail-safe and redundant
Advantages
Completely redundant server
hardware platform
Eliminating non-planable fail-
ures
Automatic transfer of the tasks
in case of a problem from one
server to the other in less than
2 minutes
No loss of data by switching
over the server
Performance enhancement of
the system
Simple backup solution
23
ays online
Independent from server hardware
VMware infrastructure
By using server virtualization a
physical server will be divided
into several virtual servers. These
apparently available servers
share the main resources like
main memory, hard disks and
network connections.
Advantages
Provision of new servers in
minutes without the need to
invest in new hardware.
Increasing the capacity utiliza-
tion of physical servers
Moving a virtual machine from
one server to another without
reconfiguration
Simple migration of virtual
machines to the VMware in-
frastructure
Simple backup solution
OrgaTEX on the go
The WEB interface
Citrix access essentials
Access via Intranet or Internet
Wherever your employees are
currently located be it in the
office, in a field office, travel-
ling or in a home office the
centrally provided applications
by Citrix Access Essentials are
available for all users within and
outside of the LAN with the
same functionality, actuality and
performance.
Advantages
Fast and simple access via
Internet or Intranet
Every terminal can be used
Immediate availability of new
applications and information
for travelling employees or
staff in subsidiaries and home
offices
Protection of sensible data by
limitation of the information
access
Encryption of the communica-
tion
Time saving administration by
using a centralized concept
23
24
OrgaTEX service contract
OrgaTEX
Service and support
Activate your potential
An important element of our
business activities are the intro-
duction and realization of opti-
mization features in the textile
finishing plants. Use your exist-
ing machinery and infrastructure
within your company efficiently
and benefit from our long-time
experience.
Conducting workshops and
training courses
Performing process and per-
formance analysis
Identification of optimization
potential
28
Headquarter
Agencies
Service stations
s c h e r m u l y t e x t i l e c o m p u t e r
SETEX Schermuly textile computer GmbH
Hauptstrae 2325
35794 Mengerskirchen
Germany
Phone: +49 6476 9147-0
Fax: +49 6476 9147-31
www.setex-germany.com
info@setex-germany.com
Technical modifications reserved.
All brand and product names are
trademarks or registered trademarks
of their respective owners.
Printed in Germany.
Your Distributor
01.10.2007 SD1400501 OT-KEA-010-0005-2
SETEX America
www.setex-america.com
SETEX Asia
www.setex-asia.com
SETEX Brasil
www.setex-brasil.com
SETEX China
www.setex-china.com
SETEX Far East
www.setex-fareast.com
SETEX France
www.setex-france.com
SETEX Honduras
www.setex-honduras.com
SETEX India
www.setex-india.com
SETEX Taiwan
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