Konfeksiyon fabrikalarında yazılım tabanlı üretim ve takip otomasyonları

Abstract

Bu tez kapsamında, konfeksiyon sektörünün otomasyon çalışmaları ile ilgili bir yazılım geliştirme projesinin detayları anlatılmıştır. Sektörün ihtiyaç duyduğu, kullanımı kolay, çabuk öğrenilebilir bir yazılım geliştirilmiştir. Verim ve hız artırılmıştır. Bunlara ilaveten kullanıcılara verilen kapsamlı eğitim programlan ve yazılımın kullanıcıya kolaylık getiren yönleri sonucunda vasıfsız bir çok eleman işletme içinde önemli fonksiyonlar yerine getirmeye başlamıştır. Bu ise programın başarısı olmuştur. Detaylı bir Sistem Analizi çerçevesinde gerçekleştirilen uygulamalar birçok çözüm ortaya koymuştur. ? Personel ve Sistem Kaynaklarında herhangi bir değişim gerçekleştirilmeksizin Model Tanım ve İhtiyaç Hesaplarının üç aylık süreden ortalama bir güne düşürülmesi, ? Sınırlandırılmamış bilgi girişine izin veren ilişkisel veri yapısı, ? Malzemelerin yazılım içinde otomatik ve tekil kodlanması, ? Çok parametreli model malzeme tanımlarının yapılabilmesi, ? Veri giriş ve çıkışlarının çok kullanıcılı gerçekleştirilebilmesi, ? Karar merkezlerinin üretim denklemleri çerçevesinde yorumlar yapabilmesine imkan veren ekranlar yazılımın en temel özellikleri olmuştur. Ayrıca sektörde mevcut yazılımların birçok eksik yönü bu yazılımda tamamlanmış, bazı yönleri ise geliştirilerek birarada kullanılabilmeleri sağlanmıştır. Yazılım geliştirme ortamı olarak Microsoft Windows işletim sistemi ve Microsoft Access ilişkisel veritabanı yazılımı seçilmiştir. Modüler bir yapı içinde gerçekleştirilen kodlama, kullanıcı seviyesi göz önünde bulundurularak gerçekleştirilmiştir. İşlemlerin mümkün olduğunca menüye girmeden ekran esaslı gerçekleştirilmesi ve birçok sürekli işlemin tek tuşla bitirilmesi hedefine büyük ölçüde ulaşılmıştır.

In this thesis, a software project regarding the automation process in ready-made and textile market is detailed. The developed application with its easy to use and learning tools will bring efficiency and speed to the automation in the market. Apart from the usability and user-friendly interface, it has stated that the training part of the software as well as its "do things and watch results in one click technology" will utilize the staff and help them to take part in the outstanding positions of the manufacturing site. This was the main goal of the project which is believed to be achieved. With a detailed System Analysis, many of the problems of the market has been solved and many of them are improved. The outlined properties of the software application are as follows: ? ? Minimization of The Model Definition and Requirement Calculations" to approximately one day from three months without any change on the system resources: After the preparation of Model Materials with their consumption and color/size details, the problem is to calculate the requirements according to varying color/size production amounts. Apart from these calculations, the amounts of the similar materials in different models should also be consolidated during this period. The most important thing about this process is its number of recalculations because of its unpredictable updates coming from the customers. With the help of the improvement on the calculation period, companies are able to shorten their production cycle and delivery time after the final order. Relational Database Structure permitting unlimited data entry on Model Definitions: None of the data inputting modules contain limitations in the number of items entered. As an example many of the applications on the market says "More than 20 combinations of colors on a model is not supported". As the applications developed for this project is based on a relational database tool, users can always enter limitless items for definitions and can utilize the flexibility of the developed application. Coding of new materials automatically and uniquely in the application without the user interaction and abbreviations: Materials are defined on four different levels:. Material itself,. Color,. Size and. The time the material is ordered or manufactured. VIII Many of the coding systems already available are only dependent on. material and its color,. material and its size,. rarely (not suitable for all materials) material, its color and size together. Additionally users should control the materials' code and its uniqueness. According to the developed and integrated coding system all codes are created automatically and uniquely by the system itself. By the help of this system all order and stock processing actions run accurately. Bounding material to the models on a parameter basis which means a material can have different color and size from its model: In the ready-made industry, all collections of models vary with small details in materials used and this needs a special kind of definition system for each material of the model composed of different colors and sizes. In other words, a model can be in color red and its zip for red-colored model can be yellow. This definition is very common for the industry and many applications support this type of definitions. But in addition to the color dependence, that same yellow zip for the red-colored model can vary for small- sized model when compared to medium-sized model. For small-sized model it can be 15cm whereas for medium-sized model it can be 17cm. This type of definitions known as three-dimensional material definitions are supported by the application developed. One more detail on the definitions which makes the system four-dimensional is the time concept Those materials which are dependent on color can vary in color tones in different times. Because of that reason, material definition should also support the materials production or ordering details. This concept is also supported. Multi-user environment with groups and users defined separately and securely. A complete multi-user environment with levels of security is developed. Security is designed on the group level as the circulation in the personnel is very dynamic in the market According to the security system, all actions are defined and permitted only for specific groups. All the users belonging to this group will inherit the group's rights and the applications run independent of user names. Those user groups listed below are created according to their functions in the system and their responsibility in real-time decisions:. Everyone. Accounting. Customer services ? Developers. Super users Cut-house planning Material planning and Logistics Print/Embroidery planning Storage controls Sub-Contractor product/material flow control IX Allow users to reach manufacturing details and decide ordering units and etc. on one screen using Order Functions in Figure 1. Order functions is the heart of any textile production job. The variety of software packages used widely in textile industry, usually are not capable of handling these functions together. The program was designed to satisfy the following four order functions: Function 1 This function defines the consolidated requirements. Using the unit consumption in each model, this function yields the total requirement for each model. Consolidating each model yields the total requirement for the whole production batch. Function 2 Excess material from previous orders affects the amount to order. The consolidated model requirement minus excess material yields the total amount to order for this period. Function 3 One of the major problems of the ready-made industry is that the amount of material received may be different than the ordered amount As a result of the orders the company can get more or less than the ordered amount. For 950 m required amount the order is 1000 m. When the consumption is recalculated, the required amount may change to 1080 m. Classic software can solve this problem by making an extra order. Actually the amount company got is 1 100 m and there may be no need for extra order. Figure 1 Function 4 Actual used amounts affects the next order for the same model and this makes the fourth function. There are two conditions for this function. 1. The material used in production is less than the calculated amount. The next order must be calculated for these new consumption amounts. 2. The material that has to be used in production is more than the ordered amount. In real life, this second condition appears more. Generally the consumption in production is more than the calculated amount because of miss use of production material. Solving these four functions at the same time gives us the material requirement for the process. The variety of software packages used in textile industry do not solve or show these functions at the same time. For an effective material management, the user should see these four functions' results at the same time. This requisite is satisfied in the program. For the development environment, Microsoft Windows Version 3.1 that runs on Novell Netware as an operating system and Microsoft Access [1], [3] as a database coding tool is selected. Microsoft Access was used to create the data pools and to process the data. Microsoft Excel (used for calculations done outside the program) and Microsoft Word (used for creating reports) greatly supported the project. Microsoft Visual Basic [2], [4], [5] was used as a run shell and to create supporting programs. The code and the database system is designed to be modular with modules of;. Materials' pool All material details indexed with automatically assigned material codes. This pool is the base of all modules which are all dependent to the material details and movements. ? Models' pool All models with their summary information and color/size amounts are included in this pool. Additionally materials forming a model with their consumption and dependencies are also stored in this pool.. Consolidation and order processing (+ storage control) This module is designed to make all the calculations for the models and materials. With the help this calculations and the other modules it also deals with the order processing and its related items coming from the storage. According to the material consumption in the production cycle and the orders processed it automatically controls the stock and allows user interaction. XI Models' archive At the end of each season, the models and its related transaction are no more used apart from the archive purposes. Because of that reason, all data of the last season is archived and the pools became less crowded. This module also enables users to retrieve all or some models from the archive according to their security level. Cut-house actions This module is one of the production control modules. The main material of ready-made and textile industry is cloth and its cutting, consumption and separation for the models all controlled in this module. Print/Embroidery actions As another production module, print/embroidery controls models' actions and follows the material flow. Additionally it prepares reports for the current status of flie production. Sub-contractor actions Controls material output to the sub-contractors and product input from the sub contractor. It also follows the repairing actions. Reports each sub-contractors' production for the accounting department for payments and financial planning. Delivery actions Final level of production modules. It creates a feedback to the production modules with the items delivered and allows comparison of planned and actual model productions. General product planning and control module Collects all the data from the production modules and creates screen and paper reports. It is just a read-only module and helps users to control the production process, its progress and its problems. This module is used periodically in the day-time to see the progress of production. Reaching the important actions and data on "one click technology" rather than reaching them on a hierarchic menu system is also one of the design goals and the project is concluded with the full satisfaction of the beta-site users.