Real time weaving monitoring and production reporting is still one of the primary functions of a MES system (Manufacturing Execution System) for a textile plant. WeaveMaster is a loom monitoring system. Through a Graphical User Interface (GUI), WeaveMaster users are constantly informed about the actual situation in the weave room resulting in faster reactions to problems and an increased efficiency. Powerful analysis tools allow quick identification of poor performing machines and bottlenecks in planning, resulting in an optimal usage of production capacities.

With today’s small order quantities and short delivery times, scheduling has become a critical function for the textile mill. WeaveMaster offers the planning department an interactive tool allowing them to optimize loom loading based on real time information.

Modules

WeaveMaster Real Time Monitoring
WeaveMaster's most important real time analysis tool is the “Color Mill”. On this color-coded layout of the mill, the machines are displayed in a number of colors, each color indicating a certain machine status or alarm condition.

WeaveMaster Reporting
All data is stored in an Oracle relational database. By means of a powerful report and formula generator, users can define and configure their own calculations and reports. Once a report layout has been defined, the user can select it for a variety of keys such as by machine type, by weaver, by style, and for any period such as shift, day, week, month or even year.

WeaveMaster Production Scheduling
- The graphical plan board : With WeaveMaster, the planner conducts his demanding job by means of an electronic plan board. Integrated with the style database and the monitoring system, the plan board software automatically calculates the time needed for every order and warp and updates it based on real time information such as actual speed, efficiency and stop level.
- Printing of warp tickets and piece labels : Based on the loom loading and the information available in this database, WeaveMaster prints the beam ticket, piece labels as well as instructions for warp preparation, drawing in, etc.
- Warp out prediction and yarn requirements calculation : WeaveMaster can calculate yarn requirements for warp as well as filling yarn. Several reports are available such as a consumption report used to transfer yarn from inventory to the weave room and reports with requirements of yarn to be dyed or to be purchased.

Optional Modules

Yarn inventory management
The software module for yarn inventory management is fully integrated with the WeaveMaster planning software. The first function of this module is the management of the yarn delivery contracts with all its technical and commercial details.

Traceability
For each cloth roll coming out of the mil, the system reports about yarn lots used stop levels and quality information.

Temperature and humidity monitoring
BarcoVision’s climate monitoring solution consists of temperature and humidity sensors connected to one of BarcoVision’s Data Units and a software module. With this software, actual temperature and humidity values are displayed in the weave room layout and in the trend reports, efficiency and stop levels are compared with the temperature and humidity levels as function of time.