Diamond Fabrics Ltd (Lahore, Pakistan)
implements BMSvision MES solution
in its denim division
Diamond Fabrics, part of Pakistan’s premier vertically
integrated Sapphire Group, has selected Belgian based BMSvision
as a partner for its prestigious MES project, keystone in
the roadmap towards a I 4.0 company.
Mr. Tayyab Abdullah explains: ”We were looking for a solution
that goes far beyond the traditional production and machine
monitoring. In order to prepare for an I 4.0 compliant
manufacturing operation, we need a Manufacturing Execution
System (MES) that can manage and track the entire production
flow, from yarn to finished fabric. Furthermore, the system
needs to seamlessly integrate with the SAP ERP system in place.
After a thorough market research and various demo’s and
workshops, we selected BMSvision as our partner because of their
vast experience in the industry and the turnkey project approach
including hardware, software and services”.
In a first phase of the project, the warp preparation
department including ball warping, sizing and rebeaming as well
as the complete denim finishing department are covered. These
are the most challenging operations within a denim mill.
In a second phase, all looms will be connected. Each machine
in the preparation and finishing department is equipped with a
state-of-the-art touch screen based DU11 data collection
terminal with wireless barcode scanner.
Once the production orders are released by the SAP system,
the planning department uses the BMSvision scheduling software
(PlanBoard) to assign the orders to the individual
machines. Orders are started at the machine by scanning the
barcoded batch travel card. The PlantView
application visualizes the complete production process in real
time and highlights any possible deviation from standard.
A powerful reporting tool featuring interactive reports and
charts, allows the users to create their own calculations and
reports. After each production step, the MES systems prints a
barcoded ticket and all relevant production data is transferred
to the SAP system.
Diamond’s request to monitor and document the flow of goods
throughout the whole production chain, to be able to trace all
materials used and to know the current status Work in Process
all the time, is handled by BMSvision’s traceability
Besides managing the production flow, Diamond Denim also
implements the BMSvision EnergyMaster solution. Mr. Tayyab
Abdullah: “Energy consumption is becoming a very important
factor in the overall operating cost of our factory. With ever
rising energy prices and increasing environmental legislation,
energy management has become a very critical success factor to
run our business in a profitable way.
The EnergyMaster system makes all our energy
streams transparent and allows to allocate the exact energy cost
to each production batch”. The finishing lines are equipped with
power meters and various flow meters to monitor consumption of
compressed air, steam, water, gas and caustic.
All these meters are connected to the DU11 data collection
terminal and combining consumption with production data allows
correct calculation of the energy cost for each production
batch. Excessive consumptions or consumptions while the machine
is idle, are immediately detected and highlighted.
BMSvision is proud to be a partner of Diamond Fabrics in the
continuous improvement program of their operations.BMSvision is
represented in Pakistan by ZONA Technologies.
About Sapphire Textile Group
Sapphire Textile Group is one of the largest textile
producers and exporters in Pakistan. The manufacturing from yarn
to finished fabric is done in various plants using the most
advanced machinery and equipment. Its customer base includes the
industry’s biggest names in Asia, Europe and North America.
BMSvision, established in 2007 as a carve-out from the Barco
group, is a leading supplier of Manufacturing Execution Systems
(MES) for discrete manufacturing, with focus on the textile and
plastics industry. Under the brand name BMSvision (formerly
BarcoVision) and with over 40 years of experience as a former
division of the Barco group, BMSvision offers a wide range of
systems aimed at productivity, quality improvement and energy
management. BMSvision is present at key locations around the
world, either with own branch offices or through a world wide
network of agents and service centers.