Computer System

The word computer is derived from the Latin word 'computare', which
means 'to calculate', 'to count', 'to think', or 'to sum up'.

But now-a-days in addition to handling complex arithmetic computations,

computers perform many other tasks like accepting, sorting, selecting,
moving, comparing various types of information.

A computer is a fast and accurate data manipulating system that is

designed to automatically accept and store input data & then process
them & produce output results (Information) under the directions of a
stored program.

or

A computer is a machine or device that performs processes, calculations

and operations based on instructions provided by a software or hardware
program. It has the ability to accept data (input), process it, and then
produce outputs.

Data

Data is plural of the word Datum which means fact. A fact can be any
characteristic of an object. Data is represented by symbols i.e. 1, 4, 5,
9, 0 or A, B, G, T, R or %, ?, $.

Not all data make sense to a person when looking at the data.
Information
Data is a raw material for information. When data is processed,
organized, structured or presented in a given context so as to make it
useful, understandable, it is called information.

The data shown in the previous example was of no use but after doing
some processing on that data we can produce information from that data
which makes sense to us and the information from the data is
BANGLADESH.

Evolution of Computer
Generation 1st 2nd 3rd 4th 5th
TimeSpan 1941-1956 1956-1963 1964-1971 1971- Present
present and
beyond
Technology Vacuum Transistors Integrated Microchips AI
Tubes circuits
Size 30-50 Filled half Comparatively Can be Smallest
feet a room smaller fitted in a
pocket

Components of Computer

A computer system essentially has three important components:

➢ Input Unit: This component of the computer accepts instructions
and data.
➢ Central Processing Unit (CPU): This unit performs processing of
instructions and data inside the computer.
➢ Output Unit: This unit communicates the results to the user.
 Fig: Working Procedure in Computer

The terms hardware and software are almost always used in connection with
the computer
The Hardware: The hardware is the machinery itself. It is made up of the
physical parts or devices of the computer system.
➢ System Unit
➢ Input Devices
➢ Output Devices
➢ Storage Devices

The Software: The computer hardware itself is not capable of doing

anything on its own. It has to be given explicit instructions to perform the
specific task. The computer thus functions according to the instructions
written in the software.
➢ Operating System
➢ Application Software
➢ Utility Software
Types of Computer

Scope of Computers In Textile Industry

CAD
CAD stands for computer aided design. Computer-aided design (CAD) is the
use of computer systems to assist in the creation, modification, analysis, or
optimization of a design.
CAD software is used to
➢ Increase the productivity of the designer,
➢ Improve the quality of design,
➢ Improve communications through documentation, and
➢ To create a database for manufacturing.
CAD output is often in the form of electronic files for print, machining, or
other manufacturing operations.

Some popular CAD Software

There are many CAD software solution providers for the garment and textile
industry. Here is a list of such popular CAD systems.
•AccuMark Pattern Design Software by GerberTechnology
•CAD.Assyst by Human Solution AssystAVM
•Modrais by LectraSystems
•Optitex Pattern Design software by Optitex
•TUKAcad by Tukateck Inc.
•Fashion Cad by Cad Cam Solutions Australia Pty.Ltd
•SDS-ONE APEX3 from Shima Seiki
•PAD System
•GT CAD by Genuine Technology and Research Limited
•Richpeace CAD system
CAM
❖ Computer-aided manufacturing (CAM) is the use of computer software
to control machine tools and related machinery in the manufacturing of
workpieces/products. CAM may also refer to the use of a computer to
assist in all operations of a manufacturing plant, including planning,
management, transportation and storage.
❖ Its primary purpose is to create a faster production process and
components and tooling with more precise dimensions and material
consistency, which in some cases, uses only the required amount of raw
material (thus minimizing waste), while simultaneously reducing energy
consumption.

CIM
Computer-Integrated Manufacturing (CIM) systems integrate or link CAD and
CAM systems. CIM is a manufacturing process in which all the functional
elements and process steps are integrated with the help of computer, so that
the process operates in the most effective and efficient way.

These combined systems link the design development, production planning and
manufacturing systems altogether. Companies that use CIM are able to design
a product in one country and manufacture it overseas where labor costs are
lower.

CIM is used to set, monitor and control the key parameters like
•Temperature, pressure and time of polymerization
•Viscosity of molten polymer
•Extrusion rate
•Draw ratio
•Fiber fineness
•Finish add-on, etc.

CIM monitoring system are two types

•On-line
•Off-line
On-Line System:
➢ On-line monitoring system is the one which is installed on-board the
machine or equipment’s for monitoring and controlling operation.
➢ On-line monitoring systems use PLC controls. PLC (Programmable Logic
Controller) have been gaining popularity on the factory.
➢ Constant and continuous monitoring ensures consistent process
performance and product quality.
➢ Quick detection of any malfunction of the machine.
➢ Reduction in personnel intervention
➢ Increase deficiency and productivity
Off-Line System
Off-line monitoring system is off the machine and performs the task
related to the machine independently.

Automation:
Automation is the use of machines, control systems and information
technologies to optimize productivity in the production of goods and delivery
of services. In other words- Automation is a technique of automatically
controlled operation of an apparatus, process or system by PLC (Programmable
Logic Controller) mechanical or electronic devices that takes place without
human observation, efforts and decision.
Automation Tools:
Computer-aided technologies now serve the basis for mathematical and
organizational tools used to create complex CIM systems (Both CAD & CAM).
Different types of automation tools are
➢ ANN -Artificial Neural Network
➢ BPM -Bonita Open Solution
➢ DCS -Distributed Control System
➢ HMI -Human Machine Interface
➢ SCADA -Supervisory Control and Data Acquisition
➢ PAC -Programmable Automation Controller
➢ Instrumentation
➢ Motion control
➢ Robotics
Advantages of Automation:
➢ Increased through output or productivity.
➢ Improved quality or increased predictability of quality.
➢ Improved robustness (consistency), of processes or product.
➢ Increased consistency of output.
➢ Reduced direct human labor costs and expenses.
➢ Performing jobs beyond human capability
Disadvantages of Automation
➢ High initial cost of installation
➢ High cost of research and development
➢ Security threats
➢ High cost of maintenance
➢ Unexpected production delays
➢ Limited scope
➢ Lack of flexibility
➢ Unemployment

CAT
CAT (computer aided testing) provides a digital and automatic solution for
quality testing, evaluation and control of textile processing and products by
using computer-related testing techniques, such as computer vision and
artificial intelligence.
In the textile industry, testing traditionally relies on heavily subjective
estimation without objective testing instruments. Computer aided testing
technology and methods have been used to replace these traditional
subjective evaluation methods.
Their use falls into two main categories:
•Recording and calculation of results
•Automation of the test procedure.
Both of these uses may be found in the most advanced instruments.
Some of example of testing machines
➢ Martindale abrasion tester
➢ Fabric inspection machine for knitted and woven fabrics
➢ Spectrophotometer (shade matching, recipe formulation, fastness
assessment, batch sorting)
➢ Computer color matching (CCM)
➢ Trash analyzer
➢ High Volume Instrument (HVI)
➢ Advanced fiber information System (AFIS)
➢ Uster tester-5 (UT-5)
CAA
CAA stands for Computer aided administration. Now a day’s textile and
apparel industry use a lot of software to promote their productivity.
MIS
• A management information system (MIS) is an information system used
for decision-making, and for the coordination, control, analysis, and
visualization of information in an organization.
• MIS uses the information technology, people, and business processes to
record, store and process data to produce information that decision
makers can use to make day to day decisions in order to ensure the
growth of the business.

DBMS

A software package/ system design to facilitate the creation and maintenance

of a computerized database. Actually, the DBMS is a general-purpose
software system that facilitates the process of defining constructing,
manipulating and sharing databases among various users and application.
EPOS
EPOS stands for Electronic Point of Sales. An EPOS is a computerized system
for recording sales, taking payments, monitoring stock and generating reports
within the retail and hospitality sectors. EPOS systems typically consist of a
touchscreen computer, receipt printer, barcode scanner, cash drawer and
software and come in a variety of configurations, shapes and sizes.
There are 2 key elements to any EPO system
• Hardware and accessories.
• The software

Necessity of EPOS system

• Allows you to record exactly which items are being sold to whom
• Integrated card payment speeds up transactions and dramatically
reduces errors
• Automatic inventory management helps you keep on top of your stock
levels
• Real-time and comprehensive reports allow you to make better business
decisions.
• Future proof, add a Customer Relationship Manager (CRM), Appointment
Booking System and Loyalty Program
• Improve store efficiency and improve customer satisfaction which
results in higher profit margins.
Different department of a Textile Industry
Production Maintenance Quality Control R&D
Designing. Ware Housing Procurement Sales
Marketing Human Resources Accounts Finance
General Administration.

How different departments use computers?

➢ Production
Production Planning, Process control systems
➢ Maintenance
PPM (Planned plant maintenance systems). (Database of part and equipment)
➢ Quality Control / R&D
Simulations, Sampling and results databases,
 ➢ Designing
Simulations, CAD
➢ Ware Housing / Stores
Inventory Control Systems, Stock Forecasting Systems.
➢ Finance
Financial Reporting Systems, Financial management and forecasting tools
➢ Accounts
Accounting systems are usually integrated within many other departments of
an organization as whole software package.
➢ Purchase /Procurement
Purchase Order Processing Systems
➢ Sales
Sales management, Sales Order Processing Systems.
➢ Marketing
CRM [Customer relationship management], Market research Systems
➢ Human Resources / Personnel
Pay Roll Systems, Employees Performance Reporting Systems, Automated
attendance.
➢ General Administration
Reporting Systems, security surveillance software.

Some Areas where computer is used in Spinning

The application of computer software in spinning sector mainly divided into 4
categories:
1.Balemanagement
2.Fibertesting
3.Yarntesting
4.QualityControl
Bale Management:
The choice of cotton bales according to the fiber characteristics in order to
achieve acceptable and economical processing condition and a constant yarn
quality is called bale management. Some of the bale management software
•BIAS software
•EFS software
BIAS software:
Bale Inventory Analysis System is developed by M/S Zellweger USTER.
According to this system, mix is formed in a way that bales taken from stock
are having minimum variation in quality parameters from bale to bale and from
day to day.
Steps of bale management of BIAS:
•100% testing of bales: All the bales received are tested in HVI. Tested
results are exported to BIAS either directly or by floppy disk.
•Categorization of Bales: All bales tested are numbered and divided into
categories. Eg. If categorized according to SCI and MIC.
•Mix Formation: Eg. mix for 20 bales.
•Print out of Mix Plan: BIAS system will consider all the necessary data and
print out the bale mixing plan to ensure optimum result. Average of all quality
parameters will be printed. Thus, BIAS helps to reduce variation in quality
parameters on a day to day basis for particular r mixing.

EFS Software
The Engineered Fiber Selection (EFS) system, developed by cotton
Incorporated, is one of the leading programs in bale management.
The EFS works in conjunction with the High-Volume Instrument (HVI) system
to access and manipulate data of cotton fibre attributes. It consists of
capable software programs and electronic data exchange system that
collectively handle management of cotton bale information, selection of cotton
bales for particular spinning systems and planning blending strategies suitable
for different levels of yarn and fabric quality.
The EFS performs 3 basic functions
➢ The first function is to handle the logistics of cotton bale information
efficiently throughout the flowchart of the cotton market.
➢ The second function is to provide different fiber selection and blending
strategies suitable for different yarn types and textile end products.
➢ The third function is to assist the textile mill in determining optimum
levels of yarn quality with respect to the required levels of fiber
attributes and the cost of fibres.
Fiber Testing:
Conventional methods of evaluating cotton fibre qualities are time consuming
and operator dependent. The development of high-volume instrument (HVI)
and Advanced fibre information system (AFIS) are capable of measuring as
many of these properties as possible, accurately and at a fast rate too.
High Volume Instrument (HVI):
In HVI, various conventional fibre-testing instruments have been automated
and integrated into a single compact operating system by using the state of
art technology in mechanics, optics and electronics. High volume instrument
systems are based on the fibre bundle testing, i.e., many fibres are checked
at the same time and their average values are determined. Example: USTER
HVI, Premier HVI, Lintronics HVI
The different HVI modules are
1. Length and strength module
2.Micronaire module
3. Color and trash module
These modules are used to measure the following fiber parameters
•Fiber length, Uniformity, Short fiber index, Micronaire, Maturity index,
Strength, Elongation, Color and Trash, and Moisture content.

Advanced fiber information system

AFIS provides single fiber information and is distinguished from earlier and
existing methods by providing distributions of basic fiber properties.
AFIS is an optical system. The fiber sample is opened into individual fibers in
the opening unit, and are then passed in the free airflow by the opto-
electronic sensor. The pulses generated by the sensor are converted into
electronic signals and evaluated by a computer.
The different AFIS measurement modules

•The L and M module: measure fibre length & diameter

•Trash Module: Determines the no. & sizes of foreign matter, dust and trash.
•Nep Module: analyzing nep count & nep size
•Multi-data module: For simultaneous determination of neps, fibre length
&dia., trash, dust of sample.
•Auto jet module: For automatic loading of test sample.
So, AFIS measures the following fiber parameters
•Fiber Length, Fiber maturity, Trash content, Nep content

Uster AFIS Pro 2

Yarn tester:
Uster tester 6:
Capacitive and optical sensor technology in the USTER® TESTER 6 opens the
door to spinning mill management. Showing spinners, the full picture, with all
the options for assured quality and cost-effective production.
Functions of Uster Tester:
•Capacitive measurement of mass variation & imperfections of staple yarn
•Hairiness amount measurement
•Hairiness length measurement
•Yarn diameter, shape, density, diameter variation can be measured
•Yarn twist measurement
•Yarn trash, dust of cotton blends measurement
•Yarn count & count variation measurement
•Fancy yarn measurement i.e. number of slubs, mass increase, slub distance,
mass decrease after a slub.
USTER TENSORAPID: Tensile tester for both staple and filament yarns.
Delivering precise data for yarn strength and elongation which is recognized
by global standards. It provides vital information, both for the downstream
process or end-use.

USTER CLASSIMAT: Instrument for classification and analysis of yarn

faults in staple yarns like thick & thin place.

Quality control software:

USTER® SLIVER GUARD: The Online Sliver Quality Monitoring and Control
System
•USTER®JOSSI VISION SHIELD T: Detection and elimination of natural
and synthetic contamination
•USTER® SENTINEL: The Ring Spinning Optimization System
•USTER® QUANTUM 3: The preventive yarn clearing system
•USTER® QUANTUM EXPERT 3: The yarn quality assurance system

Future Trend: Industry 4.0

Industry 4.0 refers to a new phase in the Industrial Revolution that focuses
heavily on interconnectivity, automation, machine learning, and real-time data.
Industry 4.0, also sometimes referred to as IIoT or smart manufacturing.
The system that uses some transformative technology to connect physical
production and operations with smart digital technology, machine learning, and
big data to create a better-connected ecosystem for companies that focus on
manufacturing and supply chain management can be defined as Industry 4.0.
Transformative technology includes
•Advanced automation and robotics (including collaborative robots or ‘cobots’)
•Machine-to-machine and human-to-machine communication
•Artificial intelligence (AI) and machine learning
•Advanced sensor technology and data analytics
Origin of Industry 4.0:
The Industry 4.0 concept comes from Germany. Germany has one of the most
competitive manufacturing industries in the world and a global leader in the
sector of manufacturing equipment. Industry 4.0 is a strategic initiative of
the German government that traditionally heavily supports development of the
industrial sector.
The basic concept was first presented at the Hannover fair in the year 2011.
The main idea is to exploit the potentials of new technologies and concepts
such as:
✓ Availability and use of the internet and IoT,
✓ Integration of technical processes and business processes in the
companies,
✓ Digital mapping and virtualization of the real world,
✓ ‘Smart’ factory including ‘smart’ means of industrial production and
‘smart’ products.
Need for Industry 4.0
✓ To convert the regular machines to self-aware and self-learning
machines to improve their overall performance and maintenance
management with the surrounding interaction.
✓ Industry 4.0 aims at the construction of an open, smart manufacturing
platform for industrial-networked information application.
✓ •Real time data monitoring, tracking the status and positions of product
as well as to hold the instructions to control production processes are
the main needs of Industry 4.0.

Evolution of Industrial Revolution (1.0 to 4.0)