What is
the G.PRO SDT (Shop floor Data Tracking) System?
- What is the G.PRO SDT
(Shop floor Data Tracking) System?
The G.PRO Shopfloor Data Tracking System (SDT) is a real-time shop-floor production tracking system designed specifically for the garment industry to improve production control and provide management information through shopfloor information and reports delivered in real-time.
- What is the G.PRO SDT for?
The G.PRO SDT helps increase productivity. With real time information on-hand for managers, problems can be anticipated and quick responses quickly taken. All work-in-progress can be closely monitored, giving the management information concerning shopfloor productivity and production status of their factories/production lines at any given time.
- Can the G.PRO SDT be used as a payroll system?
The G.PRO SDT is not a payroll system. However, it can export data in text format for any third-party payroll system.
- What are the major components of the G.PRO SDT?
The G.PRO SDT consists of the SmartTag, SmartTerm, SmartBase and the SmartTray
components.
 |
How does the G.PRO SDT work?
- How can the G.PRO SDT help increase a garment factory's productivity?
The G.PRO SDT is able to monitor the productivity of all machine operators in real-time. Instantaneous reactive measures can be taken, especially if bottlenecks occur.
- How does the G.PRO SDT replace the traditional Job-Ticketing system?
The G.PRO SDT replaces conventional job tickets with the SmartTag (robust and holds electronic data). The SmartTag can be read/written on. With this Tag, the System allows its users and managers to have real-time shopfloor production status information at their fingertips.
- How does the G.PRO SDT provide real-time information?
Every operator has a SmartTerm (terminal) that captures production data in real-time and transmits the data through a computer network. Data can then be assessed through the G.PRO Infomaster Software suite which presents live production data on demand in the form of graphs and reports.
|
- Where and when can I get back my investment on the G.PRO SDT?
All the customers who have used our system report that they have gained back their investment (through the savings generated by the G.PRO SDT) within an average period of ONE year.
- What type of reports can I get?
Daily Production Summaries, Orders Production Status reports, Daily Production Earnings By Group, Daily Production Work Hours, Productivity Analysis reports, Standard Rate Reports, etc.
- Is it possible to view a branch's production information from the head office?
Yes. Production information of the branches can be viewed from the head office via a Wide Area Network (WAN).
- Can the G.PRO SDT provide Work-In-Progress feedback data?
Yes.
- Does your system track off-standard time and job interruptions?
We can track both off-standard time and job interruptions.
- Can the G.PRO SDT help me trace the operator who has committed sewing defects?
A report stored in the computer records all the operations that have been done by the operators concerned. By matching back the bundle tag number, it is possible to determine who has made the defect on the particular bundle.
|
- How much time will training for operation take?
The Project Management team will be stationed at a site to train the users until users can handle the system themselves. This will vary between anything from 3-5 months, depending on the size of the factory.
- What happens if there is a power failure?
Each SmartTerm has a buffer memory, which can last for a period of 2 days. Each SmartTerm is able to function independently during power failures.
- How many computers do I need, and can I use my present computer system?
The G.PRO SDT requires a minimum of 1 server and 2 workstations. One of the workstations will be placed in the cutting department while the other will be placed on the production floor. If the current PC meets the minimum system requirements, you can still use your present computer system.
- Do we need extra manpower when we use the G.PRO SDT?
The company requires a G.PRO administrator who is computer literate.
- How can my staff understand and make full use of the G.PRO SDT?
The G.PRO SDT uses the Windows Operating System and your line and system operators will be fully trained by the Project Management Team.
- Is the G.PRO SDT user-friendly with the Machine/Sewing Operators?
The Machine operators will find the G.PRO System extremely helpful because it helps them increase their earnings.
The interface is also simple and user friendly.
- What type of configuration is needed?
Below are the Minimum System Requirements:
| |
A. Hardware |
| |
1. System Server c/w (HP server recommended) |
| |
Pentium III 600 Mhz and above
Minimum 128MB RAM
1 unit 1.44MB Floppy Disk Drive
Minimum 9.1GB Hard Disk storage space
1 unit Tape Drive backup unit
1 unit 52X CD ROM
1 unit SVGA color monitor c/w Windows NT driver
1 unit UPS 1KVA |
| |
2. Client Workstation c/w |
| |
Pentium III based CPU
Minimum 128MB RAM
1 unit 1.44MB Floppy Disk Drive
Minimum 9.1GB Hard Disk Storage space
1 unit 52X CD ROM
1 unit S3 Trio3D AGP Display Card
1 unit SVGA color monitor s/w Windows NT driver
1 unit UPS 700 VA |
| |
|
| |
B. Software |
| |
1. Windows NT Server with 5 clients license with service pack 3
2. Windows NT for Workstation OEM CD
3. InterBase 5.05 Simultaneous 10 User Full Pack |
| |
|
| |
C. Networking Accessories |
| |
1. RS232/485 4-port Network Interface card
2. 32 bit PCI Ethernet Network Interface card
3. 8 or 16 port 10Base-T Ethernet Stackable Hub
4. Network UTP cable
|
| |
|
| |
D. Printers Recommended : |
| |
1. Dot matrix printer 24-pin 330 cps/80columns
2. Color ink jet printer * Mnimum 1 unit |
|
The SmartTag
The SmartTag is an industrial grade reusable read/write tag that replaces traditional job tickets. It stores all relevant cutpiece/bundle information and operation status.
- How many SmartTags do I need?
Every bundle requires 1 SmartTag. Since there can be multiple bundles in the line at one time, we recommend 50 SmartTags per SmartTerm.
- What if the tag gets lost?
By using the bundle information, the administrator can identify the missing tag from the database. A new tag can be initialised to replace the missing tag.
- What is the life span of a SmartTag?
It can last for more than a million times of read(ing) and write(ing).
- What if the operator forgets to tag the bundle tag to the SmartTerm?
Supervisors can check the data from the computer to make sure all operations have been claimed by the operators. The G.PRO software can track & trace any unclaimed operations.
- How many tags do I need for a bundle?
One SmartTag is needed per bundle.
- Is there a possibility of a double claim on the same operation?
Each operation can only be claimed once.
- Do we have to use the Employee Tag each time we make a claim?
The Employee Tag is used only at the beginning of the workday or when the Operator changes workstations.
- How many operations can be stored in a SmartTag?
One SmartTag can store up to 128 operations.
- What other data can be stored in a SmartTag?
MO Number and Bundle Quantity, Fabric Batch Code, Work Stage, Garment Part, Employee Tag Number, Bundle Tag Number, MO Cut Lot, Color, Style and Size. These data can be read at the SmartTerm.
- Can I change the information that has already been stored in the tag?
Yes you can, but you will have to erase the old records and reinitialize the tag.
- How do I relate each SmartTag to its corresponding bundle?
Every SmartTag has a tag number to match with a bundle number. A bundle listing is stored in the computer; in the event of a mix up, a SmartTag can be easily traced back to its corresponding bundle.
- Is sequence important when claiming an operation?
As long as all the operations are assigned to that operator, it does not matter which operation is being claimed first.
- What if the operator tags an operation that is not supposed to be performed by him/her?
The supervisor will be able to make the correction from the computer.
- What if the operator tags in at the wrong sewing station?
She/he has to inform the supervisor. The supervisor can then rectify the mistake by correcting the information on the computer as well as reinitializing the tag.
- Can an operator finish sewing in the morning but only claim the operation in the evening?
The sewing time for that particular bundle will be extremely long since the computer records the Start Time to be in the morning but the End Time to be in the evening.
- Is it possible for the operator to claim an operation before a bundle is sewn?
It is possible to do so. However, the end time of a bundle is the start time of another bundle so the following bundle will have a longer sewn time.
- Can the G.PRO SDT help me trace the operator who has committed sewing errors?
A report stored in the computer records all the operations that have been done and the operators involved. By matching back the bundle tag number, it is very easy to determine who has sewn the bundle.
- How is information stored in the SmartTag?
Data from the computer is downloaded onto the SmartTag in a few seconds. This process is called SmartTag Initialization.
|
The SmartTerm
The SmartTerm (patent pending) is a microprocessor-based terminal that is mounted on every workstation to capture job-flow data. It reads and validates job claims from Smart Tags with an easy touch. It then transmits real-time job transactions to the G.PRO server. Its memory buffer stores approximately up to two days of transactions. It is powered by a 12V battery power supply.
- How many SmartTerms do I need?
You will need one SmartTerm per sewing station.
- Can the machine operators do more than 1 operation on the SmartTerm?
When the supervisor assigns more than 1 operation to the machine operator, they can tag in their claim. The SmartTerm can store up to 5 different operations per order and up to 14 orders at one time.
- Can SmartTerms be relocated from one sewing machine to another?
SmartTerms can be located anywhere depending on the assignment.
- Can operators obtain information on the quantity sewn and earnings made for that day?
Operators can get information on the total quantity sewn.
- Is it possible for a SmartTerm to collect other information besides quantity sewn?
SmartTerms can also detect the Start and End Times of a sewing operation.
- Can a SmartTerm take more than 1 operation at a time?
The SmartTerm can handle up to 5 operations at a time.
- Is the SmartTerm safe for users in a manufacturing environment?
The SmartTerm uses a 12 volt DC power supply, so it is perfectly safe for users.
|
The SmartBase & SmartTray
The SmartBase and SmartTray are semi-automated devices used by the cutting department to download new cut lot bundle information into the SmartTags. One SmartTray holds ten SmartTags at a time.
- How many SmartBases & SmartTrays do I need?
It is recommended for you to use 1 SmartBase & 10 SmartTrays for 100 stations.
- How long does it take to initialize?
A few seconds.
- What happens if I initialize less than 10 tags with the SmartBase?
It will pose no problem as long as the SmartTag are arranged in sequence.
|
What is the G.PRO Shop floor Data Tracking System?