Digitalization

LTM in depth

15 Mar 202128 dk okuma

SINCE 2002

Ünlü Tekstil barcoding system

LTM in depth

is actively used in production to ensure

TRACEABILITY - QUALITY - EFFICIENCY

Barcoding System

We collect every bit of information throughout the manufacturing processes and feed a big data warehouse with a unique barcode system.

LTM in depth

This barcode system is integrated to the whole production process which ensures traceability, quality and productivity.

LTM in depth

How

First we generate a unique barcode for every entity involved in the manufacturing process.

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Example Sewing Process

Before a model is stitched the pieces of models are put in a basket in groups of 20 which has a unique barcode and holds reference information to the 20 product barcodes.

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Ali is a sewing machine operator and he has his own unique employee barcode. He scans his own employee barcode when he starts work at 08:00 am.

Ali is responsible for one operation: sewing the collar.

Ali scans the operation barcode of sewing collar at 08:00 am

He finishes the first basket and scans basket barcode at 08:30 am

He finishes the second basket and scans the barcode at 09:10 am

Ali starts the third basket but he has a situation, he scans the machine malfunction barcode at 09:20 am

He finishes the third basket and scans the barcode at 10:00 am

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The Outcome

All the information generated in the process is recorded by the software system. So we know that:

Ali finished the collar sewing operation of first basket in 30 minutes, second basket in 40 minutes and the third basket in 50 minutes

Ali had a machine malfunction which caused to a 15 minutes delay

We know exactly which products’ collars are sewed by Ali

The system calculate Ali’s efficiency instantly. The efficiency ratio is more than 95%, so the light in front of Ali is green. If the ratio was between 90% - 95% the light would have been white. If lower than 90% the light would have been red.

LTM in depth

Example Quality Control Process

When a product is assembled its unique barcode is sewed to the product. After the assembly lines rest of the operations are traced on a per product basis.

Ayşe is a quality control expert and she has her own employee barcode. She scans it when she starts work.

Ayşe finishes controlling a product and scans the product barcode at 13:00 pm

She finishes controlling another product and scans the product barcode at 13:03 pm

She controls then finishes another product at 13:06 pm

She finds a fault in the collar of another product and scans the related quality barcode at 13:07 pm

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Ayşe finishes controlling a product in 3 minutes average, so we know the efficiency score of Ayşe instantly.

We know which products are controlled by Ayşe and when

A product’s collar is marked as faulty by Ayşe and we know that this collar was sewed by Ali at 10:15

LTM in depth

TRACEABILITY

We have removed the colored “quality control” and “ironing” labels that were used in the past and attached under the washing instructions and instead we have put the “data matrix” barcode. 

LTM in depth

This data matrix barcode contains information such as:

Customer name

Order number

The operation list

Standart times of the operations

Model name

Operator name

Manufacturing history from cutting to packaging

The information is accessible only by Ünlü Tekstil.

Below, we will try to explain these new works with their visuals, advantages.

During the manufacturing process, it should be sewed together with washing instructions labels.

Visually, it provides a cleaner image.

We instantly track employees’ productivity and quality.

We receive retrospectively all the quality data of all products, one by one.

We track retrospectively when and to which operation each product or model was subjected to. We see the bottlenecks and in which process the product waited.

We collect data which is highly vital for Quality Management System.

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QUALITY

All production operations that make up a model are defined in the system. The barcode is printed for these operations.

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In-line Control

In-line controllers control each operation at specific intervals. If a faulty barcode is found at quality control process, the related barcode is scanned. Thus, the data is collected. According to this data;

Errors made in the model,

Operation where most of the mistakes were made,

The operators that made the most mistakes,

Traced online. The causes are investigated and action is taken.

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In-line Control Report

This system is used in both inhouse and subcon lines.

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End-line Control

At this point, all the individual operations of each product are analyzed at the end of the line. If an operational error is found, the barcode of this operation is read and the error reduces the quality efficiency score of the operator.

The operator follows the quality efficiency from the lights in front. 

Red Light : It shows that the operator's quality efficiency is lower than 90%.

White Light : It shows that the quality efficiency of the operator is between 90% and 95%.

Green Light : It indicates that the operator has a quality efficiency higher than 95%.

According to these colors, the operator monitors the quality efficiency on-line. The chief of the band also controls the operator over these lights and takes the necessary actions.

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End-line Control Report

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Final Control

Certain error definitions are made for the final control. The products are checked one by one and the barcode on the product is scanned.

When a mistake is found in one card, error barcode and data barcode on the product are scanned and the product and error are matched. Thus;

Which products the controller has checked

How many errors occurred in which group in which model

How many errors occurred in the group across the enterprise

Followed up and necessary actions are taken.

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Final-line Control Report

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EFFICIENCY

Basically three different types of barcodes are used to calculate the efficiency.

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Efficiency Report

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Employee Barcode

Each operator is given when she/he starts working in Ünlü Tekstil. 

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Operation Barcode

All operations that form a model are identified. Operation times of these operations are determined and recorded in the system. 

Previous experiences The times when the same operations were performed on the previously worked model

Work and time studies taken during production

The type of machine

The type of fabric

Other experiences acquired related to the operation

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Product & Basket Barcode 

After the products are cut, the products are divided into groups of 20 and placed in the baskets. Products are stitched with these baskets. For each basket, a basket barcode is printed and pasted on the basket.

After assembly, all products in a basket receive their own barcodes and the basket history is transferred to the product barcodes. Subsequent processes are traced by product barcode.

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Operator efficiency

The productivity of the employee is calculated by the ratio of the total duration of the production phase calculated day by day. Employee productivity is also tracked on-line in the day as the work that the employee generates instantly enters the system.

Front terminal display, 

Big screens at the beginning of the line

Shows realtime efficiency scores during production

LTM in depth

Operator efficiency

In addition, Following the,

Instantly productivity

Daily productivity

Monthly productivity

Annual productivity

of the employees, the necessary actions are taken and the improvements are made to increase the productivity.

Employees report to the system when they have lost production time for any reason. These lost times may be;

In-line job waiting

Machine malfunction

Meeting - Education

Product Repair

These lost times are tracked instantly, reported and worked on to reduce.

Industry shift in 2020

Fast paced online startups is changing all businesses as well as garment industry.

Shift to bottom-up trend setting. Influencers and social platforms like Instagram are the new trendsetters. Trends are more likely to pop up from the Street.

The ‘PULL’ model replaced the old ‘PUSH’ model, in which products are developed, tested and produced on demand.

Industry is changing from the old preorder model to:   (The Future Outlook)

In-season reactivity, open-to-buy approaches to be more responsive.

Demand focused model,

Speed to market within weeks

Smaller batches, less stock, less waste

Reduced Lead time

Automation supported with AI and Deep Learning is going to zero the gap between labor costs, productivity and sustainability.

Near shoring

Short shipping date from Turkey to Europe, 3-6 days. Far East 30 days.

Labor cost gap between far east and Turkey is shrinking. Labor costs in Turkey were more than 5 times higher than those in China in 2005, the factor diminished to only a factor of 1.6 times by 2017. But today’s fashion industry, speed beats this margin.

6% growth of local demand in Far East each year, which makes local market attractive for local producer.

The huge source of raw materials, fabrics and ingredients in Turkey.

Incentives zones in Turkey for manufacturing which reduce labor costs.

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Solar energy panels will be installed in the Ünlü Tekstil building.

  • 70,4% of the electrical energy consumption will be provided by these panels.
  • The estimated CO2 emission to be prevented will be 523 tons per year.
  • The amount of carbon emissionprevented will be equal to planting 45000 trees annually.

We will continue contributing to renewable energy generation by obtaining IREC Certificates.

Carbon emission values will be determined by measuring the carbon footprint of Ünlü Tekstil. Reduction goals will be set.

By conducting an energy study with the consultancy of an expert firm, inefficiency points in our electricity, natural gas, water and diesel consumption will be determined and improvements will be processed.

To compensate for some of our carbon footprints, trees will be planted in cooperation with Tema Foundation.

Electricity, Water, Natural Gas consumption data will be monitored daily, weekly, and unnecessary uses will be determined and prevented.

A bicycle parking area will be constructed and the employees who live close to the business location will be encouraged to use bicycles to reduce fuel consumption.

Training on energy conservation will be prepared on the Ünlü Sustainability platform and all our employees will participate.

Devices and faucet apparatus that reduce water consumption will be provided and distributed to all our employees for use in their homes.

The taps in the business will be transformed into sensored and at the end of the year, a minimum of 5% domestic water consumption will be reduced.

Training on water saving will be prepared on the Ünlü Sustainability platform and all our employees will participate.

Fabric waste and fabric clippings will be transformed into fibers by providing suitable machinery and transformed into felt, shopping bags etc for the employees.

Cardboard or cloth bags will be used instead of plastic bags, samples sent to customers will be sent in cloth bags.

The consumption of products such as paper, cardboard, toner, stain remover etc. will be monitored and reduced. Paper usage will be tracked by installing counters on all printers.

Electronic wastes will be collected with the participation of employees in 2021, and tree planting will be carried out in cooperation with relevant institutions within the scope of Atıklar Ağaç Olsun project.

Collecting plastic cap will continue in 2021 with the participation of employees. The caps collected will be donated to the Spinal Cord Paralytics Association for wheelchairs.