Page 42 - February-March 2021

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Diamond Fabrics Ltd

implements BMSvision MES

solution in its denim division

Diamond Fabrics, part of Pakistan’s premier vertically scanning the barcoded batch travel card. The
integrated Sapphire Group, has selected Belgian PlantView application visualizes the complete
based BMSvision as a partner for its prestigious MES production process in real time and highlights any
project, keystone in the roadmap towards a I 4.0 possible deviation from standard. A powerful
company. reporting tool featuring interactive reports and charts,
allows the users to create their own calculations and
Tayyab Abdullah explains: ”We were looking for a reports. After each production step, the MES systems
solution that goes far beyond the traditional prints a barcoded ticket and all relevant production
production and machine monitoring. In order to data is transferred to the SAP system. Diamond’s
prepare for an I 4.0 compliant manufacturing request to monitor and document the flow of goods
operation, we need a Manufacturing Execution throughout the whole production chain, to be able to
System (MES) that can manage and track the entire trace all materials used and to know the current
production flow, from yarn to finished fabric. status Work in Process all the time, is handled by
Furthermore, the system needs to seamlessly BMSvision’s traceability module.
integrate with the SAP ERP system in place. After a
thorough market research and various demo’s and Besides managing the production flow, Diamond
workshops, we selected BMSvision as our partner Denim also implements the BMSvision EnergyMaster
because of their vast experience in the industry and solution. Tayyab Abdullah: “Energy consumption is
the turnkey project approach including hardware, becoming a very important factor in the overall
software and services”. operating cost of our factory. With ever rising energy
prices and increasing environmental legislation,
In a first phase of the project, the warp preparation energy management has become a very critical
department including ball warping, sizing and success factor to run our business in a profitable
rebeaming as well as the complete denim finishing way. The EnergyMaster system makes all our energy
department are covered. These are the most streams transparent and allows to allocate the exact
challenging operations within a denim mill. In a energy cost to each production batch”. The finishing
second phase, all looms will be connected. Each lines are equipped with power meters and various
machine in the preparation and finishing department flow meters to monitor consumption of compressed
is equipped with a state-of-the-art touch screen air, steam, water, gas and caustic. All these meters
based DU11 data collection terminal with wireless are connected to the DU11 data collection terminal
barcode scanner. Once the production orders are and combining consumption with production data
released by the SAP system, the planning allows correct calculation of the energy cost for each
department uses the BMSvision scheduling software production batch. Excessive consumptions or
(PlanBoard) to assign the orders to the individual consumptions while the machine is idle, are
machines. Orders are started at the machine by immediately detected and highlighted.

February/March 2021