Every cut tracked. Every seam checked.

• 

  Cutting-room MES

  A live map of every cutter and spreader: queue, work orders from the ERP, efficiency per shift and reports. Works with Lectra and Bullmer cutters.

• 

  Spreading and splice control

  Controls the spreading table: layers, splice zones, defects and roll ends. Every roll is measured, traced and labelled.

• 

  Projector-guided part sorting

  A projector lights up the marker on the table, one colour per part, and signal lights show which pieces to collect. No mix-ups after the cutter.

• 

  Vision inspection at sewing stations

  The machine stops at set stitches, a vision sensor checks the label or part, and sewing goes on only when the check passes. For airbag, ISOFIX and top-tether seams.

  How ODS works

• 

  Thread verification

  Before each piece, a scanner or camera reads the thread cones and checks thickness and colour against the part number. With the wrong thread, the machine stays locked.

  How the thread check works

• 

  Recut and replacement orders

  Sewing lines order replacement pieces in seconds. The cutting room cuts them, confirms by badge and tracks the cost of every recut.

Also delivered: digital 1:1 pattern templates on shop-floor screens · laser-cutting station control · drill-tool checks on cutters · maintenance and downtime ticket integration · cut-piece recognition by camera (R&D) · marker waste reduction for apparel (R&D).

ODS · Optymus Detection System

Vision inspection at the sewing station

ODS stops the sewing machine at the right stitch, lets a camera check the part and releases the machine only when the check passes. It is built for safety seams such as airbag (SRS), ISOFIX and top tether, and has been developed together with seat-cover plants since 2018.

Set per part number

• Camera check A Keyence or Banner vision sensor checks the label, logo or part at a set stitch.
• Stitch count A minimum and maximum number of stitches per seam. A seam cut short or sewn too long is caught.
• Printed label A label with a unique serial number is printed and must be scanned back before the machine is released.
• Component scan The barcode of an added part is scanned and matched to the part number.

One piece, step by step

1. 01Badge inThe operator scans a badge. The machine stays locked until badge, part number and serial number are accepted.
2. 02Recipe loadsThe part number loads its seams and checks. Nothing to set by hand at the machine.
3. 03Sew and stopODS counts every stitch and stops the machine exactly where a check is due.
4. 04CheckPass: the machine is released. Fail: up to three tries, then a quality badge decides rework or reject.
5. 05LabelAt the end of the piece a serial-number label is printed and scanned back.
6. 06RecordedThe piece is saved with operator, machine, serial number and result.

Also built in

• Red Rabbit test piece: each shift starts blocked until the test piece passes every check and quality approves it.
• Bobbin warning: when the bobbin runs low, the machine locks after the seam until the change is confirmed by badge.
• The same serial number cannot be produced twice, on any station.
• If the network drops, results wait on the station and are sent when it is back. After a power cut, the open piece is restored once quality confirms it.
• Web admin for part numbers, checks, users, label templates and shifts, with a camera-failure analysis and Excel export.
• Station screen in English, French, Arabic, Romanian, Macedonian and Polish. Data stays on your own SQL Server.

Thread Detection

The right thread, before the first stitch

Seat-cover seams need one exact thread colour and thickness. Thread Detection checks the threads on the machine against the part number before every piece. With the wrong thread, the machine stays locked.

Two ways to check

• Barcode Zebra scanners read the barcode on each thread cone.
• Camera A camera reads the printed cone label and compares the thickness and colour code with the part number.

One piece, step by step

1. 01Badge inThe operator logs in with a badge. The machine is locked.
2. 02Scan the partPart number, plus serial number or operation when the part needs them.
3. 03Thread checkEach thread, left and right, is checked. Up to three tries.
4. 04Sew one pieceThe machine unlocks. At the thread cut it locks again and the piece is recorded.

Also built in

• Thread data per part number and operation, imported from Excel.
• Every piece is recorded with operator, machine, part number, serial number and time, and can be searched and exported.
• Each station keeps a local copy of users and thread data and sends its records to your central SQL Server.
• Station screen in English, Romanian and Polish.

Both systems lock the sewing machine through a Turck I/O module, log operators in by badge and keep their data on your own SQL Server. We install them on the line, train operators and quality staff, and support them after go-live.

countries

6

continents

2

interface languages

32

first system in production

2016

• Romania

  Tier-1 automotive seating supplier

  • Cutting-room MES
  • Spreading control
  • Vision inspection
  • Recut orders

• North Macedonia

  Tier-1 automotive seating supplier

  • Cutting-room MES
  • Spreading control

• Moldova

  Tier-1 automotive seating supplier

  • Spreading control
  • Vision inspection
  • Thread verification

• Morocco

  Tier-1 automotive seating supplier

  • Spreading control
  • Vision inspection

• Tunisia

  Tier-1 automotive seating supplier

  • Spreading control

• Portugal

  Tier-1 automotive interiors supplier

  • Projector-guided part sorting