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Tehnilisest tekstiilist mudeli tooteprotsessi parendamine termokostüümi näitel

Järva, Miia (2018) Tehnilisest tekstiilist mudeli tooteprotsessi parendamine termokostüümi näitel. [thesis] [en] Technological Process Improvement of a Technical Textile Product Applied on Thermal Protection Aid.

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Abstract

Lõputöö tehti ettevõttes Protex Balti AS ja põhineb mudel „MKIV“ tootmise analüüsil, mille alusel sooviti parendada ka kliendi Microsoft Exceli programmis asuvat tabelit selliselt, et see hakkaks varakult märku andma, kui laost hakkab mõni kangas või furnituur otsa saama. Mudel „MKIV“ on ettevõtte uus toode, termokostüüm, mis on mõeldud päästepaadis pääsenute soojendamiseks ning kaitseks vihma eest. Mudelile koostati furnituuride tabel, detailide ja lekaalide loetelu, koostati lõiked ning helkurite märkimiseks lekaal, sest antud tootele ei tohi puurauke teha. Kirjeldati ka kostüümi tootmise tehnoloogiat ning koostati läbilõiked. Töös uuriti ka erinevaid kuumsulatusõmbluste meetodeid ning sobilikke keevitusmasinate mudeleid. Protex Balti AS-il puudub sobiv masin mudeli „MKIV“ keevitamiseks, ning seoses sellega valiti töös välja neli sobivat masinat, millega sobiks toode kokku keevitada. Mudeli tellinud klient pakkus ettevõttele omapoolse masina variandi, mille soetamist ettevõte võiks kaaluda. Lõputöös võrreldakse seda masinat autori poolt valitud seadmetega, ning pakutakse välja nendest masinatest parim variant, milleks osutus ultrahelimeetodil põhinev masin „Nucleus Rotosonic V4E“. Masin valiti välja seetõttu, et lisaks mudeli „MKIV“ ühendamisele on selle seadmega võimalik keevitada veel väga palju erinevate tehnoloogiliste sõlmedega tooteid, sealhulgas ka väga komplitseeritud mudeleid. Sellise masina soetamine tuleks ettevõttele tulevikuperspektiivis kasuks, sest ettevõtte strateegiasse on sisse kirjutatud suurendada tarkade rõivaste tootmist ning tegeleda rohkem tehniliste tekstiilidega. Sellise võimsa ja multifunktsionaalse masina, nagu seda on „Nucleus Rotosonic V4E“, olemasolu annaks Protexile võimaluse vastu võtta selliseid väljakutseid, mida iga teine ettevõte ei saaks ning seeläbi olla tehnilise tekstiili valdkonnas eesrindlik. Ettevõtte esialgne materjalide tabel oli koondatud ühele vahelehele. See sisaldas üle saja erinevat kangast ja furnituuri, 26 mudelit, lao inventuuri ning tootmisgraafikut. Nii suur andmete kogum tegi tabeliga töötamise aeganõudvaks ning ebamugavaks. Tabeli efektiivsuse parendamise eesmärgil loodi Excelisse täiesti uus materjalide tabel, kus olid andmed jagatud viiele erinevale vahelehele. Ettevõtte poolt püstitatud probleemi lahendamise jaoks koostati programmeerimiskeelega VBA kood, mille käivitades värvub tootmisgraafikus tellimuse lahter, kus on kirjas kui palju materjali kulub toodetavate mudelite peale kuus, punaseks, kui laovaru on väiksem, kui antud kuus toodetavatele mudelitele materjali kulub. Teisisõnu, tabel annab ühe nupuvajutusega märku, kui materjali peab juurde tellima. Tänu sellele võimalusele muutus tabel pea 15% efektiivsemaks, mis on umbes üks tund tööpäevast. Seda seetõttu et nüüd ei pea enam informatsiooni kättesaamiseks arutama planeerija ja juurdelõikusega ning füüsiliselt kontrollima kangaste olemasolu. Kergendatud on ka tolli jaoks informatsiooni sisse töötlemine.

Abstract [en]

The purpose of this thesis is to improve Protex Balti AS’s table of materials for it’s customer who ordered the "MKIV" suit so that timely ordering can be made when the warehouse is low on fabrics or auxiliary materials. Further, it recommends the most suitable fabric welding machine for this product. The "MKIV" suit is designed to keep survivors warm and protected against rain, wind and cold in liferafts and lifeboats. This innovative smart wear requires suitable fabric welding machines for its production, which this thesis recommends after discussing the technological process required to make this new product. Given the novel nature of the product, Protex Balti AS does not have a suitable machine for welding the MKIV suit, so four potential machines were considered as options to weld the product—plus a machine offered by the customer who ordered the MKIV suit. This thesis offers a comparative study of the machine proposed by the customer and an alternative equipment options with a recommendation by the author regarding which machine best meets the production needs. The study ultimately concludes that the Nucleus Rotosonic V4E—an ultrasonic fabric welding machine—is the superior choice. This is due to the machine’s virtuosity—not only can it weld the seams necessary for the MKIV suit’s fabric, it can produce a wide range of other complex seams. This includes other water resistant survival wear or even simple raincoats. The acquisition of such a machine would pay dividends far into the future and allow the company to energetically pursue its strategy to increase the production of smart clothing and integrate into products more technical textiles. The addition of a powerful and multifunctional machine like the Nucleus Rotosonic V4E would give Protex Balti AS the opportunity to gain a competitive edge by being able to produce products many other companies do not have the technical capacity to produce and thereby lead the cutting edge in the field of technical textiles. The company's original table of materials was grouped into one spreadsheet. It contained more than one hundred different fabrics and accessories, twenty six models, a warehouse inventory and the production schedule. The size of this data set made working with it a long and arduous process. To improve the efficiency of the table, the data was transferred to a completely new excel table of materials consisting of five new spreadsheets. A VBA code was created to alert the user of low stock. When the code is running, it colors the cells in the production schedule based on estimates of how much material will be spent on the models produced per month—with red indicating that less that a months supply is left. In other words, with one click the user can know exactly what material needs to be ordered. Thanks to this automation, the ordering process has become 15% more efficient—equivalent to approximately one hour of the workday for the worker charged with this task. To obtain information about current inventory it is no longer necessary to discuss with several departments, such as the pattern cutting department or even physically check the current fabric quantity as long as the table is kept up to date. Further, the table fascilitates faster processing of paperwork for customs. Together this translates into potential lower costs, higher profits and a competitve advantage over manufacturers of similar goods.

Item Type: thesis
Advisor: Paula Veske
Co-advisor: Anu Tšistova
Subjects: Clothing and Textiles > Technology and Textile Science > Sewing Technology
Divisions: Institute of Clothing and Textiles > Clothing Design and Technology
Depositing User: Miia Järva
Date Deposited: 06 Jun 2018 07:01
Last Modified: 06 Jun 2018 07:01
URI: http://eprints.tktk.ee/id/eprint/3964

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