Kattrapin Technologies Pvt Ltd

Clients

Partners

Technical Animation

At Kattrapin, we specialize in creating high-quality animations and technical educational content tailored specifically for the automotive industry. Our services are designed to enhance both training and customer engagement, providing clear, concise, and visually engaging content that helps users and professionals understand complex automotive concepts with ease.

Our Animation Services :

DIY Videos and Animations

We produce step-by-step DIY (Do-It-Yourself) videos and animations that guide users through various automotive tasks and repairs. Whether it's simple maintenance or complex assembly processes, our animations break down every step, making it easy for viewers to follow along.
Easily accessible Animations

Our animations are crafted to simplify complex automotive concepts, offering clear, visual demonstrations that make technical information easy to understand for both novices and experts alike.
Detailed Technical Documentation Animations

For manufacturers and technical teams, we provide animations that complement detailed technical documentation. These animations serve as a visual aid, helping engineers and technicians better understand the intricacies of vehicle components and systems.
Engineering Animations

Our engineering animations showcase the inner workings of various automotive technologies, from engine mechanics to advanced electronic systems. These animations are perfect for technical training and educational purposes.
EV Vehicle Features

With the growing popularity of electric vehicles (EVs), we specialise in creating animations that explain the key features of EVs, including battery systems, charging processes, and energy-efficient components. Our animations help users and technicians understand how electric vehicles function and what makes them unique. We also provide animations highlighting the features of traditional vehicles, including engines, suspension systems, safety features, and more. These animations help in the training of automotive professionals and provide valuable insight into vehicle functionality.

End-to-End Training and Education Solutions :

Electrical Training Videos

Our electrical training videos cover all aspects of automotive electrical systems, from wiring and circuits to diagnostics and troubleshooting. These videos are ideal for technicians and engineers looking to enhance their electrical expertise.

Body Repair Videos

Our body repair videos focus on automotive bodywork, including dent removal, paint restoration, and structural repairs. These videos are essential for auto body repair professionals seeking to refine their skills.

Training Videos for Technicians

We create in-depth training videos that explore automotive systems and repair techniques. These videos are designed to improve a technician’s skills and understanding of vehicle mechanics, electrical systems, and diagnostics.

Automotive Technical Publications

We offer comprehensive technical publications that include animations and documentation. These resources provide a thorough understanding of automotive systems and repair techniques, ideal for both industry professionals and learners.

Interactive Customer Engagement Animations

We create interactive animations designed to engage and educate customers about vehicle features, maintenance tips, and safety information. These animations enhance the customer experience by providing easy-to-understand, visually appealing explanations of how their vehicles work.

At Kattrapin, we are committed to revolutionising the way automotive professionals and customers interact with technical information. Whether you are training technicians, providing detailed documentation, or engaging customers with product features, our animations and training solutions are tailored to meet your needs and improve understanding across the automotive industry.

Training and Consulting

At Kattrapin, we specialise in providing technical training and consulting solutions tailored to meet the evolving demands of the automotive industry. Our comprehensive training programmes equip professionals with the latest industry knowledge and hands-on expertise, ensuring they are well-prepared for various automotive roles.

Our Services :

Automotive Training & Technical Education

We offer specialised training programs designed to enhance skills and knowledge in various automotive sectors, including:

• Vehicle diagnostics & repair
• Electric & hybrid vehicle technology
• Automotive engineering & manufacturing processes
• Body repair & painting techniques
• Advanced driver assistance systems (ADAS)
• Automotive software & AI integration

Our training sessions are delivered by industry experts, combining practical experience with cutting-edge technology to ensure that trainees gain practical expertise.
International Training & Knowledge Sharing

We are expanding our reach globally, offering international training programs and knowledge-sharing initiatives to empower automotive professionals across different regions. Through collaboration with global experts and institutions, we provide access to:

• Internationally recognized certifications
• Cross-border training exchanges
• Best practices in the latest automotive technologies
• Global industry insights and trends

Our training sessions are delivered by industry experts, combining practical experience with cutting-edge technology to ensure that trainees gain real-world expertise.
Manpower Solutions for the Automotive Industry

Upon completion of our training programmes, professionals are equipped with the skills needed to meet the workforce demands of the global automotive industry. Our manpower solutions include:

• Permanent & contract staffing for OEMs, dealerships, and service centers
• Technicians, engineers, and specialists for various automotive roles
• Global workforce deployment to support international automotive businesses
• Customised workforce solutions tailored to company-specific needs

Why Choose Us?

• Industry-specific training: we focus on hands-on, job-ready training programmes that align with current automotive industry standards.
• Global reach: our services extend beyond local markets, providing international expertise and workforce solutions.
• End-to-end support: from training to job placement, we ensure a seamless transition for skilled professionals into the workforce.
• Customized workforce solutions: we match the right talent with the right automotive companies, ensuring operational efficiency and excellence.

Powering the Future of the Automotive Industry

At Kattrapin we are committed to shaping the future of automotive professionals and bridging the gap between training, knowledge sharing, and manpower solutions. Whether you need skilled automotive professionals or cutting-edge technical training, we provide comprehensive solutions to help businesses and individuals thrive in the global automotive industry

Join us today and drive your success forward!

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Real-Time Apps

Incorporated in 2002, we are a progressive, customer-oriented Information Technology solution provider specializing in software development, maintenance, advisory services, and products across various platforms. We deliver state-of-the-art products and services to our customers through a powerful synergy of skilled professionals, streamlined processes, and advanced technologies.

Technology

Technological advancements in the field of Information Technology have been overwhelming in recent years, yet the gap between people and technology continues to widen. At CCS, we offer solutions that bridge this gap by leveraging cutting-edge technology and providing seamless technical support. We are committed to responding to the latest technological trends and meeting evolving needs.

Core Technologies

Microprocessor & Microprocessor & Microcontroller-Based Industrial Control Systems

Wireless Solutions

Interactive Voice Response (IVR) Systems

Smart Card-Based Solutions

RFID-Based Solutions

IoT Solutions

Client-Server Applications

Web-Based Applications

Mobile Applications

MA-JEVI RTS

Hardware

I-Tags

Software

Networking

Presentation

Dashboard

Pre-requisites

Keybenefit

Feature

Vision

A real-time system is a technology tool that collects and distributes information to everyone in the factory as events occur. Real-time systems are proven technologies for achieving realistic production goals, reducing costs, increasing profits, and meeting customer needs through on-time delivery.

Need for RealTime System

The real-time production monitoring system in manufacturing industries enables users to continuously monitor the production process and collect real-time information regarding the reliability, accessibility, and maintainability of the equipment. Information must be collected and disseminated quickly and accurately to meet production goals.

Today's manufacturers must do more with less

Improve quality, throughput, and reduce overheads.

Proactively detect and react to problems before they escalate.

Analyze and prioritize problems to direct corrective efforts effectively.

Learn from the process and use this knowledge to improve and refine operations.

Production monitoring systems provide centralized monitoring and tracking for industrial or mass production environments
The key objective of a real-time system is its ability to collect production information on a real-time basis, enabling the production management team to respond promptly to any production-related issues that may arise.
Real-Time Production Monitoring System is a revolutionary technology designed to provide real-time information to the production management team to effectively manage the complex requirements of apparel manufacturing processes.

About MA-JEVI

Crystal’s MA-JEVI is a revolutionary digital technology tool designed to achieve real-time goals in the garment and apparel manufacturing process. MA-JEVI serves as a digital assistant in the effort to maximize enterprise productivity.

Global markets and technology are driving tremendous changes in the textile and apparel industries. The MA-JEVI system focuses on the issues, complexities, and opportunities faced by apparel and textile companies and their suppliers. The MA-JEVI system is fully interactive and integrates with a comprehensive range of distribution, material and capacity planning, manufacturing, and financial systems, making it the most complete real-time solution

The key objective of the MA-JEVI system is to collect production information in real time, enabling the production management team to respond instantly and resolve any issues that may arise on the production line. The MA-JEVI system operates seamlessly without requiring changes or placing unreasonable demands on how your business operates. It delivers cost savings that generate a return on investment from the very first day it is installed. The MA-JEVI system has the potential to make nearly every apparel manufacturer more competitive and a better supplier.

MA-JEVI system can be implemented for cutting, sewing, checking, AQL, washing, finishing, and packing.

The MA-JEVI system works with the following identification technologies, commonly referred to as i-Tags.

iButton Tags

RFID – Low Frequency (125 kHz)

RFID – High Frequency (13.56 MHz)

RFID – Laundry Tags (13.56 MHz)

Keypad Input

Crystal MA-JEVI Real-Time System can be described as

Online Production Monitoring System

Process Control System

Work-in-Progress Tracking System

The MA-JEVI system consists of an i-Tag reader and i-Tag. An i-Tag is used to identify operators, supervisors, mechanics, QAs, and bundles with unique color holders. The i-Tag will have a polyethylene pouch attached to it, which will carry the printed information of the bundle/operator details.

A reader is installed at each workstation along the production line.

All readers on the line are networked and connected to a data-capturing PC, which records data for log-ins, log-outs, bundle starts, and bundle ends made by the operators, updating the information in the central repository in real time.

How does MA-JEVI work?

Operators should log in to their workstations using the operator tag.

An i-Tag is programmed and attached to each bundle at the cutting section and issued to the sewing line for production.

The i-Tag travels with the bundle along the sewing line from the start operation to the final operation.

Before starting the operation on the bundle, operators will log in the bundle's i-Tag in the reader to record the operation start time.

Upon completing all the pieces in the bundle, operators will log out the same bundle's i-Tag in the reader to record the operation end time. The bundle, along with the i-Tag, will then be moved to the next operator.

All subsequent operators will log in and log out the bundle's i-Tag for their respective operations to record production.

Operators should log out from their workstations during break times, when moving to other workstations, or at the end of the day.

Benefits of Installing a Real-Time System

The benefits of installing an effective and efficient real-time system are seen at the following levels, thanks to immediate on-screen access to all information.

Production

Work-in-Progress

Supervisors

Operators

Quality Control

Management

Customer Care

Production

Ensures that production goals are established and continually monitored.

Increases production while controlling production costs at all levels of the workforce.

Provides production scheduling based on completion dates and determines priorities.

Enables continuous improvement in line balancing.

Work-in-Progress

Incorporates automatic tracking of all work-in-process.

Provides a work-study database.

Controls work-in-progress stock through a complete transaction audit trail, reducing work-in-progress stock levels.

Displays on-screen status of work in progress.

Creates awareness when work is not flowing, ensuring it sustains the required production.

Supervisors

Provides a supervisory tool that enables the movement of people from one job to another when operators are absent or unable to meet production requirements.

Supervisors are informed of bottlenecks, summary throughput, work-in-progress, and stock information, and are given work-around solutions as problems arise.

Operators

Shows operators how to earn more money by eliminating wasted time and producing a few more units each hour, thereby increasing productive hours.

Guides operators to maintain a consistent pace throughout the day.

Enhances work morale among employees.

Informs operators of their performance to date, accurately predicted pay, etc., on a real-time basis.

Tracks accurate attendance for operators.

Quality Control

Makes each operator accountable for the units produced.

Provides management with the tools to measure and track quality problems by source, allowing them to be isolated as soon as they are identified.

Empowers everyone to recognize and solve problems as they occur.

Management

All information is presented to management and supervisors through on-screen inquiries, reports, and graphs.

Reduces clerical errors and paperwork.

Lowers overhead costs by reducing administrative overhead.

Reduces stock take costs, as accurate work-in-progress data reduces the need for stock-taking.

Provides accurate cost calculations for finished products and related jobs.

Managing orders and the combinations of orders related to work-in-progress helps analyze market trends.

The factory remains in an ever-ready state for site visits by clients and prospective investors at any time, enhancing its market value.

Increases order bookings.

Customer Care

Helps become a more reliable and trusted supplier, meeting the needs of customers.

Enhances the accurate delivery of orders to customers.

Improves customer relations by providing accurate information whenever needed.

Improves customer service across all workstations.

MA-JEVI Data Readers

i-Tag Reader (iButton) (Sewing)

The reader displays the operator’s name, target, actual production, efficiency, idle time, and excess time.

Reader Configuration

2 x 16 Liquid Crystal Display

Tx / Rx Indicator LEDs

Tag Read Indicator LED

iButton Contact Probe

64 K Backup Memory

Real Time Clock

Numeric KeyPad with Functional Buttons

Tag or Keypad inputs

0-9 - Enter Operator No or Bundle No.

Info - To view the production details

NW - To record Operator No Work time

BD - To record Machine BreakDown time

RW - To record ReWork time

Sngl - To account Single Piece Movement

Alrt - Sends an alert as SMS to the concerned person

CB - Cancel or Close Bundle

LO - LogOut current logged in Operator

i-Tag Reader (iButton) (QC)

This reader can be configured as Loading / Inline checking / End line / AQL / Finishing checking.

Reader Configuration

x 16 Liquid Crystal Display

Tx / Rx Indicator LEDs

Tag Read Indicator LED

iButton Contact Probe

5 x 4 Matrix Keypad

Qc Passed Pieces Button

Rejection Pieces Button

Rework Pieces Button

Alert Button

Function Buttons

PS - Enter Passed pieces

RW - Enter ReWork pieces

RJ - Enter Rejection pieces

NW - To record Operator No Work time

MS - Clears the current state.

Alrt - Sends an alert as SMS to the concerned person

CB - Cancel or Close Bundle

RFID Reader (LF / HF) (Sewing)

The reader displays the Operator’s name, Target, Actual production, Efficiency, Idle Time and Excess Time.

Reader Configuration

2 x 16 Liquid Crystal Display

Tx / Rx Indicator LEDs

Tag Read Indicator LED

64 K Backup Memory

Real Time Clock

Numeric KeyPad with Functional Buttons

Tag or Keypad Inputs

0-9 - Enter Operator No or Bundle No

Info - To View the Production Details

NW - To Record Operator No Work Time

BD - To Record Machine BreakDown Time

RW - To Record ReWork Time

Sngl - To Account for Single Piece Movement

Alrt - Sends an Alert as SMS to the Concerned Person

CB - Cancel or Close Bundle

LO - LogOut Current Logged-in Operator

RFID Reader (LF / HF) (QC)

This reader can be configured for Loading, Inline Checking, End Line, AQL, and Finishing Checking.

Reader Configuration

2 x 16 Liquid Crystal Display

Tx / Rx Indicator LEDs

Tag Read Indicator LED

5 x 4 Matrix Keypad

Qc Passed Pieces Button

Rejection Pieces Button

Rework Pieces Button

Alert Button

Function Buttons

PS - Enter Passed pieces

RW - Enter ReWork pieces

RJ - Enter Rejection pieces

NW - To Record Operator No Work Time

MS - Clears the current state.

Alrt - Sends an alert as SMS to the concerned person

CB - Cancel or Close Bundle

MA-JEVI Tag Assigning Reader

This reader is used to assign tags to operators and bundles.

HR Department :

This reader will be connected to the PC in the HR Department. The operator's name and token number details are printed for each operator. The operator cards are placed in the i-Tag pouch and assigned to this reader for every operator or supervisor.

Cutting Department :
This reader will be connected to the PC in the Cutting Department. Bundles are generated in the application software, and bundle cards are printed for each bundle. The bundle cards are placed in the i-Tag pouch and assigned to this reader for every bundle before being issued to the production floor.

MA-JEVI Line Display Board (LED TV)

An LED TV can be installed for each line or section to display relevant real-time information. The following types of data, along with accompanying graphs, can be shown on the LED TV for the respective line or section

Consolidated information as shown in the picture

Supervisor Dashboard with hourly production

Line / Operator Performance

Line production with W.I.P

Quality information (Rework / Rejection Defects)

Lost Time information (Operator / Line)

Bottleneck Operations in a Line

Style / Order status

In Addition to the above, any other information to be shown can be Customized according to the requirements.

MA-JEVI Workstation Status Indicator

A MA-JEVI Workstation Status Indicator is attached to each workstation to display the current status of the workstation or operator.

The status indicator features three different color LED lights, each of which can either glow or blink. Up to six status variables can be configured.

The Status Indicator can be configured to display various statuses such as Machine Breakdown, Idle Time, Rework Time, Work-In-Progress, Efficiencies, Batch Settings, Non-Productive Time, Excess Time, and more

Identification Technologies

i-Tag for bundle identification

An i-Tag is physically attached to each individual bundle and sent to the sewing line for production. The tag travels along with the bundle throughout the sewing line, from start to finish. When an operator begins working on a bundle, they scan the tag with their reader, indicating the start of the bundle. Upon completion, the operator scans the tag again to signal the end of the bundle.

i-Tag for Operator identification

An i-Tag is provided to each operator for identification purposes. The operator uses this tag to log in at the workstation before starting work and to log out when leaving the workstation.

i-Tag (iButton)

The i-Tag is a computer chip enclosed in a stainless steel casing, which proves its identity through a globally unique serial number. It is used to identify operators, supervisors, mechanics, QAs, and bundles, each with a unique color holder. The i-Tag is attached to a polythene pouch containing printed information about the bundle or employee details.

i-Tag (RFID) - Low Frequency

Typically, LF RFID systems operate at 125 KHz. This frequency band offers a short read range of about 10 cm and slower read speeds compared to higher frequencies. However, it is less sensitive to radio wave interference.

i-Tag (RFID) - High Frequency

Most HF RFID systems operate at 13.56 MHz, with read ranges ranging from 10 cm to 1 m. HF systems have moderate sensitivity to interference.

i-Tag (RFID) - High Frequency Washable Laundry Tag

Most HF RFID systems operate at 13.56 MHz, with read ranges ranging from 10 cm to 1 m. These systems experience moderate sensitivity to interference.

Input through Reader Keypad

Operators can use the reader keypad to log in themselves and the bundles by entering their token numbers and bundle numbers.

MA-JEVI Softwares

Data Capturing Software

This software is installed on the data-capturing PC on the production floor, where it captures punches from all the readers and updates the central database in real-time.

Production Management System (PMS) Application Software

This application software is installed on all client machines. It is used to enter all master and transaction details, including style order information, laying, cutting, bundle generation, tag assignment to bundles, operation bulletins, line layouts, and more.

Dashboard

MA-JEVI Dashboard is a Business Intelligence (BI) tool that displays macro-level information of all production lines in real-time, presented graphically. Users can drill down into specific cells to view micro-level information. The dashboard provides various types of graphs at all levels for analysis and comparison, aiding better decision-making.

Web based MIS Reports

This software is installed on the central server, where it automatically collects production information from all MA-JEVI-equipped factories and generates the following MIS reports.

Efficiency Report (Yearly/Monthly/Factory-wise/Line-wise/Buyer-wise/Style-wise/Day-wise)

Production Report (Yearly/Monthly/Factory-wise/Line-wise/Buyer-wise/Style-wise/Day-wise) – Cutting/Sewing/Passed/Rejections

Capacity Utilization (Planned vs. Actual – Monthly/Factory-wise/Line-wise – PCS and Time)

Cut to Ship Efficiency Report (Yearly/Monthly/Factory-wise/Line-wise/Buyer-wise/Style-wise/Day-wise)

Costing Profit & Loss (Monthly/Factory-wise/Line-wise/Buyer-wise/Style-wise/Day-wise)

Style/Order Tracking – Tracks the status of styles/orders across multiple factories/lines.

All the above reports are cross-tabbed with a drill-down feature that offers five levels: Factory, Line, Buyer, Style, and Day, and so on. This allows for comparing and analyzing multiple factories/lines across months, weeks, etc.

MA-JEVI System Networking

State-of-the-art networking based on SCADA principles ensures 100% data reliability
Readers from the sewing lines are connected to the controller PC, which captures data from the readers and updates the central database in real-time.
One controller PC can handle up to 300 readers.

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Prerequisite Hardware and Software for Installing MA-JEVI

Hardware

Server

Intel Hexa-Core Processor or higher, 32 GB RAM, 1 TB HDD, USB ports, 100 Mbps network connection, DVD drive, color monitor, keyboard, and mouse.

Controller PC

Intel i5 Processor or higher, 16 GB RAM, 250 GB HDD, network card, USB ports, monitor, keyboard, and mouse.

Controller Computer

All reader units are connected to the controller computer via the network. The controller computer is connected to the database server.
The interface software installed on the controller PC collects data from the reader units and stores it in the database server. One controller PC can handle up to 300 readers connected to it.

Software

Server Operating System – Windows Server 2012 or higher.
Client Operating System – Windows 7 Pro or higher.
Database – Microsoft SQL Server 2012 or higher.

Key benefits of MA-JEVI

The MA-JEVI system provides efficient and effective real-time information on the company's performance, enabling successful implementation of business strategies.

Instant Reports at all levels.

The MA-JEVI system provides real-time information and reports at all levels.

On-Line Production Status

The MA-JEVI system provides on-screen access to production orders and their progress, offering a real-time view of production status.

Improvements in effective and efficient usage of man & machine

Efficient Line Balancing

The MA-JEVI system provides accurate information on line balancing.

Details of employees present and absent on the day
Information on current production in progress against the set target
Status of work-in-progress relative to the current operational level and progress toward achieving the target within the fixed time
Line balancing within the workflow

Reduction of Work In Progress Time

The MA-JEVI system enhances production tracking transparency, eliminating the need to check work-in-progress every two hours. It also allows for workforce analysis, providing insights into who is working in each section of the workflow and monitoring the cost of their performance against the project as needed.

Reduction in Downtime

The MA-JEVI system reduces unproductive downtime by 20% by providing detailed downtime reports, enabling management to take corrective action.

Improved In-Line Quality Control

Eliminating the need for Supervisory Checks

Accurate time keeping

The MA-JEVI system ensures that operators check in directly at their workstation on time, resulting in a significant reduction in queuing time per operator.

Accurate Payment to Operators

The MA-JEVI system eliminates unnecessary labor time spent on maintaining individual records and resolves disputes among operators regarding the calculation of work costs. Operators are paid only for perfectly completed work, with appropriate deductions applied for faulty pieces before payment. The system also prevents the withholding of work tickets and ensures that work is not paid for twice. Additionally, errors in payroll claims are significantly reduced, and the MA-JEVI system calculates the gross payroll much faster than traditional bookkeeping methods.

Reduction in Overtime Working with maximum utilization of HR

The absence of key workers adds to overhead costs and impacts productivity. The MA-JEVI system immediately highlights such issues, helping to eliminate unnecessary overtime. An efficiently implemented real-time system can reduce overtime expenses by 50%, while also making future production planning more efficient.

Reduced Administration Costs

The MA-JEVI system reduces paperwork and minimizes clerical errors.

Accurate MIS Reports

ROI In Less than 2 Years

By installing the MA-JEVI system, you can expect a return on investment within two years. Additionally, you can benefit from the depreciation of the MA-JEVI hardware over time.

Salient Features of Crystal MA-JEVI

Centralized real-time production monitoring tool

Seamless integration with other application systems

Operation time (SAM) validation

Maintains sequential integrity of operations

Supports progressive bundle movement, piece movement, unit production system, and bundle sharing

Flexible line layout (split/merge lines)

Accountability of on-standard time (worked minutes, produced minutes, and cycle time)

Accountability of off-standard time (idle time, no-work time, breakdown time, rework time, and non-productive time)

Line balancing with pitch diagrams to identify bottleneck operations

Work-in-progress monitoring at all levels

Total quality management at in-line and end-line checkpoints

Supports piece rate, group, and individual incentive methods

Maintains skill data for all operators

Alerts for exceptional situations via SMS/email

Features and validations of this system are user-configurable

MA-JEVI IoT

MA-JEVI IoT is an app-based system installed on smartphones or tablets to capture production data.

The MA-JEVI IoT system can be implemented for cutting, sewing, checking, washing, finishing, and packing

A smartphone or tablet with the app is installed at each workstation on the production line.

All devices on the line will access and update the database via a Wi-Fi network.

The database can be hosted on your own intranet or internet server.

Identification Technologies Supported

BarCode (Linear / 2D) - BarCode Scanner / Camera

i-Tag (Contact) - i-Tag Reader

i-Tag (RFID) - Low Frequency - (125 kHz) - RFID Reader (125 kHz)

i-Tag (RFID) - High Frequency - (13.56 MHz) - RFID Reader (13.56 MHz)

i-Tag (RFID) - Washable Laundry Tag - (13.56 MHz) - RFID Reader (13.56 MHz)

i-Tag (RFID) - Ultra High Frequency - (860 - 960 MHz) - RFID Reader (860 - 960 MHz)

Input through Keypad - Device KeyPad

MA-JEVI IoT App Types

Sewing - For sewing and other manual operations.

Checking - For loading, inline, endline, AQL, and finishing operations. A smartphone or tablet can be used for sewing or checking by loading the respective app type.

Features

All features and validations from the earlier version of MA-JEVI have been implemented in this system.

Operators can view training videos for the operations.

Operators can apply for leave.

Operators can view the Tech-Pack and measurement chart of the styles.

Operators can view messages sent by supervisors in their inbox.

Operators’ hourly production can be viewed with a graph.

Information, reports, and graphs can be customized according to requirements.

MA-JEVI Reports

MA-JEVI real-time reports on smartphones and tablets for supervisors and I.Es provide access to critical information about the production lines, enabling them to identify and respond to problems instantaneously.

Attendance and Absentism Report

Hourly Production Report

Work in Process Report

Line Balancing Report

Operator Efficiency Report

Skill Matrix Report

Quality DHU Report

Order Status Report

Downtime Report

MA-JEVI - FREQUENTLY ASKED QUESTIONS

MA-JEVI is a revolutionary digital technology tool designed to achieve real-time goals in the garment and apparel manufacturing process. It serves as a digital assistant in the quest for maximizing enterprise productivity.

The global market and advancing technology are driving tremendous changes in the textile and apparel industries. The MA-JEVI system is focused on addressing the issues, complexities, and opportunities faced by apparel and textile companies and their suppliers. It is fully interactive and integrates with the complete range of distribution, material and capacity planning, manufacturing, and financial systems, making it the most comprehensive real-time system.

The key objective of the MA-JEVI system is to collect production information in real time, enabling the production management team to respond instantaneously and solve any problems that arise within the production line. MA-JEVI operates without requiring any changes or placing unreasonable demands on the way your business operates. It delivers returns with cost savings that will pay for the system from the first day it is installed. The MA-JEVI system has the capability to make almost every apparel manufacturer more competitive and a better supplier.

The MA-JEVI system can be implemented for cutting, sewing, checking, AQL, washing, finishing, and packing.

The MA-JEVI system works with the following identification technologies, commonly referred to as i-Tags.

iButton Tags

RFID - Low frequency (125 Khz)

RFID - High Frequency (13.56 Mhz)

RFID - Laundry Tags(13.56 Mhz)

KeyPad Input

Crystal MA-JEVI Real Time System can be termed as

Online Production Monitoring System

Process Control System

Work-in-Progress

The MA-JEVI system comprises an i-Tag reader and i-Tags. An i-Tag is used to identify operators, supervisors, mechanics, QAs, and bundles, each with unique color holders. The i-Tag has a polythene pouch attached, which contains printed information about the bundle or operator details.

A reader is attached to every workstation in the production line.

All readers in the line are networked and connected to a Data Capturing PC which captures the Data for Log-In, Log-out, Bundle Start and Bundle End made by the operators and updates the information in central repository in real time.

How MA-JEVI works?

Operators should log in to their workstations using the operator tag.

An i-Tag is programmed and attached to every bundle at the cutting section and issued to the sewing line for production. This i-Tag travels along with the bundle through the sewing line, from the start operation to the final operation.

This i-Tag travels along with the bundle through the sewing line, from the start operation to the final operation.

Before starting the operation on the bundle, operators must log in the bundle’s i-Tag into the reader to record the operation start time.

Upon completing all the pieces in the bundle, operators will log out the same bundle’s i-Tag from the reader to record the operation end time, and the bundle is then moved along with the i-Tag to the next operator.

All subsequent operators will log in and log out the bundle’s i-Tag for their respective operations to record the production.

Operators should log out from their workstations during break times, when moving to other workstations, or at the end of the day.

By and large, the garment-manufacturing process is based on progressive bundle movement. Every bundle goes through different stages of operations in the production line. Finally, when all the operations are completed, the finished garment comes out of the line.
The MA-JEVI system comprises an i-Tag reader and i-Tag. An i-Tag is used to identify operators, supervisors, mechanics, QAs, and bundles, each with a unique color holder. The i-Tag has a polythene pouch attached to it, which carries the printed information of the bundle/operator details.
The readers are attached to every sewing machine in the production line and are networked, connected to the data-capturing PC. The i-Tag is attached to every bundle and sent to the sewing line for production. Each operator performs his or her designated operation(s) in the sequence of the line.
By doing so, operators are expected to scan the i-Tag at the reader to log both the start and completion times (i.e., twice for each bundle). The punches captured at each reader are sent to the central database server instantaneously. As a result, the bundle’s presence/status is captured at all workstations as it passes, providing real-time data.

No, the i-Tags are re-usable; once the final operation for a garment is completed the i-Tag is removed from the bundle and can be re-used for another bundle for same style or different style.

Please refer our pre-requisite menu

HardWare:
Reader, i-Tag, Networking Accessories
Controller PC(s), Server
Software :
Data Acquisition Software
Production Management Software

All the readers are connected to the Controller PC via an RS485 multi-drop full-duplex network.

All the readers are connected to the Controller PC via an RS485 multi-drop full-duplex network using CAT 5 cable (24 AWG) with RJ45 connectors.

Readers: One reader is required for each sewing machine.
i-Tags: 10 i-Tags are required for each reader (1:10 ratio).
This calculation is based on the estimated Work in Progress (WIP) at each workstation, the number of bundles ready to issue (bundles in stock), and the number of i-Tags available in stock.

The lifespan of an i-Tag (iButton) is approximately 10 years.

We have two models,
1) MA-JEVI Reader for Sewing
2) MA-JEVI Reader for Quality Checking

QC Readers are used to record rework and rejection pieces.
These readers can be installed at various stages, including Loading, In-line, End-line, AQL, Finishing, and Packing sections, to capture data.
Bundles are checked for quality at different stages of the operations. If any rejections are identified, the bundle is sent back to the concerned operator for correction or rectification.
To identify which operator performed the faulty operation, the operator will tag the bundle onto the QC reader and enter the operation code that was found faulty. The system will then display the name of the operator who completed the operation. The QC executive will then send the bundle back to the concerned operator for correction and update the number of faulty pieces in the QC reader. The order quantity depends on the number of QC check points available.

It can be seamlessly integrated with your ERP systems.

The operator logs in at their workstation using the Operator Tag.

An i-Tag is programmed and attached to each bundle at the cutting section, which is then issued to the sewing line for production.

The i-Tag travels along with the bundle through the sewing line, from the start of the operation to the final operation.

Before starting the operation on the bundle, the operator will log in the bundle’s i-Tag in the reader to record the start time.

Upon completion of all the pieces in the bundle, the operator will log out the same bundle’s i-Tag in the reader to record the end time. The bundle is then moved with the i-Tag to the next operator.

All subsequent operators will log in and log out the bundle’s i-Tag for their respective operations to record production.

The captured data is instantaneously updated in the Central Database Server.

The operator should log out from their workstation during break times, when moving to another workstation, or at the end of the day.

Yes, each style has its own identity, allowing it to be routed through different paths in the manufacturing process. A key part of this concept is reducing Work In Process (WIP). To maintain and improve WIP, it is essential to manage style changes, manufacture according to customer orders, etc. Lower WIP positively impacts throughput time for finished products and, in turn, reduces the number of styles in the system at any given time.

Refer Dashboard Presentation

Before issuing bundles to the sewing line, a tag is attached to each bundle. This tag must be assigned to a specific bundle, and the assignment is done through the PMS application software. The system will store all the bundle details along with their respective tags.

The following are Production Methods supported by MA-JEVI either Fully or Partially.

Progressive Bundle Movement

Piece-by-Piece Movement

Unit Production System (Hanger Movement)

Bundle Sharing

In the Production Management Software, there is a process called Line Setting, where, for each style, operations need to be assigned to workstations on the line. The details of the readers attached to these workstations are pre-stored in the system.

New versions of the MA-JEVI applications will be provided to customers as they are launched.

Online support will be provided by our team from the office through remote access. Onsite support will be provided by our support engineers.

The MA-JEVI system is exclusively designed and developed by Crystal Consultancy Services Pvt. Ltd. and marketed by our authorized distributors.

The MA-JEVI reader features a 16x2 LCD at the top, where all response messages are displayed. Any messages from the server are shown on the LCD. The operator's target, actual, and efficiency values are also displayed. By pressing the 'Info' button, the target quantity set for the style/operation for the day will be displayed.

The system provides an option for resource assignment: Operation → Workstation → Machine. Possible assignments include:
1 operation → 1 workstation
1 operation → 2 or more workstations
n operations → 1 workstation
n operations → m workstations

When the start punch is made, the current i-Tag ID is displayed on the LCD. When the end punch is made, the i-Tag ID will disappear from the LCD.

Yes, MA-JEVI supports three models of incentive methods:

Piece Rate Method

Individual Operator Performance-Based

Line/Section Performance-Based

Operator Idle Time

Operator Non-Productive Time

Operator Rework Time

Operator No-Work Time

Machine Breakdown Time

Line Non-Productive Time

The MA-JEVI system captures the cycle time of all pieces produced by the operators and generates a pitch diagram graph displaying the operation cycle time. The production team continuously monitors this pitch diagram to take corrective actions for weaker processes, operators, or operations, and balance the line to achieve optimal output.

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Chennai

Ambattur Clothing Limited

Quintessential Designs India Pvt Ltd

Hallmark Industries

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Sri Saravana Mills Pvt Ltd, Dindigul

Victory Paper and Boards India Ltd, Karur

Penguin Apparels (P) Ltd, Madurai

Tirupur

Cotton Blossom India Pvt Ltd

S.P.Apparels Ltd

J.G.Hosiery (P) Ltd

M.P.Shan Tex

Sumeru Knits

Premier Knits Apparel India

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Jay Jay Mills India Pvt Ltd

JBalu Exports

Le Shark Global LLP

KKP Made-Ups Division

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Bangalore

Gokaldas Images

Page Industries Limited

Madura Fashion & Lifestyle

Integra Apparels

Delhi - NCR

Orient Fashions

Akriti Apparels Pvt Ltd

Super Fashion

EasternBase

Radnik Exports

Meenu Creation

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Chelsea Mills

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Platinum 3, Sharjah, UAE

Sparrow Apparels Ltd, Dhaka, Bangladesh

Classic Fashion Apparel Industry Ltd. Co, Vietnam

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Kitex Limited

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STI India Limited

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Ahmedabad

Ashima Group

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About MA-JEVI

MA-JEVI system can be implemented for cutting, sewing, checking, AQL, washing, finishing, and packing.

The MA-JEVI system works with the following identification technologies, commonly referred to as i-Tags.

Crystal MA-JEVI Real-Time System can be described as

How does MA-JEVI work?

Benefits of Installing a Real-Time System

Production

Work-in-Progress

Supervisors

Operators

Quality Control

Management

Customer Care

MA-JEVI Data Readers

i-Tag Reader (iButton) (Sewing)

Reader Configuration

i-Tag Reader (iButton) (QC)

Reader Configuration

RFID Reader (LF / HF) (Sewing)

Reader Configuration

RFID Reader (LF / HF) (QC)

Reader Configuration

MA-JEVI Tag Assigning Reader

HR Department :

Cutting Department :

MA-JEVI Line Display Board (LED TV)

MA-JEVI Workstation Status Indicator

Identification Technologies

i-Tag for bundle identification

i-Tag for Operator identification

i-Tag (iButton)