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, which gathers and distributes information to everyone in the factory as events are happening. Real-time System is well proven technology to achieve realistic production goals, at reduced cost and increased profit and meets customer needs at on-time delivery.

Need for RealTime System

The real time production monitoring system in manufacturing industries enables users to continually monitor production process and collect real time information with regard to reliability,accesibility and maintainability of the equipement.Information must be collected and disseminated quickly and accurately in order to meet the production goals.

Today's manufacturers must do more with less

Improve quality throughput and reduced overheads

Proactively detect and react to the problems before they escalate

Analyse and rank problems the best direct corrective efforts

Learn from the process and use this knowledge and improve and refine

Production monitoring system provides centralized production monitoring and counting for use with any industrial or mass production environment.
The key objective of a real-time system would be its ability to collect production information on real time basis which would enabable the production management team to respond in a timely manner to solve any production related issues that may arise.
RealTime Production Monitoring System is a revolutionary technology desined to provide real time information to 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 for achieving real time goals in the Garment and Apparel manufacturing Process. MA-JEVI is a digital assistant in the quest for maximizing enterprise productivity.

Global market and technology are forcing tremendous changes in the Textile and Apparel industries. MA-JEVI system is focused on the issues, complexities and opportunities for Apparel and Textile companies and their suppliers. MA-JEVI system is fully interactive and integrates with the complete range of distribution, material and capacity planning, manufacturing and financial systems which makes it the most comprehensive real-time system.

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

MA-JEVI System can be Implemented for Cutting, Sewing, Checking,AQL, Washing, Finishing and Packing.

MA-JEVI system works on following Identification Technologies commonly termed 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 Tracking System

MA-JEVI system comprises of i-Tag reader and i-Tag. An i-Tag is used to identify Operators, Supervisors , Mechanics, Qas and Bundles with unique color holders. This i-Tag will have a polythene pouch attached to it. This pouch will carry the printed information of the bundle/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?

Operator should Log-in in their workstations with the Operator tag.

An i-Tag is programmed and tied to every bundle at cutting section and issued to sewing line for production.

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

Operators prior to start the operation for the bundle, will Log-in the bundle’s i-Tag in the reader to record the operation Start time.

Operators on completion of all the pieces in the bundle, will Log-out the same bundle’s i-Tag in the reader to record the operation End time and the bundle is moved along with i-Tag to the next operator.

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

Operator should Log-out from their workstations during break-times, moving to other workstations or leaving End of the day.

Benefits of Installing Real Time System

The benefits of installing effective and efficient real time system is seen at following levels due to immediate on screen access to all informations.

Production

Work-in-Progress

Supervisors

Operators

Quality Control

Management

Customer Care

Production

Ensures production goals to be established and monitored continually

Increases production at controlled production costs at all levels of work force

Provides production scheduling against completion dates, decides priorities

Enables continuous and improved line balancing

Work-in-Progress

Incorporates automatic tracking of all work-in-process

Provides work study database

Work in progress stock control through complete transaction audit trial and reduced work in progress stock levels

On screen status of work in progress

Creates awareness when work is not flowing, as it must sustain the required production

Supervisors

Gives supervisory tool, which enables movement of people from one job to another when operators are absent or unable to meet production requirements

Supervisors are being advised of bottlenecks, summary throughput, work-in-progress, stock information and given work-around solutions as problems occur

Operators

Shows operator how to earn more money by eliminating wasted time to produce few more units each hour,hence increases productive hours

Guides the operator to maintain a consistent pace throughout the day

Better implementation of work morale among the employees

Informs operator of their performance to date, accurate predicted pay, etc., on and up to the second basis

Accurate attendance of operators

Quality Control

Makes each operator accountable for the units produced

Provides management the tools to measure and track quality problems by source and hence are isolated as soon as they are identified

Everyone is empowered to recognize and solve problems as and when they occur

Management

All informations are presented to management and supervisors by on screen enquiries, reports and graphs

Reduces clerical errors and paperwork

Reduces overhead cost by reducing administrative overhead

Reduced stock take costs, as accurate work in progress reduces the need for stock taking

Accurate cost calculations of the finished products and the related jobs

Management of orders and the combinations of the order incurred with reference to the work-in-progress helps in analyzing the market trends

Ever-ready state of the factory feasible for the site visits of the clients and prospective investors at any time enhances the market value of the factory

Increased order booking

Customer Care

Supports to become more reliable and trusted supplier, to meet the needs of customers

Enhances accurate delivery of orders to customers

Improved customer relations with accurate information on hand whenever needed

Better customer services resulting from 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 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 as Loading / Inline checking / End line / AQL / 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 for operators and bundles

HR Department :
This reader will be connected to the PC in the HR Department. The operator name and token no details are printed for the operators. The operator cards are inserted in the i-Tag’s pouch and assigned to this reader for every operator / supervisor.
Cutting Department :
This reader will be connected to the PC in the cutting department. The bundles are generated in the application software and bundle cards are printed For the bundles. The bundle cards are inserted in the i-tag’s pouch and assigned in this reader for every bundle prior to issue to the Production floor.

MA-JEVI Line Display Board (LED TV)

An LED TV can be installed for every line / section. The Following information with Graphs can be shown on the LED TV of the respective line / 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 every workstation to indicate the current status of the workstation / operator.

The Status indicator has 3 different color LED lights, each of which can glow or blink. A maximum of 6 status variables can be configured.

The Status Indicator can be configured to indicate the Machine Breakdown, Idle Time, Rework Time, Work-In-Progress, Efficiencies, Batch Setting, Non Productive Time, Excess Time etc.

Identification Technologies

i-Tags

i-Tag for bundle identification

An i-Tag is physically attached to every individual bundle and sent to sewing line for production. This Tag travels along with the bundle in the sewing line from start to end. As each operator starts his/her bundle he/she will tag onto his/her reader ,which will denotes the start of the bundle.On completion of the bundle the operator will again tag onto the reader to indicate the end of the bundle.

i-Tag for Operator identification

An i-Tag is provided to every Operator for his or her identification purpose. Operator uses this tag to login at the workstation before starting work and logout while leaving the workstation.

i-Tag (iButton)

The i-Tag is a computer chip enclosed in a stainless steel can that proves its identity by a globally unique serial number. This i-Tag is used to identify Operators, Supervisors , Mechanics, QA s and Bundles with unique color holders. This i-Tag will have a polythene pouch attached to it. This pouch will carry the printed information of the bundle/employee details.

i-Tag (RFID) - Low Frequency

Typically LF RFID systems operate at 125 KHz. This frequency band provides a short read range of 10 cm, and has slower read speed than the higher frequencies, but is not very sensitive to radio wave interference.

i-Tag (RFID) - High Frequency

Most HF RFID systems operate at 13.56 MHz with read ranges between 10 cm and 1 m. HF systems experience moderate sensitivity to interference.

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

Most HF RFID systems operate at 13.56 MHz with read ranges between 10 cm and 1 m. HF systems experience moderate sensitivity to interference.

Input through Reader Keypad

Operator can use the Reader keypad to Log-In themselves as well as Bundles by entering their Token Nos and Bundle Nos.

MA-JEVI Softwares

Data Capturing Software :

This software is installed in the Data Capturing PC in the production floor which captures the punches from all the readers and updates the central database instantaneously.

Production Management System : (PMS) Application Software

This application software is installed in all the client machines. All Masters and Transaction details are entered in this application. Style Order details, Laying, Cutting, Bundle Generation, Tag Assigning to Bundles, Operation Bulletin, Line layout etc., are entered in this application

Dashboard :

MA-JEVI DashBoard is a Business Intelligence (BI) tool that displays the Macro level information in real time of all the Production lines graphically. Micro level information can be viewed by drilling down the respective cells. Provides various types of graphs at all levels for analysis and comparison for better decision making.

Web based MIS Reports :

This software is installed in the central server. This software collects all the production information from all the MA-JEVI installed factories automatically and produces 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 – month wise / 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 used to track the style / order status when it is run in multiple factories / lines.

All the above reports are cross tab with drill down feature that has 5 levels i,e factory – line – buyer- style – day and so on. You can compare and analyze multiple factory / line across months /weeks etc.

MA-JEVI System Networking

State-of-the-art Networking based on SCADA principles ensures 100% Data reliability
Readers from sewing lines are connected to Controller PC which captures the Data from the Readers and Updates the Central Database in Real-time.
One Controller PC can handle a maximum of 300 Readers.

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Pre-requisite 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, Mouse.

Controller PC

Intel i5 Processor or higher, 16 GB RAM, 250 GB HDD, Network Card, USB Ports, Monitor, Keyboard, Mouse .

Controller Computer

All Reader units are connected to Controller computer through Network. Controller computer is connected to the Database Server.
The Interface software installed in this Controller PC collects the data from the reader units and stores in the database server.One Controller PC can handle upto 300 Readers connected to it.

Software

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

Key benefits of MA-JEVI

MA-JEVI System provides efficient and effective real time information for the performance of the company to implement business strategy successfully.

Instant Reports at all levels.

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

On-Line Production Status

MA-JEVI system provides on screen access to production order and their progress, to eye production status

Improvements in effective and efficient usage of man & machine

Efficient Line Balancing

MA-JEVI system furnishes accurate information of line balancing

Details of employees present and absent on the day
Information on current production in progress against target set
Status of work-in-progress with reference to operational level currently andin-relation to achieving target in fixed time
Line balancing in workflow

Reduction of Work In Progress Time

MA-JEVI system makes production tracking more transparent and this removes the need for checking the work-in-progress every two hours.Workforce analysis on who is working under each section of workflow and the cost of their performance against the project can be monitored whenever needed

Reduction in Downtime

MA-JEVI system reduces unproductive downtime by 20% by providing downtime reports which will enable management to initiate corrective action

Improved In-Line Quality Control

Eliminating the need for Supervisory Checks

Accurate time keeping

MA-JEVI system ensures that the operators check-in directly in time at their workstation. This ensures considerable reduction in queuing time per operator.

Accurate Payment to Operators

MA-JEVI system prevents unnecessary waste of labor time in maintaining their own records and resolves disputes among operators in calculating the cost of the work done by each Operator. The operators are paid only for perfectly completed work and appropriate reductions are applied for faulty pieces before payment. MA-JEVI system eliminates holding back of work tickets and paying twice for the same work. Errors in payroll claims are also reduced to great extent. MA-JEVI system calculates the gross payroll faster than the traditional book keeping system.

Reduction in Overtime Working with maximum utilization of HR

Absence of key workers adds on to the overhead charges and affects the productivity. MA-JEVI system highlights the problem immediately and eliminates unnecessary overtime. An efficiently implemented real time system would reduce the overtime expenses by 50%. Future production planning is made easier.

Reduced Administration Costs

MA-JEVI system reduces paperwork and clerical errors.

Accurate MIS Reports

ROI In Less than 2 Years

By installing MA-JEVI system, you will reap return of investment within two years. You can also benefit from the MA-JEVI hardware depreciation over a period of time.

Salient Features of Crystal MA-JEVI

Centralized real time production monitoring tool

Seamless integration to other application systems

Operation time (SAM) validation

Maintains Sequential integrity of the operations

Supports Progressive Bundle movement, Piece movement, Unit Production System and Bundle Sharing

Flexible Line Layout ( Split / Merge Lines )

Accountability of On-standard time viz, Worked Minutes, Produced Minutes and Cycle time

Accountability of Off-standard time viz, Idle time, Nowork time, Breakdown time, Rework time and Non Productive time

Line balancing - Pitch Diagram to identify bottleneck operations

Work In Process monitoring at all levels

Total Quality Management at In-Line & End-Line Check points

Supports Piece Rate / Group / Individual Incentive methods

Maintains the Skill data of 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 Smart Phone / Tablet to capture the Production Data.

MA-JEVI IoT System can be Implemented for Cutting, Sewing, Checking, Washing, Finishing and Packing.

A Smart phone / tablet with the App is installed on every workstation in the production line.

All devices in the line will access and update the database through Wi-Fi network.

The database can reside on your own Intranet / Internet server.

Identification Technologies Supported

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

i-Tag (Contact) - (i-Tag Reader)

i-Tag (RFID) - Low Frequency - (RF Id Reader - 125 Khz)

i-Tag (RFID) - High Frequency - (RF Id Reader - 13.56 Mhz)

i-Tag (RFID) - Washable Laundry Tag - (RF Id Reader - 13.56 Mhz)

i-Tag (RFID) - Ultra High Frequency - (RF Id 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 / Finishing Operations Smart Phone / Tab can be made to work for sewing or checking by loading the respective App Type

Features

All features and validations of earlier version of MA-JEVI has been implemented in this System

Operator can view the training videos of the operations.

Operator can apply for leave.

Operator can view the Tech-Pack / Measurement Chart of the Styles.

Operator can view their messages in the Inbox sent by the supervisors

Operaor’s Hourly Production with graph can be seen.

Information / Reports / Graph shown can be customised according to the requirements.

MA-JEVI Reports

MA-JEVI real-time reports on a Smart Phone / Tablet for Supervisors & I.Es enables access to critical information about the Production Lines to identify and react to the 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 for achieving real time goals in the Garment and Apparel manufacturing Process. MA-JEVI is a digital assistant in the quest for maximizing enterprise productivity.

Global market and technology are forcing tremendous changes in the Textile and Apparel industries. MA-JEVI system is focused on the issues, complexities and opportunities for Apparel and Textile companies and their suppliers. MA-JEVI system is fully interactive and integrates with the complete range of distribution, material and capacity planning, manufacturing and financial systems which makes it the most comprehensive real-time system.

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

MA-JEVI System can be Implemented for Cutting, Sewing, Checking,AQL, Washing, Finishing and Packing.

MA-JEVI system works on following Identification Technologies commonly termed 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 Tracking System

MA-JEVI system comprises of i-Tag reader and i-Tag. An i-Tag is used to identify Operators, Supervisors , Mechanics, Qas and Bundles with unique color holders. This i-Tag will have a polythene pouch attached to it. This pouch will carry the printed information of the bundle/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?

Operator should Log-in in their workstations with the Operator tag.

An i-Tag is programmed and tied to every bundle at cutting section and issued to sewing line for production.

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

Operators prior to start the operation for the bundle, will Log-in the bundle’s i-Tag in the reader to record the operation Start time.

Operators on completion of all the pieces in the bundle, will Log-out the same bundle’s i-Tag in the reader to record the operation End time and the bundle is moved along with i-Tag to the next operator.

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

Operator should Log-out from their workstations during break-times, moving to other workstations or leaving End of the day.

By and Large, 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 will come out of the line.
MA-JEVI system comprises of i-Tag reader and i-Tag. An i-Tag is used to identify Operators, Supervisors , Mechanics, Qas and Bundles with unique color holders. This i-Tag will have a polythene pouch attached to it. This pouch will carry the printed information of the bundle/Operator details.
The Readers are attached to every sewing machine in the production line and Networked and connected to the Data Capturing PC.
The i-Tag is attached to every bundle and sent in the sewing line for Production.Every operator will do his or her designated operation(s) in the sequence in the line.
By doing so, operators are expected to punch the tag on to the reader for start and completion (i,e twice for each bundle) of the bundle.The punches captured at each reader are sent to the central database server instantaneously. So the bundle’s presence / status are captured at all workstations as and when it passes thereby 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 thru RS485 Multi-drop full duplex network.

No, We use CAT 5 Cable (24 AWG) for networking with RJ45 Connector

Readers - One reader is required for every sewing machine.
i-Tags - 10 Tags required for each reader. (1:10)
This calculation is based on the estimated WIP at each workstation, Ready to issue (bundles in stock) and i-Tags in stock.

The life of i-Tag (iButton) is around 10 years

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

Qc readers used to record rework and rejection pieces.
Qc Readers can be installed for capturing data at Loading, In-line, End-line, AQL, Finishing and packing sections.
Bundles are checked for quality at various stages of operations. On identifying the rejections the bundle is sent back to the concerned operator for correction / rectification.
For the operator to know which particular operator has done the operation, the operator will tag in the bundle on to the QC reader and should enter the operation code which is found faulty, then the system will display the operator name of the concerned operator who had done the bundle, then the QC executive will send the bundle to that operator and updates the no. of faulty pieces in the qc reader.
Order qty depends on the no. of QC check points you have.

Yes, can be seamlessly integrated with your ERP systems.

Operator should Log-in in their workstations with the Operator tag.

An i-Tag is programmed and tied to every bundle at cutting section and issued to sewing line for production.

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

Operators prior to start the operation for the bundle, will Log-in the bundle’s i-Tag in the reader to record the operation Start time.

Operators on completion of all the pieces in the bundle, will Log-out the same bundle’s i-Tag in the reader to record the operation End time and the bundle is moved along with i-Tag to the next operator.

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

The captuerd Data is instantaneously updated in the Central Database Server

Operator should Log-out from their workstations during break-times, moving to other workstations or leaving End of the day.

Yes, Every Style has its own identity therefore it is possible to rout different styles through various paths of the manufacturing process. A part of the concept is to reduce Work In Process (WIP). To be able to maintain and improve WIP you must be able to change styles, manufacture to costumers orders etc. Low WIP has a positive impact on the throughput time for finished products and in it self it reduces the number of styles in the system at one time.

refer Dashboard Presentation

Prior to issuing bundles to sewing line, a tag is attached to the bundle.
This tag should be assigned to a particular bundle. This assignment is done thru PMS application software. The system will store all the bundle details with their respective tags that are assigned.

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 every style, you need to assign Operations to WorkStations in the Line.
The details of readers attached to these workstations are pre-stored in the system.

New versions of MA-JEVI Applications will be provided to customers as and when launched.

Online Support will be provided by our team from our Office through Remote Access.
Onsite Support will be provided by our Support Engineers

MA-JEVI System is solely Designed and Developed by Crystal Consultancy Services Pvt.Ltd. and Marketed by our Authorized Distributors.

MA-JEVI reader has a 16x2 LCD at the top.
All response messages are displayed on the LCD.
Any message from the server is displayed.
Operator's Target, Actual,Efficiency values are displayed. On pressing the Info button , style / operation’s target qty set for the day is displayed

The system has got the option of assignment of resources
Operation -> workstation -> machine
possible assignments are
1 operation-> 1 workstation
1 operation -> 2 or more workstations
n Operation-> 1 workstation
n operation-> m workstations

When start punch is made, the current iTag id is displayed in the LCD And when the end punch is made, the i-Tag id will vanish from the LCD

Yes MA-JEVI Supports 3 Models of Incentive Methods.

Piece Rate Method

Individual Operator Performance based

Line / Section Performace based

Operators idle Time

Operators Non Productiove Time

Operators Rework Time

Operators Nowork Time

Machine Breakdown Time

Lines Non Productiove Time

MA-JEVI System Captures the Cycle Time of all the Pieces Produced by the Operators and generates the Pitch Diagram Graph showing the Operation Cycle Time.
The Production Team continuously monitor this Pitch Diagram to take corrective actions for the weaker Processes / Operators / Operations and balance the Line to get the Optimal Output from the Line.

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MA-JEVI - CUSTOMERS

TamilNadu

Chennai

Ambattur Clothing Limited

Quintessential Designs India Pvt Ltd

Hallmark Industries

R.K Industries

Dindigul & Madurai

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

Anugraha Fashion Mill Pvt Ltd

Jay Jay Mills India Pvt Ltd

JBalu Exports

Le Shark Global LLP

KKP Made-Ups Division

Karnataka

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

Ishman International

Chelsea Mills

Overseas

Platinum 3, Sharjah, UAE

Sparrow Apparels Ltd, Dhaka, Bangladesh

Classic Fashion Apparel Industry Ltd. Co, Vietnam

Kerala

Kitex Limited

Maharastra

Mumbai

Technocraft Industries India Ltd

MadyaPradesh

Indore

STI India Limited

Gujarath

Ahmedabad

Ashima Group

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At Kattrapin Technologies, our greatest strength lies in our people. Our diverse team of over 100 plus subject matter experts brings together a wealth of experience in the automotive sector. From skilled technical illustrators and animators to documentation specialists and app developers, we work collaboratively to deliver innovative solutions tailored to our clients' needs.

We believe in continuous learning and cultivating an environment that encourages creativity and problem solving.

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info@kattrapin.com

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Manchester

INDIA

Sholinganallur, Maraimalai Nagar

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Kattrapin Technologies

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About MA-JEVI

MA-JEVI System can be Implemented for Cutting, Sewing, Checking,AQL, Washing, Finishing and Packing.

MA-JEVI system works on following Identification Technologies commonly termed as i-Tags.

Crystal MA-JEVI Real Time System can be termed as

How MA-JEVI works?

Benefits of Installing 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-Tags

i-Tag for bundle identification

i-Tag for Operator identification