By Melissa Donovan
Part 1 of 2
There are many steps in the textile supply chain from order intake to inventory management. Keeping track of it all can be a burden and unwise use of time. Luckily, automation software is specifically designed for textile design, production, and distribution. This is useful in such segments as automotive, garment, and furnishings. Furthermore, certain solutions address the digital printing and finishing aspect of the process. Manufacturers adding digital printing hardware should simultaneously address workflow software.
Automation Software First
For fabric manufacturers in many industry verticals, implementing digital printing and/or cutting hardware also means integrating automation software. It is important to concentrate on automation software right out of the gate and not implement after the hardware has been in use.
Chris Des Biens, sales manager, ErgoSoft, explains that many production houses involved in digital textile manufacturing over the years have “hung on for the ride as they grew.” Although they’ve had success, they believe stepping back and evaluating workflow software is disruptive to the process and staff.
“Keeping production up and running is always critically important. Down time is costly and difficult to plan for, especially if a company is running multiple shifts. If there are any unforeseen issues with an implementation, it can cost dearly in terms of both time and money. Secondly, staff members often become attached to a process, and changing the way they perform work can be a long-term challenge. Training may be required, employees may resist change, and some staff may not be capable of making the adjustment,” he continues.
To avoid these challenges, it is helpful to investigate software options upfront. “I feel this is important so that you can first ensure that the software solution provides the necessary functionality and requirements that you are looking for and then investigate the necessary hardware that will integrate with the solution,” suggests Michael Rabin, president, Morgan Tecnica America Inc.
“Automation software is important to address as most digital printers and cutting hardware depend on software to create patterns or markers to send to the machine. You want to make sure that the hardware is compatible with the software as the software is where all your work takes place and is then sent to the output,” agrees Chris Walia, COO, Tukatech Inc.
The software and hardware must work together, and ensuring this happens saves money in the long run. “There can be compatibility issues between the software and the hardware. Correctly automating the process upfront ensures lower production costs and reduce some of the manual stages of post-print finishing,” recommends Bryan Manwaring, director of product marketing, Onyx Graphics, Inc.
According to Andy Arkin, strategic account manager, Zünd America, learning a new solution is challenging, but making a change to an existing solution later on is even more difficult. “Whenever possible, with new equipment and automation, manufacturers should get a complete solution right out of the gate so that they can learn and optimize their production workflow from the start. This also allows them to derive maximum benefit quickly, saving time, labor, and reducing waste, all of which impacts return on investment (ROI) sooner rather than later.”
Whether automation software is added at the same time as the hardware or not, the fact remains that it is a necessary asset to any production process. “Automation software makes it possible to connect the dots across prepress to printing and finishing. Manufacturers look to automate to reduce the number of errors due to manual input into the disconnected software and to speed up processes. Automation helps streamline the processes and make the production seamless,” says Sebastien Hanssens, VP marketing and operation, Caldera.
Leonard Marano, VP, product management and marketing, automation systems, Gerber Technology, agrees that an integrated hardware and software solution is crucial for workflow efficiency and accuracy. “Integration brings additional value though features such as quick response code order processing and color profile pass through that you can only get with systems that are meant to work together. Those who utilize an integrated solution are able to move with the speed and agility they need to compete and win.”
Don’t Hold Back
Textile manufacturers who have yet to consider automation software or have considered it and haven’t followed through are conflicted. While they understand the overall investment will be worthwhile, the initial investment is overwhelming. Secondly, time is a factor. No one wants to stop production. Thirdly, on a basic human level, no one likes change—many are fearful of the unknown.
Walia says people are stuck on the dollar sign. “They are fearful that there may not be an ROI and if it doesn’t work, they could be held liable. Many don’t look at the value and only think of the cost.”
“Sometimes, the cost of potential disruption keeps the project perpetually on the back burner. Another factor is the matter of integration with other software platforms in operation at a facility. An automation solution is only as good as its ability to communicate with other platforms. ERP/MRP, ecommerce platforms, workflow tracking—integrated all of these pieces typically require software development talent. This factor introduces an additional layer of cost and complexity that is daunting and results in increased cost,” admits Des Biens.
Time is money and relates to textile manufacturers’ uncertainty when it comes to implementing automation software. “Manufacturers need to see the value of the investment but also dedicate time and resources to implement. They are sometimes too busy and don’t take a step back to look at how to better organize and be more productive,” suggests Hanssens.
Rabin believes hesitation has a lot to do with fear. “We don’t want to admit this, but many companies although they talk about innovation and change find it difficult to implement either because of staff as well the confidence that the provider they choose can make it a success.”
“Many have tunnel vision and are set in their current ways, which worked well for 30 years, but the days of high-volume orders of the same design and large inventories are over. Today, the key to success is making only what you need and, whenever possible, only after you are paid for it. Entrepreneur start-ups understand this and are reaping automation benefits while creating disruption for big brands and large retailers,” explains Arkin.
To go beyond the familiar means committing to the right solution, but Manwaring points out that many times it is difficult to make a decision about the best solution for the environment in question. Research is the first step. Reaching out to those who have been successful is an obvious option, however, it is hard to find people who want to share their secrets. Manwaring says industry publications, application seminars, and trade shows are good methods to overcome this obstacle.
“People tend to think big when they think of automation; the better trend is to think lean,” he advises.
Tips for What’s Next
Convinced to consider automation software? Before the integration process it is imperative to conduct research on your current processes as well as future goals. Cost is also an important consideration.
Rabin suggests looking at current processes first. “This is a great opportunity to review what is happening in the operation.”
From there, issues that the prospective software will eventually address should be identified. “Understand the workflow bottlenecks, material wastage, and all manual production steps,” shares Manwaring.
“Manufacturers need to identify and understand the problem internally. Sometimes automation software is not the solution. They need to understand that if they implement a software how and what it is going to do for them, what is the opportunity, and what are the benefits?” asks Walia.
Marano suggests planning for the future as well. “Before manufacturers start their integration process, they should set up an infrastructure that puts them in a position to not only leverage what is available today, but also prepare them for tomorrow.”
Cost varies based on the manufacturer’s size requirements, production volume, and desired level of automation, according to Arkin.
In Hanssens’ experience, prices range between 2K to 20K—greater investment is completed by larger manufacturers.
“The overall cost is always going to be higher when you wait. But surprisingly, it doesn’t cost as much as you’d think,” cautions Des Biens.
Automation Software
Workflow software helps streamline processes from end to end. An expansive task, many manufacturers fear integrating such a solution into their production facilities. If digital printing or finishing is new, adding automation software at the same time is recommended. If these technologies exist already, it’s not an ideal scenario, but it is possible and recommended. “As painful as it may seem, it is never too early or too late. If you have not evaluated an automation solution, you should be looking at it now,” recommends Des Biens.
The next article in this two-part series shares product information from automation software vendors. These solutions are used in textile production.
Click here to read part two of this exclusive online series, Linked End to End.
Sep2019, Industrial Print Magazine