The present disclosure relates to producing sewing designs, and more particularly, to a sewing design manufacturing management apparatus and method, which enable a user to easily setup and modify information regarding a sewing process.
To date, in manufacturing an end product by sewing, a large company with capital and a distribution network develops an end product design to be manufactured by sewing, and asks a product manufacturer to manufacture the product based on the design and deliver the manufactured product to the large company. Given the above, the sewing industry suffers from difficulties in manufacturing the end products by sewing due to the fact that manufacturing productivity depends greatly on how well trained and cared for the skilled workers are. Also, under the above manufacturing structure, asking the product manufacturer in the form of a subcontract or outsourcing, both the large companies and the manufacturers have not been able to introduce new competitive technology or to manage end product designs in a systematic and integrated structure, and thus, the manufacturing efficiency of the end products by sewing has not been improved substantially in several decades.
As industrial technologies develop progressively, an advanced sewing manufacturing device may be configured to utilize a high-tech microprocessor in manufacturing the end products, but there are no apparatuses or methods allowing for exchanging and sharing data effectively so that end product design information is directly associated with a sewing manufacturing device.
A design system for an end product to be manufactured by sewing has been widely known. As an example of the system, there is a clothing Computer Aided Design (CAD) system for designing a clothing design, which can only provide shape and coupling information of items that comprise an entire clothing product. Therefore, even though an end product manufacturer receives sewing design information that has been generated by the CAD system, the end product manufacturer needs to input separate sewing data necessary for an actual sewing process by himself. That is, first, the sewing design information generated by the CAD system is provided to a separate sewing data input device, and then, a user of the sewing data input device needs to indicate for every sewing portion, shape information displayed on the input device by using a pointing device such as a mouse, and input further necessary information with an input means such as a keyboard.
However, since the above-described conventional sewing data input device requires a user to designate a corresponding sewing portion and input necessary sewing data by himself, a significant amount of time is spent on inputting data. Moreover, the conventional sewing data input device is quite expensive and inefficient because the sewing data input device needs to be configured separately from the CAD system.
In addition, when a sewing design has been modified by the CAD system, the sewing data input device should prepare new sewing data based on the modified sewing design, irrespective of what sewing data is already inputted. Thus, it becomes a hassle for the user, and chances are increased that an error occurs in inputting sewing data.
As a result, the conventional sewing data input device requires specialized manpower (skilled workers) having specific knowledge to input sewing data, and the quality of products is substantially dependent on the level of skill that a worker may have for inputting the sewing data.
Moreover, when an actually manufactured end product does not fit with the CAD-prepared design, there have been many disputes regarding the responsibility for the design failures between the person placing the sewing order and the end product manufacturer.
In addition, when a problem occurs in a sewing manufacturing device during a sewing task, there are hardly any means to provide an efficient and fast solution to the problem in order to resume the sewing task.
As seen from the above description, the conventional technology cannot efficiently manage an entire process from making a sewing design to produce a product. Thus, the efficiency of manufacturing a product is reduced, calculating the cost is difficult, and the time of manufacturing the product is wasted. To solve such limitations, the present disclosure provides a sewing design manufacturing management apparatus and method.
The present disclosure provides some embodiments of a sewing design manufacturing management apparatus and method, which can provide a solution to the low efficiency of manufacturing an end product due to the lack of organic association with the design of the end product and the manufacture of the product.
According to an aspect of the present disclosure, disclosed is a sewing design manufacturing management apparatus which includes a design shape display module, a design shape analysis module, a sewing information process module, a sewing data process module, a manufacturing prediction module, a factory line process module, a network interface module, an input/output module, and an after-service (A/S) module.
According to another aspect of the present disclosure, disclosed is a sewing design manufacturing management apparatus which further includes a design layout module.
According to another aspect of the present disclosure, disclosed is a sewing design manufacturing management method which includes receiving design information on an end product to be manufactured by sewing; configuring at least one component shape of the end product based on the design information; identifying one or more processes necessary for manufacturing the end product based on analysis of the one or more component shapes; enabling a user to select one process from the one or more processes; enabling a user to select one process from the processes; providing one or more process task charts related to the one or more processes; predicting at least one of process time and process cost for the selected process, on the basis of the sewing information and the sewing data; transmitting at least one of the sewing information and the sewing data to at least one sewing manufacturing device through a network; receiving a device status message from the at least one sewing manufacturing device, the device status message including an abnormal status message indicating that a status of the at least one sewing manufacturing device is abnormal; providing at least one of text data and multi-media data to address the abnormal status based on the abnormal status message; and transmitting an A/S request message to a sewing manufacturing device provider based on the abnormal status message.
A design manufacturing management method according to another embodiment of the present disclosure further includes generating design information.
The following detailed description includes various exemplifications that can implement the present disclosure. The disclosed exemplifications merely facilitate the understanding of the content of the present disclosure, and do not limit the present disclosure at all. The present disclosure may include an embodiment which is implemented with only software, include an embodiment which is implemented with only hardware, or include an embodiment which is implemented by combining software and hardware. Also, elements or operations that are separately described in one embodiment of the present disclosure may be integrated as one element or one operation in another embodiment.
According to an embodiment of the present disclosure, it is possible to enable a user to easily provide information on a plurality of sewing processes necessary for manufacturing a product and sewing data for a plurality of manufacturing devices that perform the sewing processes, on the basis of information on an end product design to be manufactured by sewing. Also, an embodiment of the present disclosure makes it possible to accurately predict the manufacturing time and the manufacturing cost for manufacturing the end product based on the provided sewing data and information on the sewing processes. According to an embodiment of the present disclosure, the user can select a plurality of manufacturing devices necessary for manufacturing a corresponding product based on the end product design information, and when a desired manufacturing device is not available, the user can ask a manufacturing device provider to deliver the corresponding manufacturing device. Moreover, an embodiment of the present disclosure may propose a factory line configuration, change, or rearrangement of workers in order to meet the required manufacturing cost and delivery date. Further, an embodiment of the present disclosure may receive a message indicating that the status of a sewing manufacturing device is abnormal, provide information necessary to address the abnormal status in the form of text data or multimedia data, and transmit an A/S request to a sewing manufacturing device provider.
A sewing design manufacturing management system according to an embodiment of the present disclosure will be described in detail with reference to
As illustrated in
The sewing design manufacturing management apparatus 110 according to an embodiment of the present disclosure may include a design shape display module 122. The design shape display module 122 may generate at least one shape for a component for a corresponding end product based on the sewing design information that is received over the first network 150. The sewing design information provided by the design layout module 180 may be used to determine an external shape of the end product, as with three-dimensional (3D) CAD data, but may not be used for seeing shapes of numerous product components that will be used to manufacture the corresponding end product. Therefore, the design shape display module 122 may provide data representing at least one shape of a component for the end product based on the sewing design information, thereby enabling a user to visually and easily input sewing information and data necessary for manufacturing the end product.
The sewing design manufacturing management apparatus 110 according to an embodiment of the present disclosure may further include a design shape analysis module 124. The design shape analysis module 124 may analyze design information, for extracting at least one shape of a component for the end product from the sewing design information. Such an analysis may include a conversion from 3D data to two-dimensional (2D) data and performing an analysis for each component for a sewing design, based on information on the components necessary for manufacturing the end product. For example, in order to make it easier to manufacture the end product, the design shape analysis module 124 may generate and provide a 2D representation through data conversion from the 3D sewing design information, to provide a plan view for each component of the end product and present each work process in a clear manner.
The sewing design manufacturing management apparatus 110 according to an embodiment of the present disclosure may further include a sewing information process module 126. The sewing information process module 126 may provide an individual component shape, which may be provided by the design shape display module 122, to a user. With the individual component shape, the sewing information process module 126 enables the user to easily input sewing information on each process. Sewing information received at the sewing information process module 126 may include a stitch shape, a member to be used in each sewing processing section, a type and color of yarn, a needle, a stitch length, a total number of stitches, a start and end position of each section, an accessory attachment type, and other guidelines/cautions of sewing, but the present embodiment is not limited thereto. The sewing information process module 126 may separately store sewing information, which is received from a user, for each section in each process.
The sewing design manufacturing management apparatus 110 according to an embodiment of the present disclosure may further include a sewing data process module 128. The sewing data process module 128 enables a user to provide sewing data, which is required for performing a corresponding sewing process, based on the sewing information stored in the sewing information process module 126. The sewing data may include a plurality of parameters for executing a component stitch pattern for each sewing process, and specifically include a stitch width, a number of stitches, an upper yarn tension, a sewing speed, a sewing machine foot pressure, etc., but the sewing data is not limited thereto. The sewing parameters may need to be adjusted according to the sewing manufacturing device that is used in a corresponding sewing process, and thus, the sewing data process module 128 may allow a user to select a sewing manufacturing device to be used. When a sewing manufacturing device that a user desires to use is not available, the sewing data process module 128 may transmit an inquiry or a request for a corresponding sewing manufacturing device to a provider. For example, when a user selects a non-available sewing manufacturing device, the sewing data process module 128 may allow for a purchase inquiry or request interface to be displayed. The purchase inquiry or request interface may operate in operational connection with a social network service such as Twitter or Facebook.
The sewing design manufacturing management apparatus 110 according to an embodiment of the present disclosure may further include a manufacturing prediction module 132. The manufacturing prediction module 132 may predict working hours for each process on the basis of the total number of stitches, start and end positions, number of yarn cuttings, and main shaft speed, which are designated for each sewing process. The manufacturing prediction module 132 may predict total manufacturing time or manufacturing cost that is expected in manufacturing an end product, in consideration of the order of assembling components, number of used manufacturing devices, daily predicted working hours, and worker wages.
The sewing design manufacturing management apparatus 110 according to an embodiment of the present disclosure may further include an input/output module 134. The input/output module 134 may include an input means for receiving a command and information from a user. In an embodiment, the input means may include a keyboard, a pointing device, a microphone, a joystick, a scanner, etc., but the present embodiment is not limited thereto. The input/output module 134 may include an output means for providing information to a user. For example, the output means may include a monitor display, a speaker, a printer, etc., and include a wired/wireless interface that transfers an information signal to be outputted to a user personal terminal, but the present embodiment is not limited thereto. A user may be provided with an interface, which may receive sewing information or sewing data from the sewing design manufacturing management apparatus 110 according to an embodiment of the present disclosure, thereby enabling the user to input corresponding information and data via the input means or the output means.
The sewing design manufacturing management apparatus 110 according to an embodiment of the present disclosure may further include an A/S module 138. The A/S module 138 may receive a device status message from the sewing manufacturing devices 190-1 to 190-n over the second network 152. The device status message may include an abnormal status message indicating that the status of the sewing manufacturing devices 190-1 to 190-n is abnormal, and the abnormal status message may include information to recognize each of the sewing manufacturing devices 190-1 to 190-n and provide details about the abnormal status. The A/S module 138 may provide the sewing manufacturing devices 190-1 to 190-n over the second network 152 with information necessary to address the abnormal status based on the details, for example, in the form of text data or multimedia data. In accordance with the information included in the text data or the multimedia data, the sewing manufacturing devices 190-1 to 190-n may be adjusted or configured by taking appropriate measures. Even after the adjustment or configuration, if the abnormal status continues, the A/S module 138 may transmit an A/S request message to a sewing manufacturing device provider over the third network 154. After transmitting the A/S request, the A/S module 138 may monitor the A/S progress. According to one embodiment of the present disclosure, the A/S module 138 may check the time from the A/S request transmission to the arrival of an A/S personnel, the status of the A/S progress, the completion of the A/S, etc.
The sewing design manufacturing management apparatus 110 according to an embodiment of the present disclosure may further include a central process module 120. The central process module 120 may control the elements of the sewing design manufacturing management apparatus 110 and issue a command, in order to perform a series of procedures necessary for the management of a sewing design. According to an embodiment of the present disclosure, the central process module 120 may be a general computer, a special purpose computer, a distributed processing system, or an independent operation processing device, but the present embodiment is not limited thereto.
In the sewing design manufacturing management system 100 according to an embodiment of the present disclosure, the sewing manufacturing devices 190-1 to 190-n may include controllers 180-1 to 180-n and display devices 182-1 to 182-n, respectively. The controllers 180-1 to 180-n of the sewing manufacturing devices may receive at least one of the sewing information and the sewing data over the second network 152 and set operating conditions on the basis of the at least one of the sewing information and the sewing data. The display devices 182-1 to 182-n of the sewing manufacturing devices may include a monitor for visual data, a speaker for audio data, an input module (e.g., a touch panel) for receiving a user input, etc. With these means, the display devices 182-1 to 182-n may provide a user with information and requirements that should be kept in mind with regard to the sewing information and the sewing data. In addition, the controllers 180-1 to 180-n of the sewing manufacturing devices may transmit manufacturing status information to the sewing design manufacturing management apparatus 110 over the second network 152.
In the sewing design manufacturing management system 100 according to an embodiment of the present disclosure, the controllers 180-1 to 180-n of the sewing manufacturing devices may transmit the device status message to the A/S module 138 over the second network 152. The device status message may include the abnormal status message indicating that at least one of the sewing manufacturing devices 190-1 to 190-n enters the abnormal status. The sewing manufacturing devices 190-1 to 190-n may receive the text data or multimedia data regarding the abnormal status from the A/S module 138. The display devices 182-1 to 182-n of the sewing manufacturing devices 190-1 to 190-n may display the received text data or multimedia data depending on a user's request received from the input module.
A sewing design manufacturing management method according to an embodiment of the present disclosure will be described in detail with reference to
The sewing design manufacturing management method is started in operation 302, and may receive sewing design information from the outside through a network or a medium such as a storage device in operation 304. In an embodiment, the sewing design information may be 3D digital information generated by a CAD program, but the present embodiment is not limited thereto.
In operation 306, the sewing design manufacturing management method may analyze the sewing design information that was received in operation 304, and thus determine a plurality of processes necessary for manufacturing a corresponding end product. In an embodiment, in order to extract at least one component shape of the corresponding end product by analyzing the sewing design information, the sewing design manufacturing management method may perform a conversion operation from 3D data into 2D data, but the operation for extracting at least one component shape is not limited thereto. Also, according to an embodiment of the present disclosure, the sewing design manufacturing management method may divide the sewing design information into that necessary for each process for manufacturing the product, and analyze each of the components used in the process. For example, in a child safety seat, the sewing design manufacturing management method may analyze each of components such as a seat cushion, a seat back, and a head rest.
In operation 308, the sewing design manufacturing management method may display a sewing design shape necessary for manufacturing a product, on the basis of the analysis of the sewing design information that was obtained in operation 306. According to an embodiment of the present disclosure, the sewing design shape may be displayed on a process basis or a component basis, but the present disclosure is not limited thereto. According to an embodiment of the present disclosure, a plurality of components may be assembled to result in an intermediate product, and then, a plurality of intermediate products may be integrated to result in a secondary intermediate product or a finally finished product. Therefore, in operation 308, in which the sewing design shape is displayed, the sewing design manufacturing management method may display not only the shape of each component, but also the shapes of a plurality of intermediate products, which are produced in a sewing process operation. The shapes displayed in operation 308 may be stored respectively as an independent object, and displayed according to a user's request.
In operation 310, in accordance with an embodiment of the sewing design manufacturing management method, sewing information and sewing data may be inputted with reference to the sewing design shape displayed in operation 308. The displayed design shape may be identified on the basis of processes necessary for manufacturing the end product, and the sewing information and sewing data may include parameters, materials, members, attachment devices, and cautions that are required respectively for each process, but the present disclosure is not limited thereto. Specifically, with reference to the displayed design shape, the sewing design manufacturing management method may allow a user to input information such as a stitch shape, a member to be used, a type and color of yarn, a needle, a stitch length, a total number of stitches, start and end positions of each section, an accessory attachment type, and other guidelines and cautions of sewing in operation 310, but the input sewing information is not limited thereto. Also, with reference to the displayed design shape and the input sewing information, the sewing design manufacturing management method may allow the user to input the sewing data such as a stitch width, a number of stitches, an upper yarn tension, a sewing speed, and a sewing machine foot pressure in operation 310. According to an embodiment of the present disclosure, the sewing design manufacturing management method may receive the sewing data, and allow the user to select a sewing manufacturing device for performing a sewing process on the basis of the sewing data. When the selected sewing manufacturing device is not included in a manufacturing factory, the sewing design manufacturing management method may provide an interface that allows the user to transmit a purchase inquiry or request to a sewing manufacturing device provider who provides a corresponding sewing manufacturing device, or transmit the purchase inquiry or request through a social network service such as Twitter or Facebook in operation 310, but a scheme of transmitting the purchase inquiry or request is not limited thereto.
In operation 312, the sewing design manufacturing management method may transmit the sewing information and data, which were inputted in operation 310, to a corresponding sewing manufacturing device. According to an embodiment of the present disclosure, in operation 312, the transmitted sewing information and data may be received by the sewing manufacturing device and automatically set the operation environment of the sewing manufacturing device, such as an upper yarn tension, a sewing speed, a sewing machine foot pressure and the like. Guidelines/cautions may be displayed on a display means that is included in the sewing manufacturing device, and thus, easily provided to a worker. The sewing manufacturing device, which has been configured with the sewing information and the sewing data transmitted in operation 312, may even be operated by an unskilled beginner, instead of a skilled worker.
In operation 314, the sewing design manufacturing management method may be completed.
A sewing design manufacturing management method according to another embodiment of the present disclosure will be described in detail with reference to
The sewing design manufacturing management method according to another embodiment of the present disclosure may start in operation 402, and may allow for configuring a sewing design in operation 404. In operation 404, for example, the sewing design may be transferred to a manufacturer in the form of a sketch or document. According to the sewing design manufacturing management method, design information necessary for manufacturing a product may be generated based on the sketch or the document.
In operation 406, the sewing design information generated in operation 404 may be analyzed to identify a plurality of processes necessary for manufacturing a corresponding end product. In operation 408, sewing information and sewing data necessary for manufacturing the end product may be inputted for each of the identified processes. In operation 410, the input sewing information and sewing data may be transmitted to a corresponding sewing manufacturing device, thereby enabling even an unskilled worker to operate the manufacturing device for manufacturing the end product. Operations 406 to 410 are similar to operations 306, 310 and 312, respectively, that have been described above with reference to
The design management menu 504 of the function selection interface 500 according to an embodiment of the present disclosure may provide at least one of a file function 520, a sewing information input function 530, a sewing data input function 540, a productivity analysis function 550, and a factory line configuration function 560, but the present embodiment is not limited thereto.
The file function 520, which may be included in the design management menu 504, may include a function to open, store, or upload the design information data to a database, but the present embodiment is not limited thereto.
The sewing information input function 530, which may be included in the design management menu 504, enables a user to input a sewing brand name, a product code, a Bill of Material (BOM) code, a process number, a process name, a type of a sewing manufacturing device, a type and color of yarn, accessory settings, and process information on start and end positions, but the present embodiment is not limited thereto. For example, the sewing information input function 530 enables a user to provide a type of needle, a stitch length, a total number of stitches, a type of sewing manufacturing device, a process code, materials used for each of the sections, and materials used for each of the stitch shapes.
According to an embodiment, the sewing data input function 540 of the design management menu 504 enables a user to input at least one of the following sewing data. As an example, the user may input a seam width, a shape and range of a stitch, a shape of a seam, a sewing speed, a number of stitches, a stitch length, a yarn to be used, an upper yarn tension, a sewing machine foot pressure, a needle, a lockstitch, a type of needle sewing, upper and lower needle sewing, a chain, overlock, zigzag, flat, post, a cylinder, a pattern size, and a bar tack, by using the sewing data input function 540, but the present embodiment is not limited thereto.
The productivity analysis function 550 included in the design management menu 504 enables the reception of information necessary to generate manufacturing information required for the end product. For example, the productivity analysis function 550 may select a sewing manufacturing device to be applied and receive working conditions, daily manufacturing amount, information on each factory line, etc., but the present embodiment is not limited thereto. According to another embodiment, the productivity analysis function 550 may predict and provide the number of sewing manufacturing devices and the number of workers that should be involved for satisfying the requested delivery deadline and the requested amount of manufacturing end products, in consideration of the selected sewing manufacturing device(s) and received working conditions.
The factory line function 560 of the design management menu 504 may be included in at least one embodiment of the present disclosure. The factory line function 560 enables a user to configure, correct, and change a series of sub factory lines and a series of main factory lines, on the basis of sewing information and sewing data that are input in connection with a sewing design.
According to at least one embodiment of the present disclosure, an A/S function 580 may be included in the design management menu 504. The A/S function 580 may provide text data or multimedia data to address a corresponding abnormal status based on an abnormal status received from a sewing manufacturing device, but the present embodiment is not limited thereto. The A/S function 580 may generate an A/S request message, which may be transmitted to a sewing manufacturing device provider, and allow a user to review and revise the A/S request message. Further, the A/S function 580 may monitor how far the requested A/S has completed and check whether the A/S is completed within a desired time. The review and revision of the A/S request message and the monitoring of the A/S will be explained below in more detail.
An A/S management method for the sewing manufacturing devices 190-1 to 190-n in the sewing design manufacturing management system according to an embodiment of the present disclosure will be described with reference to
The A/S management method is started in operation 1402, and may receive a device status message from at least one of the sewing manufacturing devices 190-1 to 190-n over a network. In operation 1406, the A/S management method may determine whether an abnormal status message is included in the device status message. If the abnormal status message is included, the A/S management method may proceed to operation 1408. If not, the A/S management method may proceed to operation 1404 to receive another device status message. In operation 1408, the A/S management method may provide text data or multimedia data including information to address the corresponding abnormal status. In accordance with the text data or the multimedia data, a sewing manufacturing device may be adjusted by taking proper measures to address the abnormal status. In operation 1410, the A/S management method may determine whether the abnormal status is addressed with the taken measures according to the text data or the multimedia data. If the abnormal status is not addressed, the A/S management method may proceed to operation 1412, and if the abnormal status is addressed, the method may return to operation 1404 to receive a new device status message. In operation 1412, the A/S management method may generate and transmit an A/S request for the abnormal status to a sewing management device provider. After transmitting the A/S request, the A/S management method may continue to monitor the progress of the A/S until the A/S is finished in operation 1414. The A/S management method may be completed in operation 1415 when the A/S is completed.
The sewing design manufacturing management apparatus and method according to the embodiments of the present disclosure may be implemented with a computer program. The computer program may be stored in a computer-readable medium. A computer-readable medium including a computer program according to an embodiment of the present disclosure includes ROM, RAM, flash memory, CD-ROM, optical storage medium such as DVD, hard disk, magnetic storage medium such as magnetic table, and the like, but the present disclosure is not limited thereto. The computer program may include source codes written with programming languages and machine codes compiled by an assembler, but the present disclosure is not limited thereto. The computer-readable medium may store the source codes or the machine codes, as distributed in a plurality of computer systems connected via a network.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosures. Indeed, the novel methods and apparatuses described herein may be embodied in a variety of other forms; furthermore, various changes, modifications, corrections, and substitutions with regard to the embodiments described herein may be made without departing from the spirit of the disclosures. Also, the elements and operations of the sewing design manufacturing management apparatus and method of the present disclosure may be implemented as a plurality of distributed hardware modules or software modules.
Therefore, the accompanying claims and their equivalents including the foregoing modifications are intended to cover the scope and spirit of the disclosures, and are not limited by the present disclosures.
Number | Date | Country | Kind |
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10-2011-0064846 | Jun 2011 | KR | national |
10-2012-0013745 | Feb 2012 | KR | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/KR2012/005185 | 6/29/2012 | WO | 00 | 12/24/2013 |