JUKI IP-110 Type F User manual

Instruction Manual
for Production Support Function
(IP-110)
ENGLISH

i
CONTENTS
!. INTRODUCTION ....................................................................................... 1
1. Outline..................................................................................................................................... 1
2. Basic operation procedure.................................................................................................... 3
2-1. Changing over between the information mode and the normal sewing mode.............3
2-2. Information mode ......................................................................................................... 4
2-3. Normal sewing mode ................................................................................................... 5
@. SETTING ................................................................................................... 6
1. Setting procedure to be taken before rst use.................................................................... 6
1-1. Entering a password .................................................................................................... 6
1-2. Setting required data items in sequence ................................................................... 8
(1) Enabling the operation of the production support function ......................................................8
(2) Setting the date and time......................................................................................................... 9
(3) Setting the sewing machine ID .............................................................................................. 10
1-3. Carrying out setting of other data............................................................................. 10
2. Setting procedure to be taken before regular operation.................................................. 11
2-1. Setting the date and time........................................................................................... 11
2-2. Setting the sewing machine ID.................................................................................. 11
2-3. Setting the enable/disable of the production support function............................. 12
2-4. Setting the sewing recorder function....................................................................... 13
2-5. Setting the production management function ........................................................ 14
(1) In the case of counting up the target production volume according to the pitch time............ 14
(2)Inthecaseofcalculatingthetargetproductionvolumeaccordingtothespeciedstarting/
nishingtimesofdayofworkandtotalproductionvolume ..................................................15
2-6. Setting common data for the production support function ................................... 18
(1) Production support common setting screen No. 1................................................................. 18
(2) Production support common setting screen No. 2................................................................. 19
#. OPERATION............................................................................................ 20
1. Operating the work management screen........................................................................... 20
2. Operating the pitch time monitor screen........................................................................... 22
2-1. Pitch time monitor screen No. 1................................................................................ 22
(1) Production volume graph mode............................................................................................. 22
(2) Pitch time graph mode...........................................................................................................24
2-2. Pitch time monitor screen No. 2................................................................................ 26
3. Operating the sewing recorder ........................................................................................... 27
3-1. Sewing recorder screen No. 1................................................................................... 27
3-2. Sewing recorder screen No. 2................................................................................... 29
3-3. Uploading/downloading the sewing recorder data ................................................. 30
4. Operating the production management function.............................................................. 31
4-1. Production management screen No. 1..................................................................... 31
4-2.Production management screen No. 2...................................................................... 33
$. ERRORS.................................................................................................. 34

– 1 –
!. INTRODUCTION
1. Outline
ThisInstructionManualdescribestheproductionsupportfunctionwhichisenabledbyinstallingtheIP
(Intelligent Panel) on the sewing machine and operating it. The IP measures the operational status of
thesewingmachineandrecordsit.Inaddition,itvisuallyindicatestherecordeddatatohelpimprove
efciencyinsewingworkfromvariouspointsofview.Themeasuredandrecordeddataonthesew-
ingmachineoperationcanalsobeloadedintoapersonalcomputerbywayofamedium.Bycollecting
andloadingoperationdatafromtwoormoresewingmachinesintoapersonalcomputer,notonlythe
detailedanalysisoftheoperationalstatuswithSMDAA(SewingManagementDataAnalysisApplication
software)butalsotheaccumulationoftheanalyzeddataareenabled.Withthoseanalyzedandaccu-
mulateddata,efciencyimprovingactivitiesfortheentiresewingplantcanbecarriedoutcontinuously.
* RefertotheInstructionManualforSMDAAfortheSMDAA.
TheproductionsupportfunctionbymeansoftheIPiscategorizedintofourfunctionalparts,i.e.,work
management function, pitch time monitor function, sewing recorder function and production manage-
mentfunction.Eachofthemhasitsownsupportcapability.Usethembyselectinganappropriateone
accordingtoyourneeds.
* Itshouldbenotedthattheworkmanagementfunctioncannotbedisabledsinceitmanagesdataon
the sewing machine operation. Operation of the other three functions can be changed over between
the enable and disable.
(1) Work management function
 Tousetheworkmanagementfunction,workhistorydatasuchastheoperatorID,productnumber
andprocessnumber,whicharetobeembeddedintheoperationdatarecordedbyeachsewing
machine,shouldbeentered.TheSMDAAcarriesoutoperationalstatusanalysisbasedonthose
pieces of data.
This function is also used when loading the operation data from the sewing machine into a personal
computer.
(2) Pitch time monitor function
 Withthepitchtimemonitorfunction,itispossibletospecifyanarbitrarytargetsectiontomonitor
thetransitionoftheproductionvolume(i.e.,thequantityofsewnitems)perunittimeandthepitch
timedistributionanddisplaythemontheIPasabarchart.Inaddition,theoperationalstatussuch
asthetotalproductionvolumeandaveragepitchtimeinthespeciedsectioncanbeanalyzedand
indicatednumerically.Throughthesecapabilities,thesewingworkcanbemonitoredoveralong
timeandvisuallyanalyzedtoenabletrackingdownofthetimewhenaproblemhasoccurred.
(3) Sewing recorder function
 Thesewingrecorderfunctioncontinuouslymeasuresthenumberofrevolutionsandthreadtrimming
timing of the sewing machine at all times to show the results on the IP as a line chart. The sewing
machineoperator'sskilllevelischeckedandtechnicaltrainingisprovidedbasedonthelinegraph.
Itispossibletodisplayanoperator'sskillleveltogetherwiththatofaskilledoperatororwithhis/her
workdataofthepastonascreenforthepurposeofcomparison,sothatthecomplicatedandhard-
to-understandsewingmachineoperationcanbevisualizedforeasieranalysis.
(4) Production management function
 Theproductionmanagementfunctiondisplaysthetargetproductionvolumeforgivenworkinghours
andtheactualproductionvolumetonotifytheoperatorofadelayorprogressofsewingworkinreal
time.Withthisfunction,theoperatorisabletocarryouthis/herworkwhilecheckinghis/herwork
pace.Thisenhanceshis/hermotivationtoachievehis/hergoal,therebyleadingtoaincreasein
productivity.Inaddition,thisfunctionallowsearlydetectionofadelayinworkmakingitpossibleto
identifyaproblemandtakeanappropriatemeasureatanearlystage.

– 2 –
<Explanation of terms used in this Instruction Manual>
Pitchtime: Lengthoftimerequiredtonishasewingitem.
Manual switch : The switch located on the screen of each production support function and used for
counting up the production volume.
Productionmanagementswitch(handyswitch):
The optional manual switch which can be connected to the IP. It is used for counting
up the production volume.
Manualinput: Itisandataentryoperationforcountingonesewingsequence.Itisagenericterm
that represents pressing of the aforementioned Manual switch or the Production man-
agement switch.
Operationdata: Dataobtainedbymeasuringtheoperationalstatusofthesewingmachineandre-
cording it.
SMDAA: ItisanabbreviationfortheSewingManagementDataAnalysisApplication.Itis
the application software used for loading the aforementioned operation data from a
sewingmachineintoapersonalcomputerbywayofamediumtocarryoutdetailed
analysisofthemachine'soperationalstatusonthepersonalcomputer.

– 3 –
2. Basic operation procedure
2-1. Changing over between the information mode and the normal sewing mode
TheIPpaneloperationisgenerallydividedintotheoperationundertheinformationmodeandthat
under the normal sewing mode. The mode can be changed over between those two modes using the
Information switch .
Information mode
 Underthismode,functionsettingsfortheproductionsupportfunctionarecarriedoutandthesew-
ingmachineoperationisset/checked.
 *Undertheinformationmode,thesewingmachinecannotperformsewing.
Normal sewing mode
 Underthismode,thesewingmachineperformssewing.
 Thesewingscreendiffersonamodel-by-modelbasis.ItispossibletousetheIPpanelbychang-
ing over the screen, with the Screen changeover switch , between the sewing screen and the
production support function screen on which the production support operation is enabled.
 <Sewingscreenwhichdiffersonamodel-by-modelbasis>
<Production support function screen on which the production support opera-
tion is enabled>
Press the
switch .

– 4 –
The following shows the outline of the operation setting procedure for the production support function
under the information mode. Refer to the item page given under the screen for detailed explanation of
the operation setting procedure for each screen.
2-2. Information mode
<Information mode screen No. 1>
<Sewing management information screen No. 1>
<Sewing management information screen No. 2>
<Productionsupportfunctionoperationenable/
disable setting screen>
<Sewing machine ID setting screen>
<Date and time setting screen>
<Production support function password setting
screen>
<Production support common setting screen
No. 2>
<Production support common setting screen
No. 1>
<Production management function setting
screen>
<Sewing recorder function setting screen>
Keep the switch held
pressed for three seconds.
Keep the switch held pressed for three seconds.
@. 1-2.(2) Setting the date and time
@. 1-1. Entering the password
@. 2-6. Setting the common data on the production
support function
@. 2-6. Setting the common data on the production
support function
@. 2-5. Setting the production management function
@. 2-4. Setting the sewing recorder function
@. 2-3. Setting the enable/disable of the operation
of the production support function
@. 2-2. Setting the sewing machine ID

– 5 –
2-3. Normal sewing mode
Thescreensforthepitchtimemonitor,sewingrecorderandproductionmanagementaredisplayedby
settingthedisplayonafunction-by-functionbasisaftertheproductionsupportfunctionoperationhas
been enabled under the information mode.
The following shows how to change over the screen under the normal sewing mode.
The screen is
changed over with
the switch.
(Caution)
The screen displayed
differs by the sewing
machine model.
<Sewingscreenwhichdiffersonamodel-by-modelbasis>
<Workmanagementscreen>
* Whentheproductionsupportfunction
operationisenabled,theworkman-
agement screen is shown without
exceptionsregardlessofthedisplay
setting of other functions.
#. 1. Operating the work
management screen
▼
▼
<Pitch time monitor screen No. 1> <Pitch time monitor screen No. 2>
▼
▼
<Sewing recorder screen No. 1> <Sewing recorder screen No. 2>
#. 2. Operating the pitch time monitor screen
▼
▼
<Production management screen No. 1> <Production management screen No. 2>
#. 3. Operating the sewing recorder
#. 4. Operating the production management function

– 6 –
@. SETTING
1. Setting procedure to be taken before rst use
Toputtheproductionsupportfunctionintouseforthersttime,itisnecessarytoenterapasswordto
unlocktheoperation.
Unlocktheoperationfollowingthestepsofproceduredescribedbelow.
1-1. Entering a password
(1) Displaying the password setting screen
1) Press the Information switch onthenormalsewingscreentodisplaytheinformationscreen
No. 1.
<Information screen No.1>
i switch 1
2) Then,keepi switch 1heldpressedforthreesecondstodisplaythesewingmanagementinforma-
tion screen No. 1 (maintainer level).
<Sewing management information screen No. 1 (maintainer level)>
3) Keep Reset switch 2heldpressedforthreesecondstodisplaythepasswordentrypopupscreen.
<Password entry popup screen>
Reset switch 2

– 7 –
(2) Entering a password
<Password entry popup screen>
Numeric input switch 3
1) Input the eight-digit password "46495963" with Numeric input switches 3.Conrmtheinputnum-
ber with Enter switch 4.
Then, input the eight-digit password again with Numeric input switches 3andre-conrmtheinput
number with Enter switch 4.
* If Cancel switch 5ispressedduringthepasswordentry,thedatabeinginputwillbecleared.
<Sewing management information screen No. 1 (maintainer level)>
Sewing management information screen No. 2 display changeover switch 6
A
* Ifthepasswordinputsecondlyisdifferentfromthatenteredrstly,thepasswordmismatchpopup
screen will appear. In this case, input the correct password.
<Password mismatch popup screen>
It is also possible to return the setting for the production support function to the disable.
The password to disable the production support function is "59634649."
2) Whenthepasswordentryhasbeencompletedproperly,theswitchdisplay ▶(Ainthegure)ad-
ditionallyappearsonthesewingmanagementinformationscreenNo.1.Thesewingmanagement
informationscreenNo.2canbedisplayedbypressingSewing management information screen No.
2displaychangeoverswitch6.
 Ifyouhaveinputawrongpassword,thesettingfaultalertwillsoundandtheswitchwillnotaddition-
allyappearonthescreen.
Numeric input switch 3
Cancel switch 5
Enter switch 4

– 8 –
1-2. Setting required data items in sequence
To use the production support function, the "production support function operation enable setting," "date
and time setting" and "sewing machine ID setting" have to be carried out without exceptions. Be sure to
enter data on the required items following the steps of procedure described below after having entered
the password to unlock the operation of the production support function.
(1) Enabling the operation of the production support function
1) On the sewing management information screen No. 1 (maintainer level) which appears after having
entered the password, press the Sewing management information screen No. 2 display changeover
switch ▶to display the sewing management information screen No. 2.
Production support function operation enable/disable changeover switch 1
<Sewing management information screen No.2>
2) Then, press Production support function operation enable/disable changeover switch 1to display
the production support function operation enable/disable setting screen.
<Production support function operation enable/disable setting screen>
Function selector switch 2
3) Select the enable for the operation of the production support function with Function selector switch 2.
When the operation of the production support function is enabled, the item for setting display/non-
display of the pitch time monitor function screen, sewing recorder function screen and production
management function screen additionally appears to allow the respective functions to be used
under the normal sewing mode.
Operation of the produc-
tion support function is
enabled
Operation of the produc-
tion support function is
disabled
Function selector switch 2