Industrial Dashboard Design - UX project

Project 2 - Report

Interactive dashboard design for weaving mills

S. Manojkumar, 166330006 Interaction Design, M.Des (2016-18)

Prof. Venkatesh Rajamanickam Guide

IDC School of Design Indian Institute of Technology, Bombay.

I

Approval sheet The Interaction design project II entitled “Interactive dashboard design for weaving mills”

by S. Manojkumar, roll number-16330006 is approved, in partial fulfillment of the Masters in Design Degree in Interaction Design at IDC School of Design, Indian Institute of Technology, Bombay.

Internal:

External:

Guide:

Chairperson:

II

Declaration I declare that this written document represents my ideas in my own words and where other’s ideas or words have been included, I have adequately cited and referenced the original sources.

I also declare that I have adhered to all principles of academic honesty and integrity and have not misrepresented or fabricated or falsified any idea data/facts/source in my submission.

I understand that any violation of the above will be cause for disciplinary action by the institute and can also evoke penal action from the sources which have thus not been properly cited or from whom the permission has not been taken when needed.

S. Manojkumar 166330006 IDC School of Design Indian Institute of Technology, Bombay.

November 2017

III

Acknowledgements

I would like to thank Prof. Venkatesh Rajamanickam for guiding my project by showing multiple directions to make progress and by giving continuous comments and feedback throughout the project, which helped me greatly and brought different perspectives in me for thinking through a problem.

I would like to thank all the professors of interaction design Prof. Ravi Poovaiah, Prof. Pramod Khambete, Prof. Anirudha Joshi, Prof. Girish Dalvi and Prof. Jayesh Pillai and all the other professors of IDC whose courses have helped me greatly in doing this project.

I also thank the staff of IDC for their continuous support.

I would like to thank Mr. Rajasekar, Head of RS Electronics, coimbatore and his co-workers who lent their support to do primary research and evaluation of the design and also helped me to interact with the weaving industry workers.

I would like to thank the countless youtubers, online bloggers for helping me to understand the basic concepts of weaving, weaving industry the purpose of industrial dashboards and make a clickable prototype of the project.

S. Manojkumar November 2017.

IV

Abstract

In India, the power loom (weaving) sector fulfils 60% of its requirement for woven fabric apart from exporting to other nations. Weaving mills concentrated in only a handful regions in India. To meet the target, they need to run 24*7. They also need continuous supply of raw materials-yarn, workforce, electricity, transport etc. which require continuous or periodical monitoring. However, there are numerous issues in existing loom monitoring systems especially the dashboard. It is inconvenient from the usability perspective and has a lot of unwanted and unused features. The goal of the project is to identify usability issues, design issues and hence offer a better solution. We suggest the dashboard redesign solution which helps user to easily monitor the loom production, performance, other mill environment information and take quick decisions. Based on the study of existing monitoring systems, user behaviours and predefined protocols, we arrived at the user-friendly dashboard design. Afterwards, the prototype is evaluated and tested amongst users to identify the effectiveness of the solution.

V

Table of contents 1. Secondary research ------------------------------------------------------------------------------------------------------------ 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7

Introduction to weaving

Weaving actions

Loom classification

Weaving industry in india Dashboards

Industrial dashboards Weaving industry dashboards

1 2 3 7 9 12 14

2. Primary research --------------------------------------------------------------------------------------------------------------- 17 2.1 2.2 2.3 2.4

How weaving mill works?

Contextual inquiry

Hierarchical task analysis Insights from task analysis

18 19 21 31

3. Interface design ---------------------------------------------------------------------------------------------------------------- 33 3.1 3.2 3.3 3.4

Sketches

Lay-out design

High-fidelity prototypes Scenario

33 36 39 51

4. Evaluation protocol ------------------------------------------------------------------------------------------------------------ 52 5. References ------------------------------------------------------------------------------------------------------------------------ 53

1

1. Secondary research 1.1 Introduction to weaving Weaving is a method of textile production in which two distinct sets of yarns or threads are interlaced at right angles to form a fabric or cloth.The longitudinal strands are called the warp, and the lateral ones are the weft or filling.

The method in which these threads are inter-woven affects the characteristics of the cloth.

Usually, the cloth gets woven by a loom, a device that holds the warp threads in place while filling threads are woven through them.

Fig.1 Weaving process

Fig.2

2

1.2 Weaving actions Weaving can be summarized as a repetition of these three actions, also called the primary motion of the loom.

Shedding: Where the ends are separated by raising or lowering heald frames (heddles) to form a clear space where the pick can pass.

Fig. 3 Weaving machine

Picking: Where the weft or pick is propelled across the loom by hand, an air-jet, a rapier or a shuttle.

Beating-up or battening: Where the weft is pushed up against the fell of the cloth by the reed.

Fig. 4 Knitting machine

Fig. 5.1

Fig. 5.2

Fig. 5.3

Shedding

Picking

Battening

3

The warp gets divided into two overlapping groups or lines (most often adjacent threads belonging to the opposite group) that run in two planes, one above another so that the shuttle can be passed between them in a straight motion. Then, the upper group is lowered by the loom mechanism, and the lower group is raised (shedding), allowing to pass the shuttle in the opposite direction, also in a straight motion. Repeating these actions form a fabric mesh but without beating-up, the final distance between the adjacent wefts would be irregular and far too large.

The secondary motion of the loom are:

1.3 Loom classification: The shuttle loom is the oldest type of weaving loom which uses a shuttle which contains a bobbin of filling yarn that appears through a hole situated in the side. The shuttle is batted across the loom and during this process, it leaves a trail of the filling at the rate of about 110 to 225 picks per minute (ppm). Although very effective and versatile, the shuttle looms are slow and noisy. Also, the shuttle sometimes leads to abrasion on the warp yarns and at other times causes thread breaks. As a result, the machine has to be stopped for tying the broken yarns.

Let off Motion: where the warp is let off the warp beam at a regulated speed to make the filling even and of the required design Take up Motion: Takes up the woven fabric in a regulated manner so that the density of filling is maintained The tertiary motions of the loom are the stop motions: to stop the loom in the event of a thread break. The two main stop motions are: • Warp stop motion • Weft stop motion

Fig. 6 Shuttle used in power loom.

4

Shuttleless loom is the modern loom. It is used to produce high fashionable fabrics with high production rate. They had different picking methods and based on that they are classified into four types.

Power loom (modern loom) are shuttleless looms which are classified as: • • • •

Projectile loom: Projectile weaving machine differs from a conventional automatic loom mainly in two respects. The method of insertion of weft into the warp shed. The method of moving the reed and the projectile track.

Projectile loom Air jet loom Rapier loom Water jet loom

Features of shuttleless looms: Shuttleless weave 2 to 4 times as much as conventional looms per unit time.

The strain upon the warp threads is reduced due to the smaller depth of shed.

Speed is not the only criterion for the selection of shuttleless looms. Efficiency is also an important criterion.

Efficiency advantage of 10-15% due to shuttle changes, Unweaving of damages, reduced time for warp changes can be obtained from shuttleless looms.

Fig. 7 Projectile loom

5

Main Features of Projectile Loom:

Rapier Loom:

The picking is projectile receiving unit separated from the moving sley. The sley carries the reed & gripper guides.

The weft is drawn directly from a large stationary cross-wound package. There is no weft winding. Picking always takes place from one side, but several projectiles are employed, and all of them return to the picking side by a conveyor chain located underneath the warp shed.

Smaller shed opening because of the smaller size projectile. This might result in lower warp breakage rate. The color changing mechanism is less complicated. In case of weft breakage the take-up beam & heald frames can be driven in reverse by a pick finding mechanism.

A useful feature of rigid rapiers is that they can be simultaneously inserted in two sheds one above the other, for producing double plush and certain carpets.

Features of Rapier Loom: A useful feature of rigid rapiers is that they can be simultaneously inserted in two sheds one above the other, for producing double plush and certain carpets.

Weft color selection: The machine adopts electronic color selector up to 8 colors, and the color selection pattern is programmed directly on the machine control panel.

Wefting: Wefting mechanism adopts the 6-lever wefting structure and can ensure the adjustment of the rapier entry and exit time and ensure stable wefting and insertion motion.

The rapier loom doesn’t require dynamic forces or anything like the magnitude as those involved in the conventional loom.

Fig. 8 Rapier Loom

6

comfort levels on board.

Fig. 9 Air jet loom

Air jet loom: To insert the weft threads here used compressed air.

Not suitable for the coarser count or heavier fabric.

It has the automatic weft repair device.

Air jet loom has some disadvantages like as floating the yarn into the wrong direction. To get the better result these main disadvantages must be reduced.

Water Jet loom: Water jet loom produce the shed by using the high force of water. No hull vibration, no torque effect and no high speed cavitations gives maximum

Fig.10 Water jet loom

7

1.4 Weaving industry in india: India is the world’s second-largest manufacturer and exporter of textiles and apparels, with a massive raw material and manufacturing base. Even today, textiles sector is one of the largest contributors to India’s exports with approximately 15 percent of total exports. The textiles industry is also labour intensive and is one of the largest employers.

The Indian textile industry can produce a wide variety of products suitable to different market segments, both within India and across the world.

Some of the leading Indian weaving industries include: - Jai India Weaving Mills Private Limited: Dealing with manufacturing and exporting of weaving products.

The textile industry has two broad segments:

- Vardhaman Spinning: Manufacturer and exporter of weaving products.

First, the unorganized sector consists of handloom, handicrafts, and sericulture, which are operated on a small scale and through traditional tools and methods.

- Arvind Mills: Manufactures and trades weaving products.

Second is the organized sector consisting of spinning, weaving and garments segment which apply modern machinery and techniques such as economies of scale.

The Indian textiles industry is extremely varied, with the hand-spun and hand-woven textiles sectors at one end of the spectrum, while the capital-intensive sophisticated mill’s sector at the other end of the spectrum.

The decentralized power looms, and knitting sector forms the largest component of the textiles sector.

The close linkage of the textile industry to agriculture (for raw materials such as cotton) and the ancient culture and traditions of the country regarding textiles make the Indian textiles sector unique in comparison to the industries of other countries.

Employment status: As per the studies, it has been found that weaving industry in India employs approximately 12.5 million people, thereby making this industry the largest provider of the workforce.

Contribution: The manufacturing of the weaving products makes a remarkable contribution to the national GDP and even in the exports revenue.The power loom sector produces more than 60 percent of cloth, and the Indian Textile Ministry’s estimation says that more than 60 percent of the country’s cloth exports originated from that sector.

8

Obsolete technology: Most of the Powerloom clusters in India are still using obsolete plain looms. Due to outdated technology, looms run at a very low speed and manufacture narrow width fabric. Most of the power looms are rejected looms from Mumbai’s textile mills, and other second-hand power looms. Because of this, loom’s depreciation and maintenance cost is very high. It increases the operating cost and the overall cost of production also increases.

Fig.11 Weaving industry in india

Major issues faced by Power loom sector: Poor infrastructure: Most of the power loom clusters face common problems like poor roads, effluent issues, frequent power cuts, non-availability of water, no warehouses, logistic issues, etc.

Unskilled labour: Most of the labors lack good technical knowledge. They are working on the same age-old technology. They are not trained for increasing productivity & efficiency. The labor training play very important role here, but most of the investors hesitant to invest into labor training programs.

Moreover, the productivity of plain power loom is very low as compared to automatic, shuttleless and semi-automatic looms. The plain looms can only produce 80 meters of fabric per day whereas the automatic looms are 6 times productive than the plain looms. Moreover, these looms require low depreciation & maintenance cost. The cost of production is also very low as compared to plain looms.

Lack of marketing support: Marketing of the power loom products is one of the main problems which becomes a challenge for the owners of power loom industry. Mostly, the weavers are uneducated or less educated and are unable to estimate the demand for their products according to the need of the market. They are unaware of economic norms like demand & supply and business ethics.

9

They are dependent on the middlemen to sell their products. The middlemen purchase the products from them at low prices and sell the same at higher prices.

Lack of financial support: The majority of the weavers start their business with the self-finance. They don’t have an adequate supply of finance to modernize their power looms which will have greater productivity and better quality of the fabric.

Moreover, they don’t have sufficient capital to pile up the stock of raw material when the prices are low. Because of these, they purchase the yarn at higher prices and sell the cloth at lower prices, which results in losses.

Problems: • • • •

Generally, our power loom sector is characterized by the smaller units.

The units established around erode & coimbatore made grey and yarn-dyed fabric and catered mainly to the domestic market.

33% of power looms are located in this area, and they are in unorganized form, and most of them are running the units on job work basis.

Out of total 2.43 million registered looms, only 1.05 Lakhs looms are shuttleless.

1.5 Dashboards: In the words of Stephen few, (Information Dashboard Design, 2006): “A dashboard is a visual display of the most important information needed to achieve one or more objectives; consolidated and arranged on a single screen so the information can be monitored at a glance.”

Dashboard normally has its unique features which are: The entire visual content should be covered in the single screen. It means the scrolling will affect the effectiveness and real purpose of the dashboard.

The KPI(Key Performance Indicators) which are mainly shown in the screen front. Interactivity such as filtering and drill-down can be used in a dashboard; however, those types of actions should not be required to see which performance indicators are underperforming.

The displayed data updated both manually and automatically. The frequency of the update will vary by organization and by purpose.

Option for analysis & insights: Dashboards can also be the tools that offer the ability to select various date ranges, pick different products, or drill down to more detailed data.

10

The main characteristics:

•

•

•

• • • • •

There may be scroll bars for tables with too many rows or charts with too many data points.

It includes interactivity and functionality such as filtering, drill downs.

It is mainly used to find insights, correlations, trends, patterns from the data.

The data used here will be both real-time data and historical data.

Its users range from normal users to tech-savvy persons such as analysts etc.

The dashboard also tends to be identified as the score card.

A scorecard is a tabular visualization of measures and their respective targets with visual indicators to see how each measure is performing against their targets at a glance. It doesn’t need to be interactive and contain columns that show trends in sparklines.

Reports: Reports contain detailed data in a tabular format and typically display numbers and text only, but they can use visualizations to highlight key data.

The key characteristics of a report are: • •

It displays numbers and text in a tabular form.

It has visualizations but only used to highlight findings in the data.

•

It is optimized for printing and exporting to a digital document format such as Excel or PDF. It is prepared for people who prefer to read data: lawyers & accountants.

They would rather read the text over interpreting visualizations and are comfortable working with raw numbers.

Classification of dashboards: In the industrial and business world, the dashboards are classified into analytical & operational dashboards.

Analytical dashboards which establish targets and goals from data collected over a period of time, whether over the past month, quarter or year. This helps decision makers understand what happened, why and how to implement change for better results.

Operational dashboards allow employees to monitor KPIs and other current performance metrics to immediately see the impact of certain campaigns or identify potential operational issues.

Uses of the dashboard: Data transparency: Data is any company’s most important asset. However, it doesn’t do much good if no one can understand or access it. A well-designed dashboard provides on-demand access to all core metrics inter-departmentally.

11

Access to data: As the name implies, a dashboard gathers multiple data sources including Excel into a single interface. That means you can immediately see a detailed overview of your business in one quick glance.

Even better yet, it reduces the amount of time it takes to compile reports, saving you time.

Better decision making: Focused identification of problems, inefficiencies or negative trends for immediate action and improved performance Users can immediately see any problems and drill down on charts and links to explore detailed information and analyze data in real time, to determine causes and to correct negative trends.

Examples of dashboards in real life: Vehicle dashboards: Car, motorcycle.

Motorcycle dashboard which helps to know the fuel level, vehicle speed, indicator status, etc. everything in one front dashboard which makes driver’s life easy and don’t want to turn back and check frequently.

Car dashboard which uses traditional gauge display and modern LCD that shows the distance traveled, fuel status, speed, etc. It also has infotainment options along with the door status, temperature level, etc.

Accountability: While it’s always nice to see what you’re doing right, you also need to see and understand what you’re doing wrong to increase your performance.

Business dashboards can show you exactly where your trouble areas are and arm you with the information you need to improve. Also by making the dashboards visible throughout the company, it holds different departments accountable for both the ups and downs.

Interactivity: Rather than providing static information, users can filter data, interact with charts to see changes over time and even allow for an ad-hoc component for on-the-fly. That means to get as much or as little detail on specific metrics as you want.

Fig. 12 Honda motorcycle-LCD gauge

12

1.6 Industrial dashboards: As per wikipedia, “Industrial Dashboard is the term used to describe the graphical display of manufacturing information. Much like the dashboard in a car, an industrial dashboard shows data collected from a multitude of sensors displayed as one quick overview of the general operating situation”.

Examples of industrial dashboards:

Fig.13 Typical modern car dashboard

Carton, box folding machine dashboard monitors their operation, performance, output, downtime etc.

Fig 14. Qualitek solutions’ dashboard on carton box manufacturing plant monitoring.

13

AM Dashboard is a desktop application used to provide users a quick view of shop floor production by displaying asset status and performance in a priority driven real-time list.

Manufacturing Execution System (above image) for the pharmaceutical and biopharmaceutical industries.

It demonstrates the status of each sensor module.

Fig 15. Shop floor monitoring dashboard

Fig 17. Multipurpose factory star monitoring solutions

It is the general purpose factory monitoring dashboard which shows the warning/alarm events for selected period and equipment status.

Fig 16. Werum IT solutions’ pharmaceutical unit dashboard

14

An MT Connect-enabled machine monitoring system gives shopfloor managers information that is driving up utilization rates and improving workforce communication for this manufacturer of high-pressure aerospace fittings.

1.7 Weaving industry dashboards: These dashboards are nothing but the web application acessed using the browser in computer where all loom data points are interconnected and display the collective loom data in a useful manner. They normally display real-time data and periodical (historical) data.

The data points connected to the computer by either wired unit or wireless systems. The wireless systems also offers remote monitoring where the information can be viewed from anywhere as the dashboard will be in the form of web application. So, the dashboard application can also be accessible through a smartphone.

Some monitoring software providers offer the option of SMS alerts.

Fig 18. Merlin dashboard solutions’ CNC monitoring dashboard

Fig 19. Electrocom’s weaving industry datalogger dashboard

15

This dashboard depicts the overall view of looms in the mill. The top area shows the no.of looms running and efficiency percentage of those looms.

Then the production information is classified based on shift: past and present, past day and running month.

The series of boxes shows the running status of every looms along with their production, efficiency, yarn style and loom name.

This is also the shuttleless loom monitoring dashboard which displays the details Including production, efficiency, stoppage, performance etc. All these information are filtered and displayed as shift-wise, day-wise and monthly manner.

Fig 21. Intes solutions’ weaving datalogger dashboard

Fig 20. Tekhsol’s weaving datalogger dashboard

16

This is the efficiency view of all looms which shows individual and reference efficiency of every loom.

Along with it shows the status of the looms, yarn style, reason for stops. Color code is used to represent the efficiency range of looms. Overall efficiency for past and present day/shift are shown at the top of dashboard.

There are numerous issues in the dashboards which are shown above. Those are identified during the primary research.

17

2. Primary research In order to study the practicalities of dashboard in weaving industry, interviews were conducted by the method of contextual inquiry wherequestions were asked in response to their replies. The profile of people varied from owners, managers, supervisors, technicians, fitters and operators.

The interview was conducted at weaving mills in coimbatore and palladam regions, tamilnadu among the three categories: power loom industry, shuttlelessloom industry and data monitoring system manufacturer.

Fig 22. Contextual inquiry

18

2.1 How weaving mill works ?

2.1.1 Workers’ hierarchy

19

2.1 How weaving mill works ?

20

2.2 Contextual inquiry During the interview, questions were asked of the user groups to explain: - Routine tasks followed by each user profile.

- Work condition before and after the data monitoring system.

- Set of tasks included in the given scenario.

- Pros and cons of the manual loom data monitoring system.

- Pain-points and issues faced daily in their task routine.

- Key reasons for the loss of fabric production.

- Reasons for delay in order and stock transport.

- Reasons for machine stoppage, service and repair and much more.

Hierarchical task analysis protocol: Hierarchical Task Analysis helps to identify how the users perform their tasks, what are their goals to achieve in the end.

It helps to identify the key elements of consideration while designing the website, application, etc. Here it helps to identify the key elements of dashboard application.

It is normally focused on getting down to the lower end tasks from the main tasks and their subtasks.

This task analysis uses the information gathered from the contextual inquiry above.

The sub-divisions of hierarchical task analysis include: Stakeholders: The user groups include: owner, manager, supervisor, technician, fitter, loom operator and PC operator.

User scenarios: The common and rare scenarios of the particular stakeholder who normally encounter in their work routine.

Main tasks- Based on the scenario the main bulletin tasks are framed.

Sub-tasks: Each main task was divided into small sub-tasks which will be quiet detailed one.

Pain points: The issues, difficulties faced while performing those tasks.

Functionalities- From the tabulated tasks, scenarios and pain-points the key functions of particular tasks are identified and noted. Those functionalities are the building blocks of the dashboard interface design.

21

2.3 Hierarchical task analysis: Here is the complete table of task analysis, created based on the field interview and observance.

22

23

24

25

26

27

28

29

30

31

2.4 Insights from the task analysis: Insights are obtained from the hierarchical task analysis which helps to design the new better dashboard for weaving mills.

This efficiency value does not take into account time lost for such matters as major mechanical breakdown, waiting for new warp and gaiting new warp, type new warp to old warp.

They are of two categories: Before & after the arrival of monitoring systems.

The history of LAN based data logging system for air-jet looms is of about 20 years. So people in weaving industry are familiar with the layout that had undergone few changes so far and moved on. The new players on the monitoring software design adopted the same layout of the past software version and done some changes in it.

Now it stands on the stage of wireless data logging system with SMS feature, but the layout and information are almost same from the beginning.

The calculated efficiency is compared with actual efficiency. This is confusing and misleading.

As the calculated efficiency which includes running time + stoppage time.

But the stoppage time is unable to pre-determine as it may vary.

So the efficiency forecast is not accurate.

With same stoppage time, the calculation of beam run-out as bar chart which is also erroneous.

The stoppage time differs day to day and machine to machine. So roll-doff forecast is not accurate and may mislead them to keep the new warp beam ready and to handle the order.

People are confined to numbers and not visual charts.

The data scientist job can’t be offered to weaving mill managers. Need to design industry focused and easily

32

accessible visual charts for the normal users.

If the production value converted to monetary value then it helps all users from manager to operators.

So the manager will see the monetary value along with efficiency, RPM, fabric length etc. But live mobile web app option can’t be given to operators as it affects the production and the discipline issue will arise among operators. They also need to offer wifi facility to handle it.

No need for the regional language option as they are mostly confined to numbers, symbols and abbreviations (RPM, PPI, Metres, % etc.) as the users are from closed groups.

Dashboard design needs to be done for power loom industry also. So it should be hybrid. So far the design is done for only air-jet looms as they are big bosses than power loom owners. This is the actual challenge.

In that case, fork stop option to be added.

Designing the apt chart to denote the live status of woven fabric length. This helps to cut the fabric and stop the machine for round off values as the customer need to change in between.

RPM is one of the important parameters that decides efficiency. If the RPM reduces -5 value from standard value then it is because some machine fault is there.

But, the RPM is mentioned so bluntly.

The dashboard layout is not designed/classified based on stakeholders’ usage: Owners, managers, supervisors, technicians, and operators. Power loom users are first time users and air-jet looms who already use dashboard apps in the market.

Customization for colour blind, low eye-powered people.

Relative humidity and temperature level maintenance is an important factor and it is to be observed regularly in industries that don’t have automatic adjustment systems-lua HVAC system. That needs to be embedded in data monitoring dashboard.

33

3. Interface design: 3.1 Sketches Based on the insights obtained, the dashboard interface design sketches were created.

The sketches describe the design elements and interactive elements for the information access.

Home screen- layout & elements

Fig. 25 Interface design sketches

Detailed view - layout & elements

Production report - layout & details

34

The positioning of interface elements are decided based on the hierarchy of information access, how frequent the tasks are performed and how important the information for user to take necessary action on behalf on emergent information.

Prodution report- table & chart

Fig. 25 Interface design sketches

Stoppage report- chart details

Stoppage report- table & chart

35

Beam & roll-doff table & chart

Fig. 25 Interface design sketches

Order & stock - table

Order & stock - chart

36

3.2 Lay-out design:

Fig. 26 Interface design layout-1

37

Fig. 27 Interface design layout-2

Fig. 28 Interface design layout-3

38

The fixed layout (Fig.27 which continuously shows the current shift information about looms.

Those include: - Number of running looms.

- Number of stopped looms: Over all stops and categorized-warp, weft, other & long stops.

- Efficiency: Combined efficiency percentage of all looms and looms count of different efficiency levels.

- Notifications: This notification area shows the alerts, warning information that tends the user to take immediate action. This area shows hierarchical notifications about loom stops, beam & roll deadline, order & stock deadline, workers’ attendance update, and lubrication status. All these alerts are displayed with time and respective color code for quick identification for the user to know and take further action.

- Loom stoppage: The stop reason for the particular loom for long time and its duration.

The top bar in the interface which displays the current shift, date, time and relative humidity level of the sheds in the mill. If the humidity level reduces below the average, then the yarn gets drier and frequent warp cut occurs.

Also if the humidity level increases the yarn will stick to each other. It causes both warp and weft cut and loom stops frequently.

- Production: It refers to the fabric produced in terms of length and kilo picks. Picks refer to the no. of threads per inch. Here the current shift which is live status and past shift production status is shown.

- Beam & roll: The warp beam gets over, and the fabric roll gets completed. The warning shows the current yarn and fabric length. Based on that user makes arrangements to load warp beam and unload the fabric roll.

- Workers: This is about workers’ attendance, the absentees, and substitutes for them. Apart from referring the complete attendance report, this highlights will be quite informative to the user.

- Lubrication deadline: It is the reminder for the scheduled loom lubrication.

39

3.3 High fidelity protoype: Home screen

Fig. 29 Home screen- default

40

The standard menu items include: -

Home Detailed view Reports User profile

This standard left menu bar which is foldable which shows only icons and by default, it is expanded with both text and icon display.

Home menu: The home screen is the default view of the dashboard interface. It displays the following information along with the fixed layout elements showing the current shift information as mentioned above.

The middle area which is wide and it shows abstract information about the looms. Basically the mill area where the looms present are grouped into sheds. Each shed has a certain number of looms which will not be even and of different brands.

The layout of the loom in the shed also looks different.

The dashboard loom data layout also designed to mimic the real- layout of loom sheds. So the user can quickly identify the loom he looks for.

Detailed view menu: This is just an expanded view of details of each loom.

The detailed view has flexible options to keep it minimal and user-friendly. The parameters are displayed in tabular form and they are classified as, - Products - Performance - Stoppage - Order & stock The filter option is provided to select the looms based on the sheds.

41

Fig. 30 Detailed view of loom data

42

Reports menu: Reports are the records which display the past information except for the beam & roll which is the live information.

Reports are further classified into sub-menus: - Production - Efficiency - Beam & roll - Order & stock - Workers The detailed content of reports are available in the form of both tabulation and graphs.

Production report: Production information is the amount of fabric produced by the looms and the report which shows the details based on the filtering options provided.

The filters present at the top of the menu content space and it is available in the order: - Date/Date range - Filters: Shed, loom, style, operator, technician, supervisor, warp supplier and weft supplier.

- Toggle option for selecting either table or graph for the visual report display.

Grouped bar-charts are used to show the production report of both shifts: A & B for the requested date/date range.

43

Fig. 31 Production report-table

44

Fig. 32 Production report-chart

45

Stoppage report: In case of stoppage information, it includes the no. of stops occurred and the stop duration of each loom.

This stop report is also categorized and filtered as same as the production report mentioned above.

The graphical report which shows the grouped bar charts for the four different stoppages: warp, weft, other and long stops.

Fig. 33 Stoppage report-table

46

Fig. 34 Stoppage report-chart

47

Beam & roll doff report: The beam is the roll of warp threads rolled parallelly by the process called warping and sizing. Roll is nothing but the roll of fabric produced from the loom. Roll-doff is mentioned normally as roll. Roll-doff refers to the point where the fabric got rolled completely and can’t hold further. It is the live information which shows the current length of warp yarn and fabric.

Fig. 35 Beam & roll report-table

48

If the time arrives for beam out and rol-doff then the alert will be offered at notification section. Normally the alert for beam & roll will be provided before one day it happens. Parallel beam-out and roll doff won’t occur as they beam loading done at different time intervals. It takes around 4 hours for loading the beam and perform the process called knotting to tie the warp thread to the main flow and to the roll on the other side.

Fig. 36 Beam & roll report-chart

49

Order & stock: Order and stock report in which both are the different categories and they are selected using radio button either or option to display the details. Here the graph which is the grouped charts which shows both the order and stock information.

If the target date arrives, then the alert will be offered in the notification section.

Fig. 37 Order & stock report-table

50

Fig. 38 Order & stock report-chart

51

3.4 Scenario: Supervisor’s action after getting the loom-stop information from the dashboard.

52

4. Evaluation protocol: At first, the stakeholders will be given the introduction and demo about the dashboard operation and operations in it.

They will be given time to explore the screens.

The evaluation will be done based on the Usability testing tool developed by Prof. Anirudha Joshi. As per the tool’s guidelines, the user profile will be created, predefined tasks and scenarios will be given to them.

Then they are asked to perform the tasks and each user will be observed that how much time they take to complete the task, where they get stuck, which part they forget, gets confusion etc.

Their performance was rated to do further analysis at last and decide the level of usability of the dashboard among actual users.

53

5. References Book [1] Few, Stephen. 2006. Information Dashboard Design. Italy: O’Reilly

Journals [2] Hongjun CUi, Jianping Lin, Lijun Li. 2011. “The Impact of Weft Quality on Air-jet Loom Weaving Efficiency “ Scientific. https://doi.org/10.4028/www.scientific.net/AMR.331.454 [3] M. Ogan, Yigitbasioglu, Velcu Oana. 2012:”A review of dashboards in performance management: Implications for design and research” ScienceDirect: 41-59. https://doi.org/10.1016/j.accinf.2011.08.002.

[4] Tokolaa Henri, Grögerb Christoph, Järvenpääc Eeva, Niemia Esko. 2016: “Designing manufacturing dashboards on the basis of a Key Performance Indicator(KPI) survey” ScienceDirect.

Articles [5] Gonzalez, W. Thomas. “Dashboard Design: Key Performance Indicators and Metrics” Brightpoint. http://www.brightpointinc.com/download/key-performace-indicators/ [6] Hulle, Ashish. 2013. “Project Report: Reduction of Yarn Breakages in Weaving” Textile Centre. July 19, 2013. http://textilecentre.blogspot.com/2013/07/project-report-reduction-of-yarn.html [7] Mulla Riyajahamad, Khandekar Gandhali. 2017. “Loom Data Monitoring System in Weaving Industry” Textilelearner, February 2017. http://textilelearner.blogspot.in/2017/02/loom-data-monitoring-system-weaving.html [8] Parmar Shivendra, Malik Taveer. “Use of ERP in Textiles” Fibre2Fashion. http://www.fibre2fashion.com/industry-article/2110/use-of-erp-in-textiles?page=1 [9] Prajapati, Ramesh. 2010.”Production Calculation for Weaving Looms” Weavetex, January 21, 2010.

[10] Smith, Nick. 2015. “Designing and Building Great Dashboards - 6 Golden Rules to Successful Dashboard Design” GeckoBoard, October 2015. https://www.geckoboard.com/blog/building-great-dashboards-6-golden-rules-to-successful-dashboard-design/#.WgjWQYjhXIV [11] Tröster, Heiko. 2016. “Make Sure You Know the Difference Between Strategic, Analytical, Operational and Tactical Dashboards.” Datapine, October 12, 2016. https://www.datapine.com/blog/strategic-operational-analytical-tactical-dashboards/ [12] Thompson, Doug. 2013. “Responsive Design for Internet of Things” Beekn, November 10, 2013. http://beekn.net/2013/11/responsive-design-for-the-internet-of-things/