Textile Calculations

Fabric Design Calculation Validation

'Calculations (In Order)

Reed Width

                Ends per dent = sum of values separated by periods divided by count of values (from Warp table)

                Ends Sum = sum of end values from WarpDetail table

                Lenos = sum of lenos from Weft table

                Reed Width = (Ends Sum / (Ends Per Dent * Dents Per Inch) + Lenos * 0.85) * 2.54

‘ Formerly:            Reed Width = (Ends Sum / (Ends Per Dent * Dents Per Inch)) * 2.54

               

                Calculated Reed Width stored in Warp table

Warp Length

Target Length from Project table

                Heat Set Shrinkage from InFinish table

                Coating Shrinkage from InFinish table

Outside shrinkage from OutFinish table

                Take up from WarpDetail table

                For each warp in WarpDetail table:

                Warp Length = (1+ Sum(3 shrinkages)) * target length / (1 - take up)

                Calculated Warp Length stored in WarpDetail table

Greige Width

Calculated Reed Width from Warp table

Width Contraction from Weft table

                Greige Width = Reed Width * (1 – Width Contraction)

                Calculated Greige Width stored in Project table

Warp Quantity

                Dtex from WarpDetail table

                Ends from WarpDetail table

                TakeUp from WarpDetail table

For each warp in WarpDetail:

warp quantity = [Dtex] * [Ends]/ (1 – [TakeUp]) / 10000000

[Quantity] in [WarpDetail] set to calculated warp quantity

TakeUp is a percentage (between 0 and 1).

Weft Quantity

                Dtex from WeftDetail table

                Ends from WeftDetail table

                TakeUp from WeftDetail table

                ReedWidth from Warp table

                Selvage from Weft table

                Fringe from Weft table

For each weft:

weft quantity = [Dtex] * [Picks] / 0.254 * ([ReedWidth] + [Selvage] + [Fringe]) / 100000000

[Quantity] in [WeftDetail] set to calculated quantity

Mass Calculation:

Weft Quantity:

weft quantity = Sum of (weft quantity + ([dtex] * [picks] / 0.254 * [reed width] / 100000000) in [weft detail] table

Warp Quantity:

warp quantity = Sum of [quantity] in [warp detail] table

Mass:

mass = 100000 * (warp quantity +  weft quantity) / (greige width)

Calculate Costs:

Twist Labour Rate = From FixedCosts table

Warp Labour Rate = From FixedCosts table

Weft Labour Rate = From FixedCosts table

Coat Labour Rate = From FixedCosts table

Finish Labour Rate = From FixedCosts table

Inspect Labour Rate = From FixedCosts table

   

Total Cost = 0

   

Target Length = From Project table

Coating Run = From InFinish table

Heat Set Run = From InFinish table

Heat Shrinkage = From InFinish table

                Coating Shrinkage = From InFinish table

Outside Shrinkage = From OutFinish table

   

Sum of Shrinkage = Heat Shrinkage + Coating Shrinkage + Outside Shrinkage

Twist Waste = From WeftDetail table

Beam Off Speed = From Warp table

' Default Waste amounts

Warp Waste = 0.02

                Weft Waste = 0.02

Twist Waste = 0.02

Exchange Rate = From Project table

'Calculate Warp costs in Project

For each warp in WarpDetail:

Get Yarn Cost and Twist Yarn Cost from WarpDetail

If Warp Speed Or Beam Off Speed = 0 Then

Run Time = 0

Else

RunTime = Sections * Length / WarpSpeed / 60 +SetupTime +

Sections * 0.25 + Length / Beam Off Speed / 60

                                End If

Labour Cost = Run Time * Warp Labour Rate / Length * (1 + Warp Waste)

Get Take Up from WarpDetail (default is 1)

If (IsNull(varTwistYarnCost) Or varTwistYarnCost = 0) Then

TwistLabourCost = TwistTime * TwistLabourRate / Length *

(1 + WarpWaste + TwistWaste)

MaterialCost = YarnCost * Quantity * (1 + WarpWaste) *

(1 + SumShrinkage)

Else

TwistLabourCost = 0

MaterialCost = TwistYarnCost * Quantity *

(1 + WarpWaste + TwistWaste) *

(1 + SumShrinkage)

End If

       

                                WarpTotalCost = LabourCost + TwistLabourCost +MaterialCost

                               

                                Fields updated with calculated values

TotalCost = TotalCost + WarpTotalCost

'Calculate Weaving costs in Project

LoomSpeed = From Weft table

LoomEfficiency = From Weft table

WeftSetupTime = from Weft table

For each weft in WeftDetail

WeftLength = varTargetLength / (1 - varSumShrinkage)

        

YarnCost = From WeftDetail

TwistYarnCost = From WeftDetail

                                Picks = From WeftDetail

WeaveTime = Picks * 39.37 * WeftLength / LoomSpeed / LoomEfficiency * 100 / 60 +

WeftSetupTime

LabourCost = WeaveTime * WeftLabourRate / TargetLength * (1 + WeftWaste)

       

If varTwistYarnCost = 0 Then

MaterialCost] = varYarnCost * Quantity] * (1 + varWeftWaste) *

(1 + varSumShrinkage)

                                Else

                                                MaterialCost] = varTwistYarnCost * Quantity] *

(1 + WeftWaste + TwistWaste) * (1 + SumShrinkage)

End If

       

                                WarpTotalCost = LabourCost + TwistLabourCost + MaterialCost

TotalCost = TotalCost + WeftTotalCost

CoatingCost = 0

                                For each Coating

If Amount > 0 And Cost> 0Then

CoatingCost = CoatingCost + Amount * Cost

End If

CoatingCost = CoatingCost / TargetLength

CoatingLabour = CoatingRun * FinishLabourRate / TargetLength

InFinishLabour = HeatSetRun * FinishLabourRate / TargetLength + CoatingLabour) *

(1 + SumShrinkage)

                               

                                Update LabourCost in InFinish table with InFinishLabour

                                Update Material Cost in InFinish table with CoatingCost

OutFinishCost = From OutFinish table

   

InspectCost = InspectLabourRate * 0.5 / 300

Update InspectionCost in Inspect table with calculated InspectCost

PackageSkid = 25 / TargetLength

BagSkid = 5 / TargetLength

BoxSkid = 15 / TargetLength

                                UpdateField [PackageCost] in Inspect table with (PackageSkid + BagSkid + BoxSkid)

       

                                TotalCost = TotalCost + InFinishLabour + CoatingCost + OutFinishCost + InspectCost +

PackageSkid + BagSkid + BoxSkid

   

Update ProjectCost in Project table with TotalCost'