Shima Seiki in the zone – Present and Future

September 2008, Wakayama - As the largest textile producer in the world, China is obviously one of the most important markets for any textile machine manufacturer, and for Shima Seiki,  ITMA Asia + CITME 2008 presented an opportunity for the company to re-emphasize its position as leader in flatbed knitting machine technology.

Despite the effects on China of the economic downturn in the U.S., Shima still sees continued opportunities in the Chinese knitting industry. Rising wages and labour shortages as well as increased demand for higher quality by its customers will continue to promote the growth in the area of computerization, factory automation and quality control.

Now that Shima is selling directly to the Chinese market through its new subsidiary Shima Seiki Win Win Ltd., large-scale exhibitions such as ITMA Asia + CITME 2008 are even more important, as they present a rare opportunity for direct contact with a wide range of customers for sales promotion and market feedback.Shima’s ‘Your Choice’ concept was presented at ITMA + CITME using the same unified colour scheme and design found in the company’s advertisements for 2008. The Shima stand was divided into two distinct zones, each representing different targets within the Chinese market. The green area represented the ‘Present Zone’ which displayed products geared for today’s Chinese market such as SSG and SIG-series shaped knitting machines and SDS-ONE design system, while the purple area represented the ‘Future Zone’, displaying new offerings in Wholegarment knitting and 3D design technology for tomorrow’s market needs.

Features

There were a number of features on the Shima stand which helped the company communicate with its customers. As well as a Total Knitting System demonstration, Shima made a fashion presentation,  video presentations and exhibited a swatch archive.

In the middle of the Present Zone Shima demonstrated its Total Knitting System concept. From planning and design on SDS-ONE, knitting on the SIG123SC intarsia machine, to production management using Shima Network Solutions, the Total Knitting System, according to Shima presents a smooth workflow at every stage of the knit production process. Total Knitting System demonstrations were held daily on a regular basis and a mini fashion show featuring the Spring/Summer 2009 Collection of Italian designer Yasmin Naqvi was also held three times daily.

Key features of Shima Seiki, the company, its products and technology were also presented in video format. Ten video terminals were placed throughout the booth in locations pertaining to each topic.

About 300 knit samples were on display at the Shima Seiki stand. Of these, nearly 200 were swatch samples knitted on SSG and SIG machines, displayed in the Swatch Archive area. Shima users could select a limited number of swatches and receive their programming data as a gift. Shima also performed a marketing survey in its booth, where visitors could fill out the questionnaires on computers, and receive a gift as a token of appreciation. In addition, all visitors to the Shima Seiki booth received a Japanese-style 'uchiwa' fan to help them cope with the Shanghai heat during the exhibition.

SSG and SIG

Replacing Shima’s best-selling computerized flat knitting machines, the SES series, the short-bed SSG and SIG machines are according to Shima, the new benchmark in shaped knitting technology. The R2CARRIAGE Rapid Response Carriage System features a new high-performance motor for faster carriage speeds and quicker carriage returns, resulting in a 10% or greater increase in productivity over the previous SES series.

A new built-in computer control unit allows simplified shipping and installation, easier maintenance, and more efficient use of space. USB memory interface and a backup power supply are standard. The new machines also feature a 100mm lower overall height for improved access to top tension units. In addition, SIG has superior intarsia capability with capacity for up to 30 intarsia carriers. SV-type machines feature WideGauge variable gauge technology. Special needles offer a wide range of production possibilities, from tighter, finer-gauge fabrics using all-needle knitting, to more airy, lower-gauge fabrics in half-gauge knitting. Such gauge variation is possible on a single machine without the need for complex and time-consuming gauge conversion, supporting changes in seasons and trends quickly and economically.

Wide Gauge

Each of the WideGauge models is available in 7G, 12G and 14G variants for achieving the best possible quality while knitting each gauge range. Gaugeless knitting is also possible, where different gauges can be knit into a single piece of fabric for greater patterning variety. Shima says that overall, the SSG- and SIG-series achieve a balanced blend of quality, productivity, user-friendliness and cost-performance. At ITMA Asia, a SIG123SC in 12 gauge was shown as part of the Total Knitting System demonstration. Other SIG and SSG models on show were: SSG122SV 07G, SSG122SV 14G, SIG122SV 12G, SIG123SC 12G and SSG122FC 18G SSG234SC.

Wide Tandem

The SSG234SC features all the benefits of Shima’s SSG series, including the R2CARRIAGE for higher productivity. In addition, SSG234SC features Wide Tandem capability that further adds to its appeal as a long-bed flat knitting machine.

Like the SES234-S model before it, SSG234SC’s twin carriages can knit panels along the entire width of its 90-inch wide needle bed in four-system mode, or two identical pieces in tandem mode. With Wide Tandem, tandem width stretches from 37 to 42 inches, offering a significant increase in versatility matching the capability of the larger SES254-S. A built-in controller with standard USB memory interface and backup power supply, as well as lower machine height are also benefits as part of the new SSG series. On display at ITMA Asia + CITME 2008 was a SSG234SC 12 gauge machine.

SDS-ONE

Continuing with Shima Seiki’s tradition of providing total knitting solutions, Shima says that the SDS-ONE apparel design workstation is the only apparel design workstation which features true all-in-one capability. The company emphasizes that, as the central hub of the Total Knitting System, which ties together various stages of product planning, design, programming, production and retail promotion, no other design system is as dedicated to the all-around support of knit production as an integral part of the apparel supply chain.

The key to this all-in-one capability is photo-realistic knit simulation, which begins with the basic starting point in any knit project—yarn. Yarn data can be created from scratch or scanned in from an existing yarn. Super-realistic simulations can be created and mapped onto bodies for accurate evaluation and impressive presentations to clients, without the need for costly, time-consuming sampling work. Furthermore, since machine programming data is prepared simultaneously with design data, production can begin immediately as soon as design approval is obtained. A brand new feature is Knitting Assist, which automatically evaluates given programming data and detects any problematic areas prior to actual knitting, preventing costly mistakes later. At ITMA Asia, SDS-ONE was shown as part of the Total Knitting System demonstration, where it displayed its capabilities in complex 19-colour intarsia programming through pattern-based grading, easy argyle database selection, and automatic carrier assignment. These new features contribute to significant time savings, compressing a typical programming job which previously took up to 50 hours down to 20 minutes.

Shima Network Solutions

Shima Network Solutions take advantage of the networking capabilities of Shima’s knitting machines to get the most out of the production capability of each machine. Knit Data Transfer software allows file data to be transmitted between SDS-ONE and knitting machines. Remote data management such as upload or download of files, deletion of files, creation/deletion of subdirectories are all possible.

Shima Production Report, monitors production status of knitting machines 24 hours a day and outputs production reports automatically. SPR analyzes knitting machine data and outputs reports in preset intervals. The report outlines the total number of knitted pieces completed per shift, as well as operating rate, average knitting time, stop time, and error information. Production progress can be cross-checked with the report viewer, and machines can be monitored in real-time using the machine status window. Shima Network Solutions can be customized according to the specific needs of each factory configuration, beginning with an entry-level system and performing upgrades to keep up with growing production capacity. At ITMA Asia, Shima Network Solutions was shown as part of the Total Knitting System demonstration.

Products in the Future Zone

MACH2X

Like the SWG-X on which it is based, the new MACH2X is a Wholegarment specialty machine that features 4 needle beds and Shima Seiki’s original SlideNeedle. Also like the SWG-X, it can knit beautifully shaped, high-quality Wholegarment products which conform to the body for improved comfort and a more elegant silhouette. As the MACH name suggests, what sets the MACH2X apart is its speed and productivity. The new R2CARRIAGE system increases maximum knitting speed to 1.6 meters per second, and permits quicker carriage returns for higher efficiency per knitted course. A New Split Stitch technique furthermore allows efficient knitting by eliminating empty courses.

According to Shima, when combined, these features allow up to twice the productivity of SWG-X, depending on conditions. MACH2X also allows for a tighter fabric especially for ribs, contributing to higher-quality Wholegarment items. Shima’s i-DSCS Digital Stitch Control System with Intelligence, a quality-control device that actively regulates yarn tension to provide consistent loop length, is also standard. The MACH2X demonstrated was in 15 gauge.

MACH2S

The new MACH2S is based on the NewSES-S WG Wholegarment machine. Shima claims that it is an extremely flexible machine which realizes quality knitting in a range of production styles. As a conventional shaping machine, it is capable of all-needle knitting in its available range of 12 to 16 gauges, while Wholegarment knitwear can be produced in half-gauge fabrics.

The MACH2S adopts the new R2CARRIAGE system, increasing maximum knitting speed to 1.6 meters per second, and more notably, permitting quicker carriage returns. Shima’s Yarn Carrier Kickback Device is also available and enhances productivity by eliminating empty carriage courses for knitting intarsia and integral knits. Shima says that combined, they yield up to 50 per cent improved productivity. Other features include i-DSCS Digital Stitch Control System with Intelligence, as well as adjustable Second Stitch for high-quality production through the use of loose/tight stitches.

MACH2S is also capable of gaugeless knitting whereby a number of different gauges can be knit into a single garment. Shima says that the great versatility of the MACH2S makes it the perfect choice for adopting Wholegarment production while maintaining flexible support of varying market demands. A 16 gauge version of the MACH2S was exhibited.

SWG061N

Originally introduced at the International Knitting Machine Exhibition (IKME) in Milan, Italy in 2003 as a prototype, Shima Seiki’s SWG021 opened up a whole new genre of Wholegarment production. Joined by SWG041 at IKME2005, the  so called SWG-Mini line up’s compact knitting widths and transfer capability of the SlideNeedle make them suitable for production of a range of Wholegarment accessory items from gloves, socks, five-toe socks and leg warmers to hats, mufflers, scarves and neck-ties.

These items can be produced with a variety of patterns, including full jacquard, intarsia, mesh and even new transfer patterns, offering added value for product differentiation. Motorized Auto Yarn Carriers move independently of the carriage and improve productivity and efficiency. This year’s line up, indicated by the N designation, featured several mechanical improvements for further improvements in production efficiency, a significant increase in memory capacity and an expanded range of knitting widths. The SWG041N (16-inch knitting width) is joined by SWG061N (24 inches) and SWG091N (36 inches), increasing product range dramatically, including a wider range of hats, and even garments such as ladies’ leggings and tank tops. A 10 gauge SWG061N was exhibited.

SDS-ONE APEX

Reviving the APEX designation which once graced the most powerful version in Shima Seiki’s computer graphic system line up, it now distinguishes the SDS-ONE APEX as the pinnacle of Shima Seiki computer graphics technology. The most significant feature of SDS-ONE APEX is its 3D modeling capability. 3D Modelist software first creates a virtual body. Loop simulation data is then mapped on for a virtual image far more realistic than any previous attempts at mesh mapping.

Layering of multiple garments for checking coordinated items is possible as well. And of course, 3D loop simulation for Wholegarment is also possible. SDS-ONE APEX features hardware upgrades such as powerful 8-CPU processing for 3D applications, a 3D Sub keyboard for instinctive manipulation of 3D images, and a 24-inch high-resolution widescreen monitor. Unlike other 3D design systems, hardware and software for SDS-ONE APEX are developed and manufactured in house for optimum compatibility and quick development support of market feedback.