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PLC with Servo Drive

Journal of Residuals Science & Technology, Vol. 13, No. 7, 2016 238.1
© 2016 DEStech Publications, Inc.
doi:10.12783/issn.1544-8053/13/7/238
Positioning Servo Control System Based on PLC and Touch Screen
Jianping Shia,*, Yijuan Dia and Jun Guoa
a School of Electrical and Photoelectronic Engineering, Changzhou Institute of Technology, No.666 Liaohe Road, Xinbei District,

Changzhou Jiangsu Province, P.R.China

Abstract: To improve the precision and performance of shearing machine, a servo control system with servo motor, PLC and touch
screen
is investigated in this paper. By this servo control system, position auto detection and quantity auto detection can be achieved.
The practical
results demonstrate that the servo control system has high machining precision and high reliability, and it can improve work
efficiency.
Keywords: Servo Control, PLC, Touch Screen
1. Introduction
In order to improve working efficiency and precision of shearing machine [1], a servo control system is investigated based on
PLC,
touch screen and AC servo system [2] in this paper. In this servo control system, accurate positioning with parameters of shearing
machine
is studied.
2. Thought of designing
In this research, a servo control system is proposed to solve the problem of accurate positioning, automatic detect position and
quantity
of the shearing machine. In this servo control system, AC servo drive, PLC and touch screen is used to implement accurate
positioning,
position can be set within the specialized range, and tolerance less than 0.1 mm. Position signal and width of shear set by the
touch, PLC
change these signals to pulse and send them to servo driver, the servo motor then drives the back system to finish the shearing
action
.
3. Hardware design
In this servo control system, Mitsubishi PLC (FX1S-10MT-001), Mitsubishi touch screen (F930G0T), YASKAWA servo driver
(SGDM-10ADA) and YASKAWA servo motor (SGMGH-09ACA61), incremental encoder (2500P/R) are used. The system
structure is
shown in Fig. 1.
Servo Drive
F930GOT
Servo Code
Pulse Servo Motor Shearing Machine
PLC
Figure. 1. System Structure.
FX1S-10MT programmable controller has high performance, high speed and compact package and is adopted in this servo
control
system. System input and output signals are shown as following:
X0: Set executive
X1: Origin detect, controlled by switch sensor, as the signal of back to original position
X2: Servo Ready
X5: Shearing count
Y0: Output pulse to control servo driver
Y1: Output direction control signal
Y2: Output clearing signal (low level effective)
Y3: Output warning reset signal (low level effective)
The input and output signals of PLC and external connection of CN1 are shown as follows:
PLC
external
wiring
Y0
Y1
Y2
COM
Y3
External wiring of
the servo unit
CN 1 +1 2V
37 8
13
11
12
18
15
14
44
Brown
green
Orange
1
Alarm reset
X0
X1
X2
3
X4
X5
COM
PLC
Set the implementation
Origin detection
The servo is ready
Shear plate count
X
Figure. 2 PLC output and input, and external connection of CN1.
.
238.2 Journal of Residuals Science & Technology, Vol. 13, No. 7, 2016
© 2016 DEStech Publications, Inc.
doi:10.12783/issn.1544-8053/13/7/238
4.Servo system
4.1.Position Control Parameters
This system uses 17 digit increment encoder, the number of pulse is 32768P/R. Electronic gear function means the future of
setting
working movement to any value as 1 pulse command from command controller.

Due to electrical stopping precision  = 0.001  mm, so we set position detecting unit 
=0.001mm/pulse . The mechanical reduction

ration between motor shaft and load side is m/n, so when servo motor rotates m laps the load axle rotates n laps. The electronic
gear ratio
can be described as follows:

202 coder,number of pulse 4 32768

Electronic gear ratio n

4 2 16384
= 100
n203 ,lturnofloadaxle 10 / 0.001 1 625
BPm
A P movement n
 
     
(1)
4.2 Interface and connection of Servo Unit CN1
In the control requirements, servo system is powered by servo signal “ON” when it is ready. Two position switches are used to
stop
clockwise driving and counterclockwise driving and the alarm devices are designed. The interface circuit of CN1 is shown in Fig.
3.
CN1
47
External wiring of the servo unit
42
40
43
41
44
-- 24V+
Servo ON
Forward drive
is prohibited
Reverse drive
is prohibited
29
30
31
32
KA1
KA2
CN1
+24V
+24V
Servo ON output
LC1
LC2
AB
Servo alarm
output

Figure. 3. Interface circuit of CN1.

5.Touch screen
To make the operation simple and convenient, Mitsubishi F930G0T touch screen is utilized. Because of its RS422 interface, it
has good
visual interface and is easy to operation. By communicating with the PCL [3], machining parameters (dimensions and processing
quantity)
are set up and real-time system parameters are displayed. In the meantime, the operations, such as touch operation testing,
automatic original
spot returning and pausing etc. can be operated on touch screen. It can avoid multiple buttons and complicated operations on the
old system.
6.Software design
6.1.Design idea
According to the requirements of the design of the control software: Setting shear position and quantity on touch screen. Position
will
be recorded after the completion of the current shear, instead of returning to the original position (Switch sensor at the origin
position), the
system will wait for the next command, PLC will compare the current position of the baffle plate and the position to be reached,
and send
out corresponding pulse signal to control the servo motor, adjust (back or forth) baffle plate until it reached the required position.
As the
design of the system, it is also possible to return to the original position after the completion of the first shearing, then control the
servo
motor and move to the right position according to the required width of next shearing. The software flow chart is showing in
Fig.4.
Journal of Residuals Science & Technology, Vol. 13, No. 7, 2016 238.3
© 2016 DEStech Publications, Inc.
doi:10.12783/issn.1544-8053/13/7/238
Start
Setting
parameters （
Shear length，
Quantity ）
Determine whether
the shear plate
count is zero？
Count down
by one
Front by the
system to stop
N
Y
Set the
length >= The current value
YY
N
N
Set the
length > The current value
Stop the
servo motor
Adjust the servo
motor to reverse
Adjust the
servomotor
forward rotation

Figure. 4 Software Flow Chart.

6.2.Shear Positioning
Positioning is the key of the whole system. There are lots of ways to position in the use of PLC, there are also plenty of
commands can
be used, among them, FNC158 is a relative position control command, it is convenient because it uses the current position as the
base
position every time the command is executed [4].
When executing position control command, PLC will increase or decrease the current value by producing positive pulse or
negative
pulse, and save it to the current register, thus it can always keep the position of machinery. But the current value in register will
disappear if
there was no power. Because of this, the returning to original position must be executed to write the origin position data of
machinery action
to the register during power up and initial operation.

When executing relative position command, the lowest output pulse frequency (

calculated as follows:
PFlowest ) can be

PF TopSpeed D D Hz
AccelerateDeceratetimeD
lowest  （ 8147, 8146 2 ）

  8148 1000  (2)

For the output pulse frequency S2, the above result will be out put even it was specified a lower value than this result. calculation,
the
output frequency of the initial part of acceleration and final part of the deceleration will not lower than the above result frequency
as well
[5].
When executing positioning program, it will compare the set value and current value first, then calculate the output pulse
parameters
using the comparing result, and then output parameter of motor rotating direction and set the appropriate output pulse frequency
according
to the difference of set value and current value. PLC program is shown in Fig.5.
238.4 Journal of Residuals Science & Technology, Vol. 13, No. 7, 2016
© 2016 DEStech Publications, Inc.
doi:10.12783/issn.1544-8053/13/7/238
CMP D100 D 8140 M40
SET S10
M30
STL S10
M40
M50
X000
M30
X002
SUB D1 00 D 81 40 D200
M0
M2
DMUL K100 D2 00 D202
M 8000
CMP D200 K8 00 M4 3
M43
MOV K 10000 D208
M44
M45
MOV K 5000 D 208
M40
Y001
M 8000
FNC1 58 D204 D 208 Y00 0 Y001
M 8029
Y002
RST D 202
RST D 200
RST D 208
RST M42
RST M41
RST M40
SET S11
M50
M 8000
M42

Figure. 5 PLC program.

6.3Shearing Counting and Returning of Origin Position
Shearing quantity can be set on touch screen and written into quantity register, and then sent to shearing counter, it will decrease
by 1
each time there is a signal until it reaches 0, a shearing signal is then sent to control system and clear the relevant memory at the
meantime.
M8140 is preset to “ON”, it can sent reset signal to servo motor when returning to original position is finished. The output
address of
reset signal is depending on the pulse output address, pulse output Y000, reset signal output Y002.
7. Conclusion
To improve actuate positioning of shearing machine, a servo control system based on PLC, touch screen is presented. This
system has
the futures of high precision, stable performance, reliability, improving labor productivity and profit. This system is designed and
test in a
short period of time with small investment. The practical results show this system has high precision, high stable performance
and good
reliable. It is easy for operation, visual display and automatic protection. The system satisfies the design requirements and is
efficient to
improve the automation level of shearing machine.
Acknowledgments
This work is supported by Jiangsu science and technology plan project under Grant No. BY2016031-06.
Motion control is generally understood to mean the use of servo and/or stepper systems as the “muscle” to
move a given load. These motion control systems are capable of extremely precise speed, position, and torque
control. Applications which require positioning of product, synchronization of separate elements, or rapid
start/stop motion are all perfect candidates for the use of motion control. PLCs are very capable of providing
the signals required to command these servo and stepper systems in a cost-effective and digital (noise-free)
manner.

In a
typical motion control system there are three basic components: the controller, the drive (sometimes referred to
as an amplifier), and the motor. The path planning or trajectory calculations are performed in the controller,
which sends low-voltage command signals to the drive, which in turn applies the necessary voltage and current
to the motor, resulting in the desired motion. Sometimes feedback devices on the motor or the load are used to
notify the drive or the controller with specific details about the actual movement of the motor shaft or the load.
This feedback data is used to increase the accuracy of the motion, and can be used to compensate for dynamic
changes that may occur at the load, such as changes in mass, friction or other disturbances. Servo systems
operate in a closed-loop fashion and vary output torque to move into/stay at the commanded position, while
most stepper systems typically provide open-loop position control (a stepper will drive at full force to get to
the commanded position or fail trying).
 The choice of open-loop versus closed-loop control depends on
many factors and both are useful methods for controlling motion. PLC-based controllers can be used for either
type of system. Applications that can be accomplished with a low-cost PLC and servo/stepper components
include cut-to-length, indexing tables or conveyors, and x/y tables (plotter/cutter/router/placer).
The classic ‘pulse and direction’ signals that are widely used with PLCs provide an inexpensive, noise-free
(digital) method for precision motion control. Extensions or function blocks within the PLC ladder logic are
typically used for programming and are easy for factory personnel to understand and maintain. While typically
limited to a few axes of control and where coordination between axes is limited, PLC controllers with pulse
and direction capability are an excellent fit for many motion applications. Often, low-cost PLCs are already
being used for logic control on the machinery and can also handle the motion tasks with the addition of a pulse
output card and some additional programming. This can eliminate the need to integrate the logic controller
with a separate motion controller. Machine builders can also save considerable time when implementing PLC-
based systems, especially if they are already familiar with the PLC and its programming software.

In a typical PLC-based motion control system, high-speed pulse output cards are used in the PLC to generate a
‘pulse train’ for each servo or stepper drive. The drive receives the pulses and indexes the motor shaft by a pre-
set amount for each pulse. Typical stepper systems might index 1/200 of a revolution per pulse, while micro-
stepping or servo systems might be configured for as little as 1/10,000 of a revolution for each incoming pulse.
The amount of motion dictated by a single pulse can be adjusted in the drive to obtain a desired resolution, or
to achieve a required top speed (as a resolution/top speed trade-off may be required to accommodate the
maximum pulse output frequency from some PLCs). A separate signal is used to determine the direction of
travel. This control method is referred to as ‘step and direction’. A similar but functionally equivalent method,
‘clockwise/counterclockwise’, uses a separate pulse train for each direction of travel. This method is somewhat
less popular, but has advantages in some applications. Electronic gearing can usually be enabled in the drive to
allow high-resolution moves at low speeds, as well as a high-speed mode for faster moves with lower
resolution.

Encoder feedback, when used in these types of systems, is normally handled at the drive level. Two simple
hardwired signals from the drive back to the PLC, drive fault and in-position, are often used to notify the PLC
of exceptions and/or completion of each move.

Evolution of Electric Motion Control Technology

Electric motion control systems originated as alternatives to hydraulic motion systems. With most electric
systems ranging in size from a few watts into the kilowatt range, electric motion control has become prevalent
at these smaller sizes, while hydraulic systems continue to dominate the larger applications approximately
5kW and above, where electric power is impractical or unavailable and where the environment is harsh or
extreme. The electric systems are more factory-friendly, less obtrusive, and are easier to install than the
plumbing required by hydraulics. Early electric servo systems were usually operated in velocity or torque
mode, accepted analog command signals, and were quite successful despite problems with electrical noise and
drift. Early PLC-based controllers used analog output cards to provide the velocity or torque command signals.

While analog control signals are still used on some systems, most modern motion systems have migrated to
some form of digital control. The advent of the digital servo drive, with the ability to close the position loop,
was another major step forward. New types of signals between the controller and drive are now required to
send position commands to these digital servo drives.

The three most common control signals used by today’s PLC-based motion controllers are the pulse and
direction signals detailed earlier, discrete signals to an intelligent or indexing drive, and fieldbus
communications.

The pulse and direction interface that was originally developed for stepper systems has now become a standard
feature on most servo products as well. A PLC with a high-speed output is one of the most cost-effective
methods for controlling motion today. No intelligence is required in the drive and all programming is
performed in the PLC. Almost all PLCs available from AutomationDirect offer some form of high-speed pulse
output. For example, the smallest and least expensive DirectLOGIC® PLC, the DL05, includes a single 7kHz
high-speed output which can be used for limited motion control applications. The DL05 will also accept an
optional module which provides an additional high-speed output channel at up to 250kHz. The
AutomationDirect SureStep stepping system can easily be controlled by this or newer PLCs such as the
Productivity2000. In addition to the benefit of the low price for stepper components, all motion and logic
instructions are programmed in the PLC’s software for significant time s

avings.
Indexing drives offer another two options for PLC-based control. Indexing drives include a standalone
controller which is built in to the servo or stepper drive. These single-axis devices have I/O capability, and can
execute motion profiles based on a single PLC or real world input. This type of drive often includes a fieldbus
connection and can perform moves based on commands and parameters received across such a connection.

For example, the SureServo® line of servo products from AutomationDirect are indexing drives. The
SureServo drives can be pre-programmed with parameters for up to 8 separate motion profiles, which can then
be initiated via discrete inputs from a PLC or signals from other devices, even pushbuttons. These moves can
consist of precise, user defined accelerations (ramps) to preset speeds, with accurate decelerations carefully
timed to end at predefined positions. Dynamic velocities (with controlled ramps) and precise application of
torque are also possible. Parameters for vibration suppression (notch filters), load inertia range, proportional
and integral gain, and many others can also be customized for specific applications in the SureServo drive. The
SureServo offers two adaptive auto-tuning modes, which continue to tune the system while it operates.

The AutomationDirect SureStep® line of stepper products also includes drive models with built-in indexers
that offer similar capabilities.

The SureServo products also have a built-in Modbus interface. Modbus-enabled PLCs can initiate moves and
download parameters to the SureServo drive across the Modbus link. The Modbus link can also supply
information back to the controller about the performance and status of the servo motor and drive system.
Multiple SureServo systems can be controlled via a single Modbus port on the PLC. The SureServo’s ability to
download custom motion profiles from a PLC on the fly, and execute these moves on command, allows the
ultimate in flexibility and control with a PLC-based motion controller.

Trends in PLC-based Motion Control

Motion control modules for PLCs are increasing their capabilities year after year. High-speed output modules
offered by AutomationDirect now have output frequencies up to 1 MHz. The Productivity2000™ high speed
output module provides two 1MHz output channels that can allow extremely high resolution settings in the
drives while also commanding very high (if not “top”) motor speeds when required. These new high-speed
output cards are designed to be low-cost “mini-coprocessors”, capable of executing logic asynchronous to the
PLC scan.

Software is also playing a bigger role in the evolution of PLC specialty modules for both discrete and hybrid
control applications. Advancements in software that provide for intuitive graphical configuration are
eliminating the need for large amounts of setup ladder logic previously needed in the beginning of the user’s
PLC program. Microsoft Windows-based point-and-click configuration utilities are becoming more common
and provide substantial time savings for programmers and maintenance personnel. With these advancements in
PLC technology, PLCs will continue to meet the needs of machine control applications for many years.

Abstract— Servo motors are used for motion controls in variety of electro-mechanical industries such as
robotics, CNC manufacturing, aerospace technology etc. to maintain accuracy and precision. The control
of servomotor in various modes like position, velocity and torque mode is achieved using servo drive.
The position mode control is achieved through Programmable Logic Controller (PLC) ladder logic
programming to oscillate the motor shaft forward/reverse direction for required speed and position.
Position mode parameters are realized by configuring the application software (R-advanced Setup) for
Sanmotion servo-drive. PLC ladder logic program developed is capable of reading serial encoder data in
incremental mode by establishing RS485 communication with Sanmotion AC Servo drive. An attempt
has been made to establish RS232 and Ethernet communication protocols to interface Redlion’s Human
Machine Interface (HMI) and Galil’s DMC 21x3 (Digital Motion Controller) to monitor the servo motor
 parameters. The real time data related to DMC 21x3 controller and servomotor parameters are
read/write with the help of HMI for supervisory monitoring of servo motor.
(PDF) PLC & HMI Interfacing for AC Servo Drive. Available from:
https://www.researchgate.net/publication/268152130_PLC_HMI_Interfacing_for_AC_Servo_Drive
[accessed Nov 23 2018].

Advanced Motion Control brushless servo amplifier with armature connection

A servo drive is a special electronic amplifier used to power electric servomechanisms.

A servo drive monitors the feedback signal from the servomechanism and continually adjusts for
deviation from expected behavior.

Contents

 1Function
 2Use in industry
 3See also
 4References

Function[edit]
A servo drive receives a command signal from a control system, amplifies the signal, and transmits
electric current to a servo motor in order to produce motion proportional to the command signal.
Typically, the command signal represents a desired velocity, but can also represent a desired torque
or position. A sensor attached to the servo motor reports the motor's actual status back to the servo
drive. The servo drive then compares the actual motor status with the commanded motor status. It
then alters the voltage, frequency or pulse width to the motor so as to correct for any deviation from
the commanded status.[1]
In a properly configured control system, the servo motor rotates at a velocity that very closely
approximates the velocity signal being received by the servo drive from the control system. Several
parameters, such as stiffness (also known as proportional gain), damping (also known as derivative
gain), and feedback gain, can be adjusted to achieve this desired performance. The process of
adjusting these parameters is called performance tuning.
Although many servo motors require a drive specific to that particular motor brand or model, many
drives are now available that are compatible with a wide variety of motors.
Use in industry[edit]

OEM servo drive from INGENIA installed on CNC router machine controlling a Faulhaber motor

Servo systems can be used in CNC machining, factory automation, and robotics, among other uses.
Their main advantage over traditional DC or AC motors is the addition of motor feedback. This
feedback can be used to detect unwanted motion, or to ensure the accuracy of the commanded
motion. The feedback is generally provided by an encoder of some sort. Servos, in constant speed
changing use, have a better life cycle than typical AC wound motors. Servo motors can also act as a
brake by shunting off generated electricity from the motor itself.

Lenze-AC Tech is launching the latest generation of its Positionservo drive with full
Ethernet connectivity as standard.
Positionservo is described as a powerful, 'simple,' good quality, reliable servo controller
without the cost and complexity normally associated with servo automation systems.
Open standards and the proliferation of PC control in factory automation mean that the
Positionservo is now fully compatible with what is becoming the least-cost option for
many applications - namely Ethernet. There are two models available, the 940 designed
for encoder feedback and the 941 intended for resolver feedback.
From basic torque and velocity control to fully programmable co-ordinated motion, users
can choose the level of control that suits their application. As a distributed drive/control
system, Positionservo can be used without an external PLC, thereby avoiding the
additional cost of a separate controller and all the cables and connections required. By
putting the power of the motion controller in the same package as the drive, with 17
programmable I/O points, machine control becomes easy with one packaged product.
Wayne Morris, international sales manager (Asia and South America) for Lenze AC
Tech, comments: "The fundamentals of this product are to bring simplicity to servo
technology; with Positionservo it is far easier to program precise motion profiles, and
integrate low-cost yet high-resolution control into positioning systems.
"These drives suit both centralised and decentralised applications and use a Basic-like
motion-programming language to provide precise indexing and positioning, while also
accepting analogue as well as digital drive signals from motion controllers via Ethernet,
RS-485, Modbus, Canopen and Profibus."
Motionview, a Windows-based programming software package, is shipped free in the
box with each drive. Motionview is said to be easy to use with few parameters,
preconfigured motors and an auto-tune option.
Positionservo drives currently range from 2 to 18A output (up to 54A peak) and can
replace complex mechanical systems, such as line shafts and cams, clutches and
brakes, pneumatic and hydraulic cylinders. Typically the servo system will increase a
machine's speed, accuracy and flexibility, while reducing build, maintenance and
changeover times.
Programming using the removable EPM chip is also a standout feature of the product. A
shared technology with the company's AC drives range, and holding the entire drive and
motor configuration, the EPM chip is simply plugged into the front of the drive. In the
case of Positionservo models, it even holds the motion program. With the EPM, servo
control parameters and motion programs need only to be configured once, and can then
be transferred to other Positionservo controllers without having power applied to them.
Program transfer from one EPM to another is made easy by the EPM programmer, a
handheld battery powered unit.
Positionservo drives are available for machines with either single- or three-phase
supplies at nominal voltages of 240V, with an optional integrated EMC filter, and 400V.
An innovative voltage doubler feature enables 110V single-phase inputs to operate with
240V motors.

Print Mark Sensor

These Sensors have been specially designed to recognize print marks. They have a very
small spot, and use a white light LED with
long service life. Only one Sensor is required for the recognition of all color
combinations, as well as the difference in brightness
between printed markings and the background
Applications
• Differentiation of up to 100 gray scales
• Print mark recognition
• Detection of prints, stamps and labels of all kinds
 • High-speed print mark recognition
• Recognition of smallest stamps by a very small spot

Mouth Opening Device

OBJECTIVES:
This study investigated the clinical effectiveness of intervention with an open-mouth
exercise device designed to facilitate maximal interincisal opening (MIO) and
improve quality of life in patients with head and neck (H&N) cancer and oral
submucous fibrosis (OSF).
MATERIALS AND METHODS:
Sixty patients with H&N cancer, OSF, and trismus (MIO < 35 mm) participated in the
functional rehabilitation program. An open-mouth exercise device intervention group
and conventional group, each consisting of 20 patients, underwent a 12-week
training and exercising program and follow-up. For the control group, an additional
20 patients were randomly selected to match the demographic characteristics of the
aforementioned two groups.
RESULTS:
The patients' MIO improvements in the aforementioned three groups were 14.0,
10.5, and 1.3 mm, respectively.
CONCLUSION:
Results of this study confirm the significant improvement in average mouth-opening
range. In addition, according to patient feedback, significant improvements in health-
related quality of life and reductions in trismus symptoms occurred in the open-
mouth exercise device group.
CLINICAL RELEVANCE:
This newly designed open-mouth exercise device can facilitate trismus patients with
H&N cancer and OSF and improve mouth-opening range and quality of life.

ORIGINAL ARTICLE
Mouth-opening device as a treatment modality in trismus patients
with head and neck cancer and oral submucous fibrosis: a prospective
study
Yu-Hsuan Li1,2 & Wei-Chin Chang1,2 & Tien-En Chiang1,2 & Chiun-Shu Lin3 & Yuan-Wu Chen1,2
Received: 13 August 2017 /Accepted: 17 April 2018
# The Author(s) 2018
Abstract
Objectives This study investigated the clinical effectiveness of intervention with an open-mouth exercise device
designed to
facilitate maximal interincisal opening (MIO) and improve quality of life in patients with head and neck (H&N)
cancer and oral
submucous fibrosis (OSF).
Materials and methods Sixty patients with H&N cancer, OSF, and trismus (MIO < 35 mm) participated in the
functional
rehabilitation program. An open-mouth exercise device intervention group and conventional group, each consisting
of 20
patients, underwent a 12-week training and exercising program and follow-up. For the control group, an additional
20 patients
were randomly selected to match the demographic characteristics of the aforementioned two groups.
Results The patients’ MIO improvements in the aforementioned three groups were 14.0, 10.5, and 1.3 mm,
respectively.
Conclusion Results of this study confirm the significant improvement in average mouth-opening range. In
addition, according to
patient feedback, significant improvements in health-related quality of life and reductions in trismus symptoms
occurred in the
open-mouth exercise device group.
Clinical relevance This newly designed open-mouth exercise device can facilitate trismus patients with H&N
cancer and OSF
and improve mouth-opening range and quality of life.
Keywords EZBite device . Oral submucosal fibrosis . Trismus . Maximal interincisal opening
Introduction
Trismus refers to a reduced ability to open the mouth and is a
common symptom in patients with head and neck (H&N)
cancer and oral submucous fibrosis (OSF). Trismus limits an
individual’s mouth-opening range and alters various aspects
of health-related quality of life (HRQL) and an individual’s
activities of daily life including persistent problems with eating, chewing, swallowing, and oral hygiene. Impaired
HRQL
subsequently damages patients’ physical and psychological
health [1], which in turn can lead to poor nutritional condition
and depression; these symptoms have been observed in many
previous studies [2].
Previously documented risk factors for cancer-associated
trismus include tumor size, high radiotherapy dose, and tumor
location, while OSF-related trismus primarily results from
mucositis. The mucositis and muscle fibrosis caused by
cancer-associated and OSF-related factors both lead to the
development of trismus [3–6].
The definition of trismus (i.e., maximal interincisal opening [MIO] of 35 mm) described by Dijsktra [7] has been
used
extensively in studies investigating trismus in patients with
H&N cancer and those with OSF and was used in the present
study. This definition has facilitated the comparison and study
of various outcomes in different individuals.
Various devices have been applied in the treatment of
oncological- and OSF-related trismus, including passive
mouth-opening devices such as tongue depressors or spatulas
that are placed between the teeth. Moreover, a rubber hose
* Yuan-Wu Chen
h6183@yahoo.com.tw
1 Division of Oral and Maxillofacial Surgery, Tri-Service General
Hospital, No.325, Cheng-Kung Rd., Sec.2, Neihu 114,
Taipei, Taiwan, Republic of China
2 School of Dentistry, National Defense Medical Center,
Taipei, Taiwan, Republic of China
3 Department of Radiation Oncology, Tri-Service General Hospital,
Taipei, Taiwan, Republic of China
Clinical Oral Investigations
https://doi.org/10.1007/s00784-018-2456-4
could provide better mouth opening ability with high patient
satisfaction. However, these conventional treatments exposed
difficulties in training protocol design, unpredictable outcomes, and lack of patients’ subjective feedback [7].
Recently, the Therabite and Dynasplint (DTS) devices, which
are available with a complete set of training protocols, have
become increasingly popular in the Western world. With this
type of newly designed mouth-opening exercise device, improved outcomes have been reported with better
costeffectiveness than traditional methods [8–10].
Thus, currently, there is no consensus on treating trismus
related to H&N cancer and OSF. Some patients are encouraged
to receive medication, whereas some authorities encourage
physical training. Several studies have revealed that openmouth exercise devices are effective for the treatment of
trismus. However, these studies have not used prospective designs
or included patient feedback evaluations (PFEs). Therefore,
data regarding the outcome of trismus treatment in relation to
patients’ experiences and feedback are limited [11].
The present study aimed to investigate the therapeutic effect of the EZBite device and HRQL outcomes in trismus
patients with H&N cancer and OSF.
Methods and materials
EZBite
The EZBite device is an open-mouth training device 6.1 ×
5.8 × 10 cm in size and weighing 78 g. The device is
manufactured from polyvinyl chloride plastic and stainless
steel. The strength afforded by occlusal function is
25 kg/cm2 and the operation temperature range is 20–60 °C.
The minimal width of the open mouth is 0.5 cm (5 mm).
Therefore, the device is limited to trismus patients with
open-mouth ranges > 5 mm (Fig. 1). The mechanical action
of the device involves passive mouth-opening exercises, and
the EZBite is controlled by the patient. Both upper and lower
mouthpieces parts are placed between the teeth in maxilla and
mandible. The stretching range is 5 mm when the handle of
the EZBite is squeezed.
Subjects
All patients with H&N cancer and OSF were recruited from
the Tri-Service General Hospital (TSGH, Taipei City, Taiwan)
at the multidisciplinary tumor conference held once every
2 weeks. Patients diagnosed with H&N cancer and OSF in
2016 or 2017 were asked to participate in this study.
The inclusion criteria for this study were trismus with OSF
and trismus with H&N cancer status post-surgery with or
without radiation therapy. Patients with recurrent H&N tumors, poor general health, difficulties with completing
questionnaires, and who are edentulous were excluded from this
study.
Patients living in Taipei City underwent regular follow-up
and detailed clinical evaluations conducted by one oral surgeon from an oral and maxillofacial surgery (OMFS)
clinic in
TSGH. Those who developed trismus after developing H&N
cancer and undergoing OSF treatment were invited to attend
an intervention program for the treatment of trismus. In the
case of coexisting acute mucositis or painful mouth symptoms, intervention was initiated as early as patients’ oral
status
allowed. For geographical reasons, only patients living in
Taipei City were included in this study. The conventional exercise group and control group were comprised of
patients
living in Taipei City and matched according to sex, tumor
location, tumor stage, comorbidity, radiation dosage, and age.
The patients in this study were divided into three groups.
The conventional exercise group and control group followed
the standard medical center schedule in Taiwan for follow-up
visits according to the local guidelines, which included regular
MIO measurements by staff members recruited from an
OMFS of TSGH. A structured intervention program was introduced to the participants during the time of trismus
occurrence in each of the three groups. The EZBite device was used
specifically for improving mouth-opening performance in the
EZBite exercise group.
Fig. 1 The product of EZBite
device
Clin Oral Invest
Trismus intervention
The exercise program was a 12-week structured exercise program involving exercise nine times per day. The
program
consisted of the following three steps: (1) warm up movements, namely jaw opening ten times and small sideway
movements of the jaws ten times without using the jaw device;
(2) passive stretching with the jaw-mobilizing device and conventional mouth devices such as a tongue depressor for
30 s (if
possible), to be repeated five times; and (3) five repetitions of
active exercise (bite toward resistance). Patients were
instructed to relax between each session and to gradually increase the amount and intensity of the exercises to avoid
pain
or injury. During the program, the patients were evaluated by
an oral surgeon who conducted MIO measurements after
12 weeks after intervention commencement.
The patients in control group of this study were selected
from patients originally in the other two groups, who did not
comply with instructions. The patients received written and
oral instructions and the EZBite device was demonstrated to
the patients by an oral surgeon (Fig. 2).
Endpoints and assessment
The primary endpoint in this study was MIO. The secondary
endpoint was a questionnaire surveying trismus-related symptoms and HRQL before and after treatment. A
multidimensional study protocol was used to evaluate functional outcomes before and after the trismus exercise
program. The
protocol included MIO, weight, height, sociodemographic data, treatment regimens, and tumor classification. TNM
classification and tumor staging results were retrieved according to
Fig. 2 Study population flow
chart with treatment regimens
Clin Oral Invest
the system of classification determined by the National
Comprehensive Cancer Network of the USA.
MIO
The criterion for trismus (MIO < 35 mm), suggested by
Dijsktra et al. [7], was used. MIO scores were measured using
a ruler with the patient in an upright position. MIO was measured as the maximal distance between the edges of the
incisors of the mandible and the maxilla and expressed in mm.
PFE
The Gothenburg Trismus Questionnaire (GTQ) is a newly
developed and validated symptom-specific trismus questionnaire. The GTQ has been well accepted by patients, has
satisfactory compliance with low rates of missing items, and has
exhibited good psychometric properties (validity and reliability). The questionnaire design modified the acceptable
items
of the GTQ, which contains 12 items divided into three domains, namely jaw-related problems (four items), eating
limitations (four items), and muscular tension (two items), and
two additional items that were retained as single items. The
domains and single items were scored within a range of 0–
100, in which 100 indicates the maximal number of symptoms
and 0 indicates the absence of symptoms.
Statistical methods
Because of the small sample size in the present study, the
Kruskal-Wallis test was applied to examine the correlation
between and statistical significance of differences among the
groups. All tests were conducted at 5% significance level.
Results
Patient characteristics
In total, 60 patients were identified, of whom 48 had trismus
related to H&N cancer and 12 had trismus not related to cancer. Twenty-four patients with trismus related to H&N
cancer
were referred to the Department of Radiation Oncology for
further radiation therapy. No data regarding MIO before treatment was available for these patients. Patient
characteristics,
diagnosis, and tumor localization are summarized in Table 1.
Twenty patients with trismus were enrolled in this study
and allocated to the EZBite group, with another 20 enrolled
in the conventional group. An additional 20 patients were
enrolled during the same period as a control group. Except
for the latter 20 patients, all patients completed the intervention program. In the EZBite group, the patients received
treatment for trismus with the EZBite device. The patients in the
conventional group used a conventional jaw-opening device
Table 1 Demographic data of the
participants in three groups EZBite intervention
group (n = 20)
Conventional exercise
group (n = 20)
Control group
(n = 20)
Mean (range) Mean (range) Mean (range)
Age mean (range) 56.4 (37–75) 54.2 (30–67) 55.8 (30–72)
Gender n (%) n (%) n (%)
Male 13 (65) 12 (60) 16 (80)
Female 7 (35) 8 (40) 4 (20)
Treatment regimens
Surgery only 5 (25) 3 (15) 6 (30)
Radiochemotherapy 6 (30) 5 (25) 5 (25)
Radiotherapy + surgery 7 (35) 10 (50) 7 (35)
Tumor location
Buccal 4 (20) 2 (10) 3 (15)
Lip 4 (20) 4 (20) 4 (20)
Gingiva 5 (25) 6 (30) 5 (25)
Retromolar area 3 (15) 4 (20) 4 (20)
Tumor staging
I 2 (10) 2 (10) 3 (15)
II 2 (10) 2 (10) 4 (20)
III 6 (30) 4 (20) 6 (30)
IV 6 (30) 8 (40) 3 (15)
OSF 4 (20) 4 (20) 4 (20)
Clin Oral Invest
with a tongue depressor or rubber hose. Due to difficulties in
complying with instructions, the 20 patients in the control
group used their own methods of manual stretching during
the training course. No patients in the control group used the
EZBite device or conventional jaw-opening device (Table 1).
MIO
The EZBite group had higher mean MIO outcomes than the
conventional and control groups and with differences that
were statistically significant. At the end of the intervention,
the mean MIO improvements were 14.0 mm in the EZBite
group, 10.5 mm in the conventional group, and 1.3 mm in the
control group. Changes in MIO before and after treatment
with the EZBite are presented in Table 2.
However, patients who could not comply with the treatment recommendations, grouping in the control group, did
not demonstrate significant improvement (pretreatment to
post-treatment MIO, 14.2–15.5 mm; p = 0.88). No complications were reported during treatment with the EZBite.
PFE
A questionnaire to evaluate the improvement in participant
HRQL was designed. The questionnaire included 12 items,
with 10 items divided into three domains: jaw-related problems (4 items), eating limitations (4 items), and muscular
tension (2 items). The remaining two items were retained as single items. The domains and single items range from
0 to 100,
in which 100 refers to maximal amount of symptoms and 0
indicates the complete absence of symptoms.
The results revealed improvement in the participants’
HRQL, including those related to jaw-related problems, eating
limitations, muscle tension, jaw limitations, and social activity, which were reflected in the patients’ PFEs based on
the
score improvements in the questionnaire.
Before the intervention, there were no significant differences in the questionnaire scores between the three groups.
At the end of the treatment period, the scores contained significant differences between the groups in all three
domains
(jaw-related problems, eating limitations, and muscular
tension) and two single items, indicating a significant decrease
in trismus-related symptoms in the EZBite group (Table 3). It
is especially important to note that improvement in social
activity resulted in the restoration of the patients’ inter-social
relationships. Moreover, this result supported our posttreatment expectations, rather than simply an increase in MIO.
Discussion
Previous studies have demonstrated improvements in mouthopening range after jaw exercise in patients with H&N
cancer
and trismus. Three retrospective studies found evidence that
jaw-mobilizing devices, such as the Therabite® device and
Dynasplint System®, are effective for the treatment of trismus
[6–8]. However, to our knowledge, few prospective studies
have investigated the impact and influences of exercisebased treatment on patients with H&N cancer and trismus.
In addition, various measurement methods and experimental
designs have rendered results diverse and difficult for analyzing further outcomes. We are devoted to developing
accurate
experimental designs and conducting comprehensive result
analyses, and we look forward to conducting further studies.
Despite the limited sample size in this study, we attempted to
surpass the results of previous retrospective studies.
We found the greatest improvement in the EZBite group,
including that of MIO from 15.7 to 29.7 mm and various increases in aspects of HRQL based on quantitative
evaluations of
the GTQ scores. Compared with the improvement of 6.4 mm
achieved using the Therabite system in the previous studies, the
EZBite training device demonstrated a greater capability for inducing MIO improvement.
Reduction in the increased MIO was a major problem after
completion of the mouth-opening training program. Aspects
of the treatment modality of MIO improvement remain controversial. For example, physical therapy is generally
considered to be the mainstay of trismus treatment and is often used
independently or in combination with other modalities.
However, according to several studies, treatment choices and
Table 2 Treatment results after
different regimens MIO (mm) EZBite group Conventional group Control group p value
Before intervention 15.7 (12.1–17.3) 14.8 (11.9–18.8) 14.2 (13.1–15.2) p = 0.523
Mean (mm) (CI)
3 months after treatment 29.7 (27.1–32.5) 25.3(19.7–27.1) 15.5 (12.9–17.3) p < 0.001
Mean (mm) (CI)
Change in MIO (mm) △14.0 (12.1–16.7) △10.5 (6.3–12.5) △1.3 (0.6–1.4) p = 0.021
Mean (mm) (CI)
Change in MIO (%) △89.2 (70.1–93.5) △70.9 (55.3–89.9) △8.6 (4.8–12.5) p = 0.015
Clin Oral Invest
Table 3 Questionnaire scores, mean values, and 95% confidence intervals (CIs) for patients with H&N cancer and OSF
Before study group exercise 1-month follow-up
EZBite group Conventional
group
Control group p EZBite group Conventional
group
Control group p
EZBite Conventional Control
Mean (CI) Mean (CI) Mean (CI) Mean (CI) Mean (CI) Mean (CI) Diff Δ Diff Δ Diff Δ
Jaw-related problems
Jaw spasm 68.2 (63.9–72.6) 70.9 (68.9–72.8) 74.1 (71.2–77.0) 0.037 33.6 (30.2–37.0) 50.4 (47.6–53.2) 64.7 (61.3–68.1) < 0.001
- 34.6 - 20.5 - 9.5
Jaw spontaneous pain 66.2 (60.8–71.6) 74.9 (71.5–78.2) 75.1 (72.2–78.0) 0.002 30.8 (26.9–34.6) 53.9 (50.0–57.9) 68.1 (65.0–
71.1) < 0.001 - 35.4 - 20.9 - 7.1
Pain during opening mouth and
swallowing
66.9 (61.0–72.8) 76.1 (72.9–79.2) 73.1 (69.8–76.5) 0.010 30.9 (28.1–33.6) 50.0 (47.1–52.9) 64.8 (62.9–66.7) < 0.001 - 36.0 -
26.1 - 8.3
Pain when yawning 68.1 (61.6–74.5) 75.5 (72.5–78.5) 73.0 (68.6–77.4) 0.081 30.4 (26.9–34.0) 50.9 (48.1–53.8) 66.5 (63.2–
69.8) < 0.001 - 37.6 -24.5 - 6.5
Eating limitations
Solid food limit 63.6 (54.7–72.6) 77.5 (73.4–81.6) 75.1 (71.5–78.7) 0.004 26.7 (23.1–30.3) 54.9 (49.9–59.8) 69.8 (66.6–73.0) <
0.001 - 36.9 - 22.7 - 5.3
Soft food limit 68.2 (62.4–74.0) 73.7 (70.6–76.7) 75.7 (72.0–79.4) 0.038 23.8 (19.7–27.9) 62.5 (56.9–68.0) 65.1 (60.4–69.8) <
0.001 - 41.1 - 20.7 - 5.9
Feeling of limitation when eating 69.7 (63.4 –76.0) 76.2 (70.9–81.5) 70.3 (64.7–75.9) 0.195 19.5 (16.3–22.7) 57.8 (54.6–61.0)
66.0 (63.2–68.8) < 0.001 - 45.9 - 13.7 - 5.3
Difficulty in cutting food 70.1 (63.8–76.3) 75.7 (72.0–79.3) 71.3 (66.7–75.8) 0.226 22.5 (19.4–25.6) 53.6 (47.8–59.4) 62.8
(57.8–67.8) < 0.001 - 46.7 - 17.9 - 5.3
Muscular tension
Clenching 62.8 (56.1–69.5) 73.5 (67.6–79.5) 68. 1(63.2–72.9) 0.032 22.5 (19.6–25.4) 57.1 (54.8–59.5) 59.5 (54.9–64.2) < 0.001
- 40.4 - 19.9 - 5.3
Rigid texture in buccal mucosa 67.9 (62.8–73.0) 76.4 (73.4–79.4) 66.3 (61.4–71.1) 0.004 30.6 (26.7–34.6) 57.8 (54.9–60.7) 63.5
(59.0–68.0) < 0.001 - 45.4 - 19.3 - 6.7
Jaw limitation 68.4 (61.7–75.0) 76.7 (73.9–79.6) 68.4 (63.8–73.0) 0.026 28.2 (23.4–32.9) 55.4 (54.9–60.7) 63.9 (59.0–68.0) <
0.001 - 37.7 - 18.9 - 4.9
Social activity 71.6 (65.1–78.1) 73.7 (70.5–76.9) 70.0 (64.4–75.6) 0.608 35.5 (25.5–35.8) 55.2 (35.6–68.4) 57.3 (47.5–69.7) <
0.001 - 43.4 - 18.3 - 6.1
Clin Oral Invest
outcomes remain limited after the occurrence of relapse
[9–11]. Because of the case selection time, we did not record
the relapse conditions of our participants. We still believe that
these are major problems in maintaining positive treatment
outcomes. We intend to perform further investigations to examine how to maintain positive outcomes.
We should mention that healthy anterior dentition was noted in all of our participants, without the appearance of
periodontitis or partial edentulous anterior dentition. In addition,
these patients are not suitable for this device given the difficulties in manipulation and higher risks to teeth and for
soft
tissue trauma. Further consideration should be given when
recommending the device [12].
The present investigation was designed as a pilot
study to further explore the efficacy of the EZBite device
as part of a multimodal treatment strategy for reducing
trismus. However, we used measurements of participants’
passive mouth opening rather than active mouth opening
to acquire objective data. In our opinion, data from active mouth opening and further long-term follow-up will
better reflect the real-life situations of patients’ long-term
HRQL. Therefore, further evaluation of the possibility of
relapse should be a focus in further studies. Other difficulties include short-arm force, which causes hand
manipulation difficulties according to our participants.
Further ergonomic correction should be considered in
future studies [13].
Our study had two main advantages: first, the participants’ MIO and HRQL significantly improved after
using the EZBite device and second is the costeffective characteristics of our device, which is available
to patients at a price five times lower than that of the
Therabite device. Thus, we intend to encourage more
patients to use the EZBite device to achieve more positive treatment experiences and outcomes.
Our study had several limitations, including selection bias
and a small sample size. In the future, we hope to adopt a
longer tracing time to further examine the relationship between relapse and our treatment design.
Conclusion
Regular rehabilitation and adequate device assistance facilitate the maintenance of an increased MIO and increased
HRQL among patients with H&N cancer and trismus. We
intend to conduct further investigations and develop new treatment regimens in subsequent studies.
Acknowledgments This study was supported by The Megaforce
Company, Taipei, Taiwan, R.O.C.
Funding Tri-Service General Hospital (TSGH-C106-004-006-008-S05)
Tri-Service General Hospital (TSGH-C107-008-S06)
Ministry of National Defense, Taiwan (MAB-106-090)
National Science Council, Taiwan, Republic of China (MOST 105-
2314-B-016-021-MY3)
Compliance with ethical standards
Conflict of interest The authors declare that they have no conflict of
interest.
Ethical approval All procedures performed in studies involving human
participants were in accordance with the ethical standards of the institutional and/or national research committee and with the
1964 Helsinki
declaration and its later amendments or comparable ethical standards.
Informed consent Informed consent was obtained from all individual
participants included in the study.
Open Access This article is distributed under the terms of the Creative
Commons Attribution 4.0 International Li cense (http://
creativecommons.org/licenses/by/4.0/), which permits unrestricted use,
distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source,
provide a link to the
Creative Commons license, and indicate if changes were made.

Cutting Length of Woven Fabric

The main traditional technique for commercial manufacturing of composite pipes is filament winding
in which the winding angle and the discontinuity of the structure (caused by starting and ending
points of the winding process) are two important matters of concern. In the present study, circular
woven fabric with its orthogonal net-shaped continuous structure was produced from polyester
yarns. The fabric was wet with epoxy and hand layup was used to manufacture the composite pipes.
The composite pipes were subjected to internal hydrostatic pressure and their burst strength was
recorded. In addition, the tensile strength of flat laminas was assessed in the warp and weft
directions. We estimated and analyzed the failure strength of composite pipes using Tresca’s failure
criterion and Finite Element (FE) modeling. The experimental burst strength was almost 23% more
than the FE model and 77% more than the theoretical estimate.
Garment prices are mainly based on the fabric consumption. Hence we must pay more
attention to find out the fabric consumption more accurately or closely. It needs sound
knowledge and good practical experience to find out the fabric consumption. Let us
analyze here how to make this calculation.

As the knitted fabrics are knitted by the circular knitting machines, the fabrics will be in
tabular form only. Here we are going to see the garments which are made of 100%
Cotton fabrics in tubular form.

To work on the prices exactly, we must have full measurements of the garment. But
compulsorily, we must have the measurements of Chest, Body Length and Sleeve
Length.

Variable Functions
1. Fabric Consumption
2. Fabric Cost
3. Accessories Cost
4. Print/Embroidery/Washing Charge
5. C.M.
6. Freight (C & F)
7. Payment mode (at sight deferred payment 60days or 90 days or 120 days, TT,
Sales Contract)

Consumption of fabric
1. Consumption (Kg/ Doz) =

(L + S.L. + AL-01) × (½ C + AL-02) × GSM ×2×12+Wastage%

100 100 1000

L (Length) = HPS (High Point Shoulder

= CBL (Central Back length)
= BL (Body Length)
 S.L = Sleeve Length

AL = Allowance

Allowance

1.Sewing Allowance:

This is actually sewing allowance in lengthwise of a garment.

For T-Shirt:

Bottom Hem = 2.5-3 Cm

Shoulder Join = 1.5 Cm

Sleeve Hem = 2.5- 3 Cm

Sleeve Join = 1.5 cm

Sub Total = 9 cm

In Hand = 1 cm

Grand Total =10 cm

Per Cut and Sewn allowance = 2 cm

Note: Pocket, Half moon, double layer bottom hem, and double layer sleeve s/b
calculated on lengthwise.

2. Chest Allowance:

This is sewing allowance in widthwise of garment

a.Side Seam = ½ Chest + 3cm
b.Tube Seam= ½ Chest + 0 cm
c.Per cut and sewn allowance= 2 cm2.

Consumption (Kg/ Doz)= Length in Meter X Width In M X GSM in Kg X 2 X 12 +

WastagePercentage

3. Neck Rib # 1×1/1×1 elastane rib circular

Neck Rib Consumption:

Height (Length) = Rib height or rib width or rib depth

Total Height= Rib Height X 2 + Allowance

Width = Neck opening or neck width x 2 + 2 cm (Round)

= Neck opening or neck width x 2 + 5 cm (V-shape)

A=Body Length= 70 cm

B=Sleeve length=25 cm

½ C ==1/2Chest =55 cm

A= Body length 1=15 cm

B=Body Length 2= 15 cm

C= Body Length 3=40 cm

D= ½ Chest=55 cm

A1= Sleeve length1=10 cm

B1= Sleeve Length2=5 cm

C1=Sleeve length3=10 cm

RELATED POSTS
Cost of fabric in Garment manufacturing
Example:-Calculate the consumption/doz on the basis of 180 GSM, S/J and neck rib gsm
230

Consumption (Kg/ Doz) =

 ( 70 + 25 + 10) ( 55 + 3) 180
× × × 2 × 12 + 5 %
100 100 1000

= 2.76 kg/ doz

For picture 02:

Consumption (Kg/ Doz For color A) =

( 15 + 10 + 8) ( 55 + 3 ) 180
× × × 2 × 12 + 5 %
100 100 1000

= 0.86 kg/ doz

Consumption (Kg/ Doz For color B) =

( 15 + 5 + 4) ( 55 + 3 ) 180
× × × 2 × 12 + 5 %
100 100 1000

= 0.63 kg/ doz

Consumption (Kg/ Doz For color C) =

( 40 + 10 + 5) × ( 55 + 3 ) × 180 × 2 × 12 + 5 %
 100 100 1000

= 1.44 kg/ doz

Total consumption: 0.86+0.63+1.44 = 2.93 kg/ doz

Neck Rib Consumption:

Width = Neck width x 2 + 2 cm (Round)

= 19X2+2 = 40 cm

Total Height= Rib Height X 2 + Allowance= 2X2 +2=6 cm

= Length in Meter X Width In M X GSM in Kg X 12 +

2. Consumption (Kg/ Wastage
Doz) = .06 X .4X.230X12+18%
=.07 kg/ Doz

Note:
Following point s/b considered during marketing cost:
1.Fleece dia is not available.
2.Y/D stripe wastage is huge

Math 02
Question: Fabric Length 100yds width 58 inches (Open) GSM 230, what is fabric
weight?
Ans:Fabric weight in Kg = Length (Meter) X Width (Meter) X GSM in Kg

= l x w x GSM= (100 Yds X36 X 2.54)/100 X (58 X 2.54)/100X 230/1000

W (Kg) = 91.44 x 1.4732 x .230
= 30.99 kg
2.Question: Fabric weight 50 kg, Fabric width 40 inch (tube) GSM 180. What is fabric
length in meter?

Ans:Fabric weight in Kg = Length (Meter) X Width (Meter) X GSM in KgW (Kg) = l x

w x GSM

50 = l x (40x 2.54x 2)/ 100 X 180/1000

= 136.70 meter
L = 136.70 x 1.0937 yds [ 1 meter = 1.0937 yds]
= 149.50 yds

3.Question: Fabric price 2.25 USD/ yds, Width 45 inch open, GSM 200, Consumption
3.20 kg/doz, what is the garment fabric cost for per doz garments?

= L (M) X w (M) X GSM (kg)

Ans: W (kg)
= L (M) X (45X2.54)/100 X 200/1000

= (3.20 X100X 1000) / (45X 2.54 X 200)

= 13.99 (M)
L (M)
= 13.99 X 1.0937 yds
= 15.30 yds

= Length X Unit price/ yds

= 13.99 (M)
Fabric cost (Per doz gmt)
= 15.30 x 2.25
= 34.56 USD / Doz

Piping or Binding or Back Tape:

Cons: Length in M x width in M x GSM in Kg x 12 + allowance (18%)

Length: Neck width x 2 + 2 (R shape)

Width: If width is 1 cm or any unit Pls multiply by 4
Wastage:
Distribution:

1. Sewing wastage = 3%
2. Cutting and Finishing=2%
3. Print Wastage=2-3%
4. Emb. Wastage=2-3%
5. Garment Wash wastage=5% above (Depends on wash type)

Wash types and their wastage

 Garment Normal Wash=2-3%

 Garment Enzyme Wash=3-5%
 Garment Stone Wash= 5-10%
 Garment Pigment dyeing & wash=10-20%

Note: Wastage is variable depending on factory to factory.

Maximum Bag Length

There is normally a maximum weight limit of 50 pounds per checked bag as well as a size
restriction. The most common maximum size bag allowed is 62 linear (total) inches. A common
size bag for checking through is: 27" x 21" x 14".

To keep ticket prices (Bare Fare™) low for everyone, we charge for carry-ons
and checked bags. We charge more for checked bags over 40 lbs. This is
because the added weight requires more gas for the plane. One personal item
that fits entirely in the smaller sizer box (like a purse, small backpack, etc.) is
included with your ticket. Another personal item or anything larger like a
standard carry-on or checked bag will need to be paid for.

Additional Mouth Opening Device

Objectives
This study investigated the clinical effectiveness of intervention with an open-mouth exercise
device designed to facilitate maximal interincisal opening (MIO) and improve quality of life in
patients with head and neck (H&N) cancer and oral submucous fibrosis (OSF).

Materials and methods

Sixty patients with H&N cancer, OSF, and trismus (MIO < 35 mm) participated in the functional
rehabilitation program. An open-mouth exercise device intervention group and conventional
group, each consisting of 20 patients, underwent a 12-week training and exercising program and
follow-up. For the control group, an additional 20 patients were randomly selected to match the
demographic characteristics of the aforementioned two groups.

Results
The patients’ MIO improvements in the aforementioned three groups were 14.0, 10.5, and
1.3 mm, respectively.

Conclusion
Results of this study confirm the significant improvement in average mouth-opening range. In
addition, according to patient feedback, significant improvements in health-related quality of life
and reductions in trismus symptoms occurred in the open-mouth exercise device group.

Clinical relevance
This newly designed open-mouth exercise device can facilitate trismus patients with H&N
cancer and OSF and improve mouth-opening range and quality of life.

Keywords
EZBite device Oral submucosal fibrosis Trismus Maximal interincisal opening
Introduction

Trismus refers to a reduced ability to open the mouth and is a common

symptom in patients with head and neck (H&N) cancer and oral submucous
fibrosis (OSF). Trismus limits an individual’s mouth-opening range and alters
various aspects of health-related quality of life (HRQL) and an individual’s
activities of daily life including persistent problems with eating, chewing,
swallowing, and oral hygiene. Impaired HRQL subsequently damages patients’
physical and psychological health [1], which in turn can lead to poor nutritional
condition and depression; these symptoms have been observed in many
previous studies [2].

Previously documented risk factors for cancer-associated trismus include tumor

size, high radiotherapy dose, and tumor location, while OSF-related trismus
primarily results from mucositis. The mucositis and muscle fibrosis caused by
cancer-associated and OSF-related factors both lead to the development of
trismus [3, 4, 5, 6].

The definition of trismus (i.e., maximal interincisal opening [MIO] of 35 mm)

described by Dijsktra [7] has been used extensively in studies investigating
trismus in patients with H&N cancer and those with OSF and was used in the
present study. This definition has facilitated the comparison and study of
various outcomes in different individuals.

Various devices have been applied in the treatment of oncological- and OSF-
related trismus, including passive mouth-opening devices such as tongue
depressors or spatulas that are placed between the teeth. Moreover, a rubber
hose could provide better mouth opening ability with high patient satisfaction.
However, these conventional treatments exposed difficulties in training
protocol design, unpredictable outcomes, and lack of patients’ subjective
feedback [7]. Recently, the Therabite and Dynasplint (DTS) devices, which are
available with a complete set of training protocols, have become increasingly
popular in the Western world. With this type of newly designed mouth-opening
exercise device, improved outcomes have been reported with better cost-
effectiveness than traditional methods [8, 9, 10].

Thus, currently, there is no consensus on treating trismus related to H&N

cancer and OSF. Some patients are encouraged to receive medication, whereas
some authorities encourage physical training. Several studies have revealed that
open-mouth exercise devices are effective for the treatment of trismus.
However, these studies have not used prospective designs or included patient
feedback evaluations (PFEs). Therefore, data regarding the outcome of trismus
treatment in relation to patients’ experiences and feedback are limited [11].

The present study aimed to investigate the therapeutic effect of the EZBite
device and HRQL outcomes in trismus patients with H&N cancer and OSF.

Methods and materials

EZBite
The EZBite device is an open-mouth training device 6.1 × 5.8 × 10 cm in size and
weighing 78 g. The device is manufactured from polyvinyl chloride plastic and
stainless steel. The strength afforded by occlusal function is 25 kg/cm2 and the
operation temperature range is 20–60 °C. The minimal width of the
open mouth is 0.5 cm (5 mm). Therefore, the device is limited to trismus
patients with open-mouth ranges > 5 mm (Fig. 1). The mechanical action of the
device involves passive mouth-opening exercises, and the EZBite is controlled
by the patient. Both upper and lower mouthpieces parts are placed between the
teeth in maxilla and mandible. The stretching range is 5 mm when the handle of
the EZBite is squeezed.
Open image in new window

Fig. 1
The product of EZBite device

Subjects
All patients with H&N cancer and OSF were recruited from the Tri-Service
General Hospital (TSGH, Taipei City, Taiwan) at the multidisciplinary tumor
conference held once every 2 weeks. Patients diagnosed with H&N cancer and
OSF in 2016 or 2017 were asked to participate in this study.

The inclusion criteria for this study were trismus with OSF and trismus with
H&N cancer status post-surgery with or without radiation therapy. Patients
with recurrent H&N tumors, poor general health, difficulties with completing
questionnaires, and who are edentulous were excluded from this study.

Patients living in Taipei City underwent regular follow-up and detailed clinical
evaluations conducted by one oral surgeon from an oral and maxillofacial
surgery (OMFS) clinic in TSGH. Those who developed trismus after developing
H&N cancer and undergoing OSF treatment were invited to attend an
intervention program for the treatment of trismus. In the case of coexisting
acute mucositis or painful mouth symptoms, intervention was initiated as early
as patients’ oral status allowed. For geographical reasons, only patients living in
Taipei City were included in this study. The conventional exercise group and
control group were comprised of patients living in Taipei City and matched
according to sex, tumor location, tumor stage, comorbidity, radiation dosage,
and age.

The patients in this study were divided into three groups. The conventional
exercise group and control group followed the standard medical center schedule
in Taiwan for follow-up visits according to the local guidelines, which included
regular MIO measurements by staff members recruited from an OMFS of
TSGH. A structured intervention program was introduced to the participants
during the time of trismus occurrence in each of the three groups. The EZBite
device was used specifically for improving mouth-opening performance in the
EZBite exercise group.

Trismus intervention
The exercise program was a 12-week structured exercise program involving
exercise nine times per day. The program consisted of the following three steps:
(1) warm up movements, namely jaw opening ten times and small sideway
movements of the jaws ten times without using the jaw device; (2) passive
stretching with the jaw-mobilizing device and conventional mouthdevices such
as a tongue depressor for 30 s (if possible), to be repeated five times; and (3)
five repetitions of active exercise (bite toward resistance). Patients were
instructed to relax between each session and to gradually increase the amount
and intensity of the exercises to avoid pain or injury. During the program, the
patients were evaluated by an oral surgeon who conducted MIO measurements
after 12 weeks after intervention commencement.

The patients in control group of this study were selected from patients originally
in the other two groups, who did not comply with instructions. The patients
received written and oral instructions and the EZBite device was demonstrated
to the patients by an oral surgeon (Fig. 2).
Open image in new window

Fig. 2
Study population flow chart with treatment regimens

Endpoints and assessment

The primary endpoint in this study was MIO. The secondary endpoint was a
questionnaire surveying trismus-related symptoms and HRQL before and after
treatment. A multidimensional study protocol was used to evaluate functional
outcomes before and after the trismus exercise program. The protocol included
MIO, weight, height, sociodemographic data, treatment regimens, and tumor
classification. TNM classification and tumor staging results were retrieved
according to the system of classification determined by the National
Comprehensive Cancer Network of the USA.

MIO
The criterion for trismus (MIO < 35 mm), suggested by Dijsktra et al. [7], was
used. MIO scores were measured using a ruler with the patient in an upright
position. MIO was measured as the maximal distance between the edges of the
incisors of the mandible and the maxilla and expressed in mm.

PFE
The Gothenburg Trismus Questionnaire (GTQ) is a newly developed and
validated symptom-specific trismus questionnaire. The GTQ has been well
accepted by patients, has satisfactory compliance with low rates of missing
items, and has exhibited good psychometric properties (validity and reliability).
The questionnaire design modified the acceptable items of the GTQ, which
contains 12 items divided into three domains, namely jaw-related problems
(four items), eating limitations (four items), and muscular tension (two items),
and two additional items that were retained as single items. The domains and
single items were scored within a range of 0–100, in which 100 indicates the
maximal number of symptoms and 0 indicates the absence of symptoms.

Statistical methods
Because of the small sample size in the present study, the Kruskal-Wallis test
was applied to examine the correlation between and statistical significance of
differences among the groups. All tests were conducted at 5% significance level.

Results

Patient characteristics
In total, 60 patients were identified, of whom 48 had trismus related to H&N
cancer and 12 had trismus not related to cancer. Twenty-four patients with
trismus related to H&N cancer were referred to the Department of Radiation
Oncology for further radiation therapy. No data regarding MIO before
treatment was available for these patients. Patient characteristics, diagnosis,
and tumor localization are summarized in Table 1.
Table 1
Demographic data of the participants in three groups
EZBite intervention Conventional exercise Control
group (n = 20) group (n = 20) group
(n = 20)

Mean (range) Mean (range) Mean

(range)

Age mean (range) 56.4 (37–75) 54.2 (30–67) 55.8 (30–72)

Gender n (%) n (%) n (%)

Male 13 (65) 12 (60) 16 (80)

Female 7 (35) 8 (40) 4 (20)

Treatment regimens

Surgery only 5 (25) 3 (15) 6 (30)

Radiochemotherapy 6 (30) 5 (25) 5 (25)

Radiotherapy + 7 (35) 10 (50) 7 (35)

surgery

Tumor location

Buccal 4 (20) 2 (10) 3 (15)

Lip 4 (20) 4 (20) 4 (20)

Gingiva 5 (25) 6 (30) 5 (25)

Retromolar area 3 (15) 4 (20) 4 (20)

Tumor staging

I 2 (10) 2 (10) 3 (15)

II 2 (10) 2 (10) 4 (20)

III 6 (30) 4 (20) 6 (30)

 EZBite intervention Conventional exercise Control
group (n = 20) group (n = 20) group
(n = 20)

Mean (range) Mean (range) Mean

(range)

IV 6 (30) 8 (40) 3 (15)

OSF 4 (20) 4 (20) 4 (20)

Twenty patients with trismus were enrolled in this study and allocated to the
EZBite group, with another 20 enrolled in the conventional group. An
additional 20 patients were enrolled during the same period as a control group.
Except for the latter 20 patients, all patients completed the intervention
program. In the EZBite group, the patients received treatment for trismus with
the EZBite device. The patients in the conventional group used a conventional
jaw-opening device with a tongue depressor or rubber hose. Due to difficulties
in complying with instructions, the 20 patients in the control group used their
own methods of manual stretching during the training course. No patients in
the control group used the EZBite device or conventional jaw-opening device
(Table 1).

MIO
The EZBite group had higher mean MIO outcomes than the conventional and
control groups and with differences that were statistically significant. At the end
of the intervention, the mean MIO improvements were 14.0 mm in the EZBite
group, 10.5 mm in the conventional group, and 1.3 mm in the control group.
Changes in MIO before and after treatment with the EZBite are presented in
Table 2.
Table 2
Treatment results after different regimens
MIO (mm) EZBite group Conventional Control p value
group group

Before intervention 15.7 (12.1–17.3) 14.8 (11.9–18.8) 14.2 (13.1– p = 0.523

15.2)

Mean (mm) (CI)

3 months after 29.7 (27.1– 25.3(19.7–27.1) 15.5 (12.9– p < 0.001

treatment 32.5) 17.3)
 MIO (mm) EZBite group Conventional Control p value
group group

Mean (mm) (CI)

Change in MIO (mm) △14.0 (12.1– △10.5 (6.3–12.5) △1.3 (0.6–1.4) p = 0.021
16.7)

Mean (mm) (CI)

Change in MIO (%) △89.2 (70.1– △70.9 (55.3–89.9) △8.6 (4.8– p = 0.015
93.5) 12.5)

However, patients who could not comply with the treatment recommendations,
grouping in the control group, did not demonstrate significant improvement
(pretreatment to post-treatment MIO, 14.2–15.5 mm; p = 0.88). No
complications were reported during treatment with the EZBite.

PFE
A questionnaire to evaluate the improvement in participant HRQL was
designed. The questionnaire included 12 items, with 10 items divided into three
domains: jaw-related problems (4 items), eating limitations (4 items), and
muscular tension (2 items). The remaining two items were retained as single
items. The domains and single items range from 0 to 100, in which 100 refers to
maximal amount of symptoms and 0 indicates the complete absence of
symptoms.

The results revealed improvement in the participants’ HRQL, including those

related to jaw-related problems, eating limitations, muscle tension, jaw
limitations, and social activity, which were reflected in the patients’ PFEs based
on the score improvements in the questionnaire.

Before the intervention, there were no significant differences in the

questionnaire scores between the three groups. At the end of the treatment
period, the scores contained significant differences between the groups in all
three domains (jaw-related problems, eating limitations, and muscular tension)
and two single items, indicating a significant decrease in trismus-related
symptoms in the EZBite group (Table 3). It is especially important to note that
improvement in social activity resulted in the restoration of the patients’ inter-
social relationships. Moreover, this result supported our post-treatment
expectations, rather than simply an increase in MIO.
Table 3
Questionnaire scores, mean values, and 95% confidence intervals (CIs) for
patients with H&N cancer and OSF
Before study group exercise 1-month follow-up

EZBite Conventional Control p EZBite Conventiona

group group group group group

Mean Mean (CI) Mean Mean Mean (CI)

(CI) (CI) (CI)

Jaw-related problems

Jaw spasm 68.2 70.9 (68.9– 74.1 0.037 33.6 50.4 (47.6–
(63.9– 72.8) (71.2– (30.2– 53.2)
72.6) 77.0) 37.0)

Jaw spontaneous 66.2 74.9 (71.5– 75.1 0.002 30.8 53.9 (50.0–
pain (60.8– 78.2) (72.2– (26.9– 57.9)
71.6) 78.0) 34.6)

Pain during 66.9 76.1 (72.9– 73.1 0.010 30.9 50.0 (47.1–
opening mouth and (61.0– 79.2) (69.8– (28.1– 52.9)
swallowing 72.8) 76.5) 33.6)

Pain when 68.1 75.5 (72.5– 73.0 0.081 30.4 50.9 (48.1–
yawning (61.6– 78.5) (68.6– (26.9– 53.8)
74.5) 77.4) 34.0)

Eating limitations

Solid food limit 63.6 77.5 (73.4– 75.1 0.004 26.7 54.9 (49.9–
(54.7– 81.6) (71.5– (23.1– 59.8)
72.6) 78.7) 30.3)

Soft food limit 68.2 73.7 (70.6– 75.7 0.038 23.8 62.5 (56.9–
(62.4– 76.7) (72.0– (19.7– 68.0)
74.0) 79.4) 27.9)

Feeling of 69.7 76.2 (70.9– 70.3 0.195 19.5 57.8 (54.6–

limitation when (63.4– 81.5) (64.7– (16.3– 61.0)
eating 76.0) 75.9) 22.7)

Difficulty in 70.1 75.7 (72.0– 71.3 0.226 22.5 53.6 (47.8–

cutting food (63.8– 79.3) (66.7– (19.4– 59.4)
76.3) 75.8) 25.6)
 Before study group exercise 1-month follow-up

EZBite Conventional Control p EZBite Conventiona

group group group group group

Mean Mean (CI) Mean Mean Mean (CI)

(CI) (CI) (CI)

Muscular tension

Clenching 62.8 73.5 (67.6– 68. 0.032 22.5 57.1 (54.8–

(56.1– 79.5) 1(63.2– (19.6– 59.5)
69.5) 72.9) 25.4)

Rigid texture in 67.9 76.4 (73.4– 66.3 0.004 30.6 57.8 (54.9–
buccal mucosa (62.8– 79.4) (61.4– (26.7– 60.7)
73.0) 71.1) 34.6)

Jaw limitation 68.4 76.7 (73.9– 68.4 0.026 28.2 55.4 (54.9–
(61.7– 79.6) (63.8– (23.4– 60.7)
75.0) 73.0) 32.9)

Social activity 71.6 73.7 (70.5– 70.0 0.608 35.5 55.2 (35.6–
(65.1– 76.9) (64.4– (25.5– 68.4)
78.1) 75.6) 35.8)
Discussion

Previous studies have demonstrated improvements in mouth-opening range

after jaw exercise in patients with H&N cancer and trismus. Three retrospective
studies found evidence that jaw-mobilizing devices, such as the Therabite®
device and Dynasplint System®, are effective for the treatment of trismus
[6, 7, 8]. However, to our knowledge, few prospective studies have investigated
the impact and influences of exercise-based treatment on patients with H&N
cancer and trismus. In addition, various measurement methods and
experimental designs have rendered results diverse and difficult for analyzing
further outcomes. We are devoted to developing accurate experimental designs
and conducting comprehensive result analyses, and we look forward to
conducting further studies. Despite the limited sample size in this study, we
attempted to surpass the results of previous retrospective studies.

We found the greatest improvement in the EZBite group, including that of MIO
from 15.7 to 29.7 mm and various increases in aspects of HRQL based on
quantitative evaluations of the GTQ scores. Compared with the improvement of
6.4 mm achieved using the Therabite system in the previous studies, the EZBite
training device demonstrated a greater capability for inducing MIO
improvement.

Reduction in the increased MIO was a major problem after completion of

the mouth-opening training program. Aspects of the treatment modality of MIO
improvement remain controversial. For example, physical therapy is generally
considered to be the mainstay of trismus treatment and is often used
independently or in combination with other modalities. However, according to
several studies, treatment choices and outcomes remain limited after the
occurrence of relapse [9, 10, 11]. Because of the case selection time, we did not
record the relapse conditions of our participants. We still believe that these are
major problems in maintaining positive treatment outcomes. We intend to
perform further investigations to examine how to maintain positive outcomes.

We should mention that healthy anterior dentition was noted in all of our
participants, without the appearance of periodontitis or partial edentulous
anterior dentition. In addition, these patients are not suitable for this device
given the difficulties in manipulation and higher risks to teeth and for soft
tissue trauma. Further consideration should be given when recommending the
device [12].

The present investigation was designed as a pilot study to further explore the
efficacy of the EZBite device as part of a multimodal treatment strategy for
reducing trismus. However, we used measurements of participants’
passive mouth opening rather than active mouth opening to acquire objective
data. In our opinion, data from active mouth opening and further long-term
follow-up will better reflect the real-life situations of patients’ long-term HRQL.
Therefore, further evaluation of the possibility of relapse should be a focus in
further studies. Other difficulties include short-arm force, which causes hand
manipulation difficulties according to our participants. Further ergonomic
correction should be considered in future studies [13].

Our study had two main advantages: first, the participants’ MIO and HRQL
significantly improved after using the EZBite device and second is the cost-
effective characteristics of our device, which is available to patients at a price
five times lower than that of the Therabite device. Thus, we intend to encourage
more patients to use the EZBite device to achieve more positive treatment
experiences and outcomes.

Our study had several limitations, including selection bias and a small sample
size. In the future, we hope to adopt a longer tracing time to further examine the
relationship between relapse and our treatment design.
Conclusion

Regular rehabilitation and adequate device assistance facilitate the maintenance

of an increased MIO and increased HRQL among patients with H&N cancer and
trismus. We intend to conduct further investigations and develop new treatment
regimens in subsequent studies.

Notes

Acknowledgments

This study was supported by The Megaforce Company, Taipei, Taiwan, R.O.C.

Funding

Tri-Service General Hospital (TSGH-C106-004-006-008-S05)

Tri-Service General Hospital (TSGH-C107-008-S06)

Ministry of National Defense, Taiwan (MAB-106-090)

National Science Council, Taiwan, Republic of China (MOST 105-2314-B-016-021-MY3)

Compliance with ethical standards

Conflict of interest
The authors declare that they have no conflict of interest.

Ethical approval
All procedures performed in studies involving human participants were in accordance with the
ethical standards of the institutional and/or national research committee and with the 1964
Helsinki declaration and its later amendments or comparable ethical standards.

Informed consent
Informed consent was obtained from all individual participants included in the study.
Bottom Folding Width
For a crosswise fold, fabric is usually folded so the cut ends match. However, acrosswise
fold can also be a partial fold. A crosswise fold is often used when pattern pieces are too
wide to fit on fabric folded lengthwise.

Show what you have to offer The perfect film packaging fits like a second skin. Stubborn items such as toys
and baby accessories or elegant items like a tea blend with a cup, filter and filter papers cannot be compressed.
The bottom-folding bag gives these types of goods plenty of leeway to work their full potential in drawing in
customers.
The sturdy variant
Bottom-folding bags made from highly transparent maropack films promote connections. It becomes readily
apparent when showcasing puzzles, parts of a toy house, gourmet foods or table decorations in a clear plastic
bag that these things absolutely belong together.
A mysterious air for the unknown; new outlooks for the familiar. The sturdy stand-up base on the CPP bottom-
folding bag means the bag takes up just the space needed for its contents. The experts at maropack know when
highly transparent plastic bags with bottom folding are the best choice. This variant provides a close, perfectly
shaped fit for boxes and other bulky contents.
Fits perfectly above and below
However, it is important to carefully match the size and design of the bottom-fold bag to the goods or gift. You
also have the choice of whether the bottom-folding bag should feature a lip at the top. The experts
at maropack would like to recommend tapered lips for this design so that the brilliant packaging fits well at the
top and bottom. maropack bottom-folding bags with adhesive tape have been designed to ensure that the
contents in the bag do not become dirty or damaged when removing the adhesive seal.
For the easy-opening variant, a special dust-proof perforation guarantees that the adhesive seal can be opened
with ease. The CPP bottom-folding bag has also been tried-and-tested as convenient outer packaging. It offers
plenty of room for larger numbers of envelopes, greeting cards or congratulatory cards.
Bottom-folding bag options
 Cover lip
 Reversible adhesive seal (resealable) or permanently adhesive
 Tapered lip
 European hole punch for hanging
 Centring hole for venting after filling
 Ability to select nearly any punch positions
 Ability to support flexographic printing, rotogravure and digital printing (multi-coloured up to 8 colours,
with the option of covering the full area on both sides) or for the "PP05" material ID, "The Green Dot" or
individualised logo with hot stamping and with thermal transfer printing for monochromatic, one-sided
prints, print area up to 50 x 90 mm

Double Stitching
I understand first start off with a simple stitch with a seam allowance
from the cut edge like a 1/4 inch. The part that confuses me is that u
have to run another stitch but either it goes higher or below the first
simple stitch? I dont know this. And how much room to leave of
leftover trim?? and i look-uped and they said the second stitch should
be 1/8 of an inch from the first stitch. which leaves me again to the
same question. or will a zig-zag stitch be stronger then 2 running
stitches? Pictures would be great for me to see how a double stitch
would look like...
This shoe production method is primarily used to make very sturdy shoes. Hiking shoes in particular are a
prime example of double-stitched shoes. Double-stitching involves welting onto the insole from the side
instead of from below. As a result, the welt stitch isn’t located on the insole inside of the shoe, but rather
on the outside of the shoe, on the wide welting by the double seam. This method therefore gets its name
from the fact that the shaft and the bottom of the shoe are connected by two visible seams. Double-
stitched shoes are significantly sturdier and more waterproof than Goodyear -welted men’s shoes.

Twin needle or double needle is a very disused accessory;

everyone has it in their sewing kitty but not many use it.

Being afraid that changing the needle and threading with

the double needle is one big lot of trouble is one of the
reasons why people stay away from this very useful
accessory. Some are unaware of the many uses of double
needles .

But once they use this very versatile needle on their hems
and other purposes this needle will be one of the most used
accessories.
 What is a double needle ?
 What do you need to sew with double needles
 How to choose the double needle ?
 Where to keep the two threads for sewing with twin needle
 How to use the twin needles
 6 uses of double needle stitching
 1.To make a hem similar to the coverstitch hem
 2. To sew seams on sheer fabric
 3 To attach ribbon trim
 4 To make Decorative stitches
 5 To make Pintucks
 6 To make parallel rows of top stitching

What is a double needle ?

Double needle / twin needle is a needle with a single shank
and two shaft. The two needle shafts have an eye each
through which two threads are threaded. As you proceed
with the double stitching you will get two parallel rows on
the face of the fabric and a zig zag stitch on the back of the
fabric

What do you need to sew with double

needles
One pre-requisite to sewing with double needles is that you
have to have a zig zag sewing machine with a zig zag
needle plate. Ensure that the zig zag needle plate has a big
enough hole to accommodate the double needle you have
and the stitch is set to straight stitch.

Two thread spools

Two thread pins ( can do with one pin too as explained

below)

How to choose the double needle ?

All Double needles are not made alike. There are always
two numbers on each double needle to show size. The first
number shows
the distance between the two needles. The second number,
the one that follows the slash, is the size of the needle ( For
eg 2.0/80)
Depending on the distance between the two needles – They
are numbered 2.0, 3.0, 4.0 etc 2 means distance between
the two needles are 2 millimeters

Two things decide how much stitch width you can choose
with the needles – 1. width of the hole in the throat plate
and 2. the number on the needle you have ( which
denotes the distance between the two needles of the
double needle)

To know how wide you can go with the needle, if you

have a very wide throat plate, subtract the number of
your needle from the longest stitch width in your machine.

Fo eg: Width of the longest stitch width in your machine –

number of the double needle

If you get 2 as this number this is how much wide you

can go with any stitch in your machine. If you go more
than this your needle will hit the sides of the throat plate
and break

Twin needles are available as Universal and stretch

needles. If you are sewing knits it is advisable to use the
stretch double needle.

Where to keep the two threads for sewing

with twin needle
There are 5 places you can keep the thread spools
1.Check in the kit you received with the sewing machine –
you may have an extra tread pin you can keep on a hole on
top of your machine or on top of the bobbin winder . This
is for the extra thread spool used in double stitching. If you
donot have checkout the other options.

2.If you have a very long thread pin, you can stack the
two thread spools on it . Did you know that the spool
moves in a particular way when sewing . Ensure that the
second spool is moving in the other direction opposite to
the first one. This will prevent tangles

Donot worry if you donot have an extra thread pin or a

long thread pin on which you can keep the two spools
together, you can use a winded bobbin as a thread
spool. The bobbin and the thread spool can be
stacked together

3.Another place to keep the bobbin used as a top thread is

the bobbin winder pin. Just donot engage the winder by
moving it on. Then you can use it as a thread pin

4. Use a straw as the thread pin.

How to use the twin needles

Step 1

Set the Machine to Straight stitch mode.Insert the twin

needle ( just the way you insert ordinary needle- if in
doubt consult the service manual)
Step 2

Thread the sewing machine. You may need to check the

service manual for your sewing machine for steps your
particular machine. General steps are as given below.

You keep two thread spools on the thread pin and thread
the machine together till you reach the needle ; then one
thread goes to one needle and the other thread to the
twin

Bring bobbin thread up as usual.Hold it all together

Take the two threads and the bobbin thread to the back
of the machine under the pressure foot .

Step 2

Never ever use any other stitch than the straight

stitch with the double needle.

Loosen the top thread tension a little bit.

Sew slowly
Some thin fabric may need stabilizers / backing added to
the back of the fabric to prevent thread pulling in the
fabric between the stitching lines.
This is especially true for knits. You will have to hold the
fabric taut and may also need to use a stretch double
needle when sewing knit for best results

Remember to keep the thread tails to the back of the

needle at all times during sewing.
Advantage of double needle stitching
Double needle stitches makes double stitches at the same
time, so you get enforced stitching

It makes two rows of stitches at once – so less work

Disadvantages of Double needle

stitching
Twin needle uses a sort of a chain stitch. At the back of
the fabric there is a loop made So it is not as strong as a
single straight stitch.In a factory made garment a single
needle seam considered superior to a double needle seam
because of its finish and strength.

6 uses of double needle stitching

1.To make a hem similar to the coverstitch hem
You must have seen this hem on your T shirt. On the face
of the fabric two parallel lines can be seen but on the back
of the stitching a zigzag stitch connecting the two lines is
seen.
This hem can be made using a double needle. Use a 4
number needle to make this stitch. Turn under the raw edge
of the fabric to the back . Place the fabric right side up
under the pressure feet ; Position the needle so that this
raw edge will be coming directly in the middle of the two
needles of the twin needle. Remember you are going to
stitch from the top of the fabric. Start sewing . The raw
edge will be enclosed in the zig zag stitch on the back of
the fabric and you will get 2 parallel row of stitches on the
right side

If you are sewing this hem on Knit fabric the hem will
stretch and remain intact if you use a thread with a slight
stretch to it, rather than the cotton thread.

2. To sew seams on sheer fabric

To avoid bulk on the seams of sheer fabric you can sew
with this needle and cut off the seam allowance closely.
Not the most durable of seams though.

3 To attach ribbon trim

Ribbon trims can be attached in one go by sewing it with
a double needle which is the correct size for it. The
distance between two needles should just a little lesser
than the ribbon width so that both edges will be caught.
4 To make Decorative stitches

Use the decorative stitch options in your sewing machine to

make decorative borders . Remember to make sure that the
stitch width is compatible with your needle plate hole. You
can experiment with colours and stitches on a scrap fabric
before trying out on the final pieces.

You may have to use Interfacing on the back for thin

fabrics to prevent fabric puckering.

5 To make Pintucks
You can make beautiful pintucks by sewing with the
double needle and a pintuck foot. Check out the post
on Pintucks for more details
6 To make parallel rows of top stitching
The twin needle is a life saver for those who cannot sew
straight especially when you have to sew two parallel lines.
What could be more easy than sewing both the lines in one
go with a twin needle.
Unwinding PE/HDPE/LLDPE Liner
 Product: Film PE, width: 1250 mm, diameter <600mm
 Foil speed: 60 m/min
 Capacity: 3 coils
 Electromagnetic brakes, coil sensors

Features
 Durable, UV stable material
 Supplied in 22.5 ft (6.86m) wide rolls
 Good chemical resistance
 White surface available by special order
 Conductive layer available by special order

Applications
 Excellent long term exposed lining material
 Landfill liners
 Heap leach and mine ponds
 All water containment applications
High Density Polyethylene (HDPE) Specifications


Product Description
The popularity of High Density Polyethylene (HDPE) is primarily due to its low
initial material cost and excellent chemical resistance. This allows thicker
sections to be used compared to other geomembrane materials. A thick,
durable, HDPE liner can be placed in exposed applications where the cost of
other materials may be prohibitive. HDPE has excellent chemical resistance
which is often the driving force behind the selection of HDPE. HDPE is a field
assembled lining material that cannot be practically fabricated in the shop. All
HDPE projects, regardless of size, must be installed by trained installers.
HDPE is a versatile material which is used widely across all applications. One
of the main uses of HDPE is for landfill base liners where its chemical
resistance is used to good effect. HDPE can also be used in a multitude of
secondary containments, pond linings, and water containment projects. HDPE
is best used as an exposed lining material, and has the UV resistance
required for many years of outstanding service.
HDPE is the most widely used geomembrane in the world and is used more commonly
internationally due to its availability and relatively inexpensive material cost. HDPE is an
excellent product for large applications that require UV and Ozone resistance, chemical
resistance or high-quality installations. Typically used in landfill and mining applications, this
product is delivered in large rolls with a width of 22.5' and is heat welded in the field by
trained technicians providing a high quality, test certified installation. HDPE offers the most
cost effective liner for large projects. HDPE is available in thicknesses ranging from 40 to
120 mil. HDPE Lining materials are a cost effective choice for exposed lining projects. This
product is successfully used in landfills, waste water treatment lagoons, animal waste
lagoons and mining applications.

Linear Low Density Polyethylene (LLDPE) is the most flexible of the plastic sheeting
films. LLDPE is blended form of LDPE where the film has much more flexibility, tensile strength,
and more conformability. ... LLDPE is used for pond liners or blended into other films to give
them more flexibility and extra strength.
LLDPE liner is designed to be used when higher elongation properties are required. It is
similar to HDPE, but is lower in density, thus being more flexible. LLDPE is generally
shipped to job sites in large rolls and deployed by machines. Seaming by CLI's certified
installation technicians occurs in the field by heat fusion welding. LLDPE is also available in
textured versions to enhance traction.

Colorado Lining is a certified installer of Polyethylene products. We maintain year round

field crews capable of installing almost any LLDPE job.

LLDPE is a film that has higher tensile strength and higher impact and puncture
resistance than it's cousin LDPE. It is very flexible and elongates if stressed. It has good
environmental stress crack resistance, and is resistant to chemicals.

For most consumer items, “eye-appeal” is an important consideration in packaging. Consumers often
make purchasing decisions solely on the appearance of a product. High gloss packaging increases the
appeal of a package and increases the likelihood of purchase by a consumer. A package with tears or
damage decreases the likelihood of its selection. Film extruders and converters are aware of the need for
an abuse resistant and high clarity package especially for retail items.

The workhorse resin used by many extruders is an octene comonomer linear low density resin with a
nominal density of 0.920 g/cm 3 and a melt index of 1.0 dg/min. This resin offers a combination of
reasonable clarity and toughness. It is also easy to process on most extrusion and converting equipment.

In the past 2-3 years, the packaging industry has experienced a surge in new designs. These range from
zippered, stand-up pouches to high gloss form, fill, and seal packages for food items. Such packages
require low haze, high gloss film for their sophisticated multicolor graphic printing. The haze and gloss of
standard linear low density polyethylene (LLDPE) does not meet these requirements. Film extruders and
converters who are comfortable processing standard LLDPE must make modifications to process narrow
molecular weight distribution metallocene catalyzed polyethylene or use a totally different polymer in their
films.

A new option is now available to polyethylene film extruders. This LLDPE has improved optical properties
over a standard LLDPE and has good dart impact and tear strength. The polyethylene will extrude on
 conventional equipment with no modifications to temperature profiles, die gaps, or screw designs. This
polyethylene has use as a skin, core layer, or both in a coextruded structure. It is also useful for a
monolayer film. A 1.0 mil monolayer film made from this resin has <5.0 haze and >75 gloss properties.

Experimental
Blown films of 1 mil were produced on a monolayer line. Barefoot — no slip or antiblock additives — films
and films with 2500 ppm of a silica antiblock were extruded for the study. Film testing used 23°C and 50%
RH unless otherwise specified. Specific extrusion conditions were as follows:
 2.5 in. (6.35 cm) commercial extruder with 24:1 L/D
 2.4:1 blow-up ratio
 4.7 lb/h/in. die circumference
 6 in. commercial die with dual lip air ring
 88 mil die opening.
Results and Discussion
The new polyethylene is a nominal 1.0 dg/min. melt index, 0.920 g/cm 3density hexene comonomer linear
PE produced on a gas phase reactor. The resin used for comparison was a 1.0 dg/min. melt index, 0.920
g/cm3 density octene comonomer linear polyethylene. Films were extruded at nearly identical conditions
for each resin evaluated.

Impact strength testing used ASTM D1709, Method A, with a dart drop test with a 26 in. dart height. The
impact strengths for the 1 mil films produced from the octene LLDPE and the new clarity grade hexene
LLDPE were very similar as Fig. 1 shows. Figure 2 shows that the optical property testing of the films
indicated the new clarity hexene had significantly lower haze values. Tear testing on these same films
conducted per ASTM D1922 using a commercial tear tester showed that the clarity grade hexene film had
improved machine direction tear strength over the octene film.
Figure 3 shows the blocking test results using two temperatures — 100°F and 120°F. Because of the high
surface gloss associated with films containing no slip or antiblock, 2500 ppm of a diatomaceous earth
antiblock was added to all resins before evaluating film re-blocking performance. The addition of the
antiblock increased haze by approximately 2% in all films.
Conclusions
The new clarity grade hexene LLDPE's unique properties allow its use in many packaging applications.
Films produced from this PE have excellent clarity and good strength and sealing properties.

This new resin will find success in two primary packaging applications. The first type of application is a
replacement for high pressure low density polyethylene in film structures where the clarity grade hexene
resin will produce a clearer, stronger film. The second type of application is a replacement for
conventional hexene or octene LLDPE in film structures. For these applications, optical properties can be
significantly greater with no loss in film physical properties.

Roll Width
Roll Width: The width of the plotter paper roll is the first number in the specification. In the
United States, plotter paper roll widths are expressed in inches. Popular roll widths for wide-
format plotters include 11, 17, 18, 22, 24, 30, 34, 36, and 42 inches.
Roll Width: The width of the plotter paper roll is the first number in the specification. In the United States,
plotter paper roll widths are expressed in inches. Popular roll widths for wide-format plotters include 11, 17,
18, 22, 24, 30, 34, 36, and 42 inches.
These roll widths make it cost-effective and efficient to continuously print higher volumes of standard-size
engineering and architectural drawings and office documents on wide-format inkjet printers with built-in
cutters. (See the list of standard sizes for engineering and architectural drawings and letter papers in our plotter
paper size chart.)

Before buying plotter paper for your inkjet printer or xerographic copier, it’s important to understand a few
specifications related to plotter paper roll sizes. The type of plotter paper roll size you need will depend on the
specific model of wide format inkjet printer or xerographic copier that will use the paper.
Here are a few specifications to take into account (take a peek at our plotter paper size chart for a quick
reference.)

Roll Width: The width of the plotter paper roll is the first number in the specification. In the United States,
plotter paper roll widths are expressed in inches. Popular roll widths for wide-format plotters include 11, 17,
18, 22, 24, 30, 34, 36, and 42 inches.

These roll widths make it cost-effective and efficient to continuously print higher volumes of standard-size
engineering and architectural drawings and office documents on wide-format inkjet printers with built-in
cutters. (See the list of standard sizes for engineering and architectural drawings and letter papers in our plotter
paper size chart.)

Roll Length: The length of the plotter paper roll is expressed in feet. Bond papers are commonly sold in
lengths of 150, 300 and 500 feet, so you don’t have to stop to reload the paper during a job in which you are
printing multiple copies or sets of drawings. Heavier or thicker papers or clear films for special applications
are typically sold in roll lengths of 100 to 150 feet.

Core Diameter: The core size refers to the diameter of the cardboard tube on which the plotter paper is rolled.
Plotter paper rolls for inkjet printers are sold on 2-inch cores. Plotter paper rolls of xerographic copiers are
typically sold on 3-inch cores.

Caliper: The thickness of a paper is typically expressed in “mils,” which is one-thousandth of an inch. Older-
model inkjet printers that were designed to print on bond papers and clear films can only feed materials with
thicknesses of 9 mil or less. Newer models of wide-format inkjet printers were designed to handle a wide range
of bond papers, photo papers, art papers, canvas and sign materials and can feed materials much thicker than 9
mil. Some models can handle materials up to 12 mil thick; other models can print on substrates up to 31 mil
thick. Check your printer’s user manual or spec sheet to determine the maximum thickness of material that
your printer can handle.

Other Specifications: Some popular models of Xerox engineering copier require that the inside edge of the
paper be taped to the cardboard core. Freedom Paper sells some engineering copier paper rolls on taped
rolls.
If you are buying an optically clear inkjet film for an HP Designjet printer and some other aqueous-ink inkjet
printers that use optical sensors, order a clear film that has visible strips on the edges of the rolls so the sensor
can “see” the film or a film with a paper interleaf. Refer to your printer’s manual to determine if you need a
paper interleaf or side strips for the printer’s sensor to see the material.
Please call the experts at Freedom Paper at 866-310-3335 if you have any questions about plotter paper roll
sizes. If you don’t have easy access to the spec sheet or user manual for your printer, we can tell you if the
paper you plan to order isn’t for your specific printer and suggest compatible alternatives.
Standard sizes for U.S. Architectural Drawings are:
ARCH A: 9 x 12 inches
ARCH B: 12 x 18 inches
ARCH C: 18 x 24 inches
ARCH D: 24 x 36 inches
ARCH E: 36 x 48 inches

Standard sizes for U.S. Engineering Drawings are:

ANSI A: 8.5 x 11 inches
ANSI B: 11 x 17 inches
ANSI C: 17 x 22 inches
ANSI D: 22 x 34 inches
ANSI E: 34 x 44 inches

ISO (International Standards Organization) Drawing Sheet Sizes are:

A0: 33.11 x 46.81 inches (841 x 1189 millimeters)
A1: 23.39 x 33.11 inches (594 x 841 millimeters)
A2: 16.54 x 22.23 inches (420 x 495 millimeters)
A3: 11.69 x 16.54 inches (297 x 420 millimeters)
A4: 8.27 x 11.69 inches (210 x 297 millimeters)

US Letter Sizes
A: 8.5 x 11 inches
B: 11 x 17 inches
C: 17 x 22 inches
D: 22 x 34 inches
E: 34 x 44 inches
F: 28 x 40 inches

Cutting Length of Liner Roll

These Liner bags are used in packaging of hygroscopic materials such as sugar, salt, chemicals & minerals.

Technical Specifications

480 - 620 for Liner insertion

Width of Unwinding Fabric Roll
400 – 850 in BCS mode

Width of Unwinding Liner Roll 500 – 640 mm

Diameter of Fabric Roll 1300 mm

Internal Diameter of Core 70 - 115 mm**

 480 - 620 for Liner insertion
Width of Unwinding Fabric Roll
400 – 850 in BCS mode

Replacement of Fabric Roll Pneumatic System

800 – 1200 for Liner insertion

Cutting Length
500 – 1200 in BCS mode

Cutting Length Accuracy ± 1 mm for Unprinted Fabric

Bottom Folding Width 25 mm (Option - 22 mm)

Stitching Type Double Stitch

7 - 11 mm for Top Stitch

Range
6 - 9 mm for Bottom Stitch

Liner thickness 30 – 60 µ

Liner insertion mode: Upto 18 bags/min*

Production Speed
BCS mode : Upto 45 bags/min*

Liner Insertion

In the PINNACLE Hip Solutions, a variety of polyethylene liner designs are available. Each design has specific

benefits. It is important for the surgeon to understand the geometry of the various liner alternatives and their impact

on joint biomechanics and range of motion. 1

Neutral Liner

The neutral liner provides 180° of head coverage. The wide face chamfer is optimised for range of motion. The range

of motion measured is 119° with a DePuy AMT 12/14 Taper Stem and a 28 mm +5 head. The femoral head’s centre

of rotation is concentric with the outer diameter of the cup.

+4 Neutral Liner

Like the neutral liner, the +4 mm neutral liner provides 180° of head coverage. The wide face chamfer is optimised for

range of motion. The range of motion measured is 121° with a DePuy AMT 12/14 Taper Stem and a 28 mm +5 head.

This liner provides a 4 mm lateralisation of the femoral head’s centre of rotation. This 4 mm offset both increases soft

tissue tensioning and provides 4 mm of increased polyethylene thickness in the cup’s dome region. This lateralised

liner can be used as an alternative to a longer neck and may enable the surgeon to avoid using a skirted head. A +4

mm lateralised liner will result in about 3 mm of leg length and about 3 mm of offset if the cup is inserted at a 45°

abduction angle.
+4 10° Face–Changing Liner

Like the other liners, the +4 10° liner provides 180° of head coverage and the wide chamfer is optimised for range of

motion. The range of motion measured is 115° with a DePuy AMT 12/14 Taper Stem and a 28 mm +5 head. This

liner lateralises the femoral head 4 mm and a 10° face change alters inclination/version dependent upon placement of

the liner.

Lipped Liner

Range of motion is measured at 106° maximum, with a DePuy AMT 12/14 Taper Stem and a 28 mm +5 head. The lip

on this liner can provide additional stability; however, the impact on range of motion and early impingement must be

understood.

Constrained Liners

Constrained liners are available for the PINNACLE cup and are described in brochure 9068-84-052.
Polyethylene Liner Insertion and Impaction

Following insertion of the final acetabular cup and femoral component, the trial liners can be used in the cup to

confirm liner selection and evaluate joint stability and range of motion. Prior to inserting the final acetabular liner,

thoroughly irrigate and clean the cup. It is important to check the cup/liner locking groove to ensure it is clear of any

debris.

Prior to insertion/impaction, mate the liner anti-rotational device (ARD) tabs with the ARD scallops on the cup. There

are six ARD tabs on the liners and 12 ARD scallops for cup diameters 48 mm – 72 mm. Also, there are four ARD tabs

and eight ARD scallops in cup diameters 38 mm – 46 mm. This allows the liner to be rotated in 30° increments for

cups 48 mm – 80 mm and 45° increments for 38 mm – 46 mm.

Seat the liner using the ID impactor that corresponds to the selected implant. Because the locking mechanism is
tapered, it is important to impact the liner directly into the cup with multiple medium blows.
Impacting the liner in a tilted position may prevent complete seating. Seating of the liner is visually confirmed when

the liner ARDs are flush with the face of the acetabular cup; however, the liner face will remain proud in relation to the

cup face by approximately 1 mm for a neutral liner to 4 mm for a laterlised liner

Polyethylene Liner Extraction

A polyethylene liner extractor is available to aid in polyethylene liner extraction and to help ensure the PINNACLE

Acetabular Cup is not damaged during polyethylene liner extraction.

Open the extractor jaws and extend the ARD pin from the extractor tip. Place the ARD pin into an empty ARD and

tightly close the jaws of the extractor. The teeth of the extractor should dig into the inner diameter of the polyethylene.

Once the ARD tip and teeth are secure on the polyethylene, advance the extraction knob clockwise until the
polyethylene is removed
RI offers liner insertion services for its semi-bulk bags, a procedure that consists of:

1. inserting a liner in the bag by the discharge spout;

2. attaching a discharge spout onto the liner;
3. attaching the liner to the bottom of the bag;
4. putting the liner surplus into the bag.

The insertion of a liner is needed when:

1. the product cannot come into contact with the polypropylene (PP) material;
2. the product fine particle size requires tight packaging;
3. the product must be protected against contamination from external matter;
4. the product must be protected against premature transformation like cement.

1. Liner added to the bag

2. Liner attached to the discharge spout
3. Open-bottomed liner for easier discharge

we are one of the leading manufacture, supplier and exporter of linear insertion machine.
The ranges of linear insertion machine are available in varied specification and are widely
known for their high efficiency.The offered machine is various designs that cover all type
customers requirement like sizes, shapes of caps etc. The linear insertion machine is
highly used in various industries purpose. Additionally, this linear insertion machine is
available from us at market leading prices.
Production Speed
In construction, this is the rate at which workers are expected to complete a certain segment,
such as a road or building. The production rate will depend on the speedat which workers are
expected to operate, generally categorized as slow, average or fast.

Trouble with Times…

The speed of your production system is a key aspect of your manufacturing system, and
controlling it is important for the success of your organization. Unfortunately, there are
many different and confusing ways to measure the manufacturing speed. Even a simple
question on how to call a speed is often confused, with many practitioners using the
same term for different measurements, or different terms for the same measurements.
This post aims to give an overview of what is out there, and what it is good for.

Lots of confused Terms

There are tons of different terms used by practitioners about the speed of the line: cycle
time, takt time, process time, target cycle time, effective cycle time, line takt, …and
many more. Unfortunately, often different lean practitioners mean different things using
the same term, or mean the same thing but use different terms. This is not good. The
line speed is one of the important aspects in improving your system. Yet, exactly at
this key point of lean manufacturing, the terminology about line speed is
absolutely not standardized. This has potential for major confusion!

What I describe below is what I think makes most sense, but I also often point out how it
also may be called by others. So please, if you have a different idea on how to call
things, please let me know!

Many Questions to ask

To sort out these different speed measurements there are a few key
questions to help you figure out the differences:
 Does the measure include losses or not? I.e. does the time include delays like breakdowns,
defects, speed losses, and so on or not? The ratio between these two times would be the OEE.
 Do you measure a time per part, or its inverse of parts per time, or only a
time? Depending on the answer you have a unit of time per piece, pieces per time, or only time
without any pieces, e.g. the time it takes to go through the process(es). I.e. the difference
between the time between parts leaving the system or the time they stay in the system.
 Is it the actual time or the target time? I.e. do you measure how fast your system/process
should be or how fast it actually is?
 Do you look at a single process, or do you look at an entire system?
 Do you need the average, a maximum, a minimum, a median, or a percentile value? In
most cases you probably use the average, or more precisely the arithmetic mean, although the
median can also be useful sometimes. However, sometimes there are situations where you are
looking for a maximum value, i.e. if you promise your customer a delivery date, you better use
the maximum lead time, or a lead time that you are 95% sure you can reach (95 percentile).
 Do you measure the average of all parts, or separately for every part type? The number of
parts per hour will be different if you include all part types, or if you focus only on part 08/15.
 Do you mean an absolute or relative time? I.e. is it a time stamp (like June 15th 7:33 AM) or
a duration? For the remainder of the article whenever I discuss times I usually mean a duration.
 For batch processes: Do you measure the average time for a single part or for a batch? If
you bake a batch of 100 pieces in an oven, the time per batch is 100 times the average time per
piece.
 Do you include some additional times on top of the speed? This is common for
setting targets for manual work. The operators sometimes have to go to the bathroom, or need
small mini-breaks. In any case they cannot work continuously at 100% as a machine could.
Hence, the target speed is increased by an additional percentage to cover these times (often
between 5 and 20% depending on local regulations and union negotiations).

As you can easily see, there is a plethora of possible speed measurements out there.
Luckily, not all of the 768+ combinations of the questions above are useful in practice. A
brief overview is given below for the first four questions:
Different Manufacturing Speed Measurement Options

Some are more common than others, but it definitely has a lot of potential for confusion.
Let’s have a look at the most frequently used measurements. For the sake of simplicity I
use discrete parts for my examples below, but you can easily adapt it for continuous
production in process industry, e.g. if you produce liters of beer per hour .

Different Speed Measurements

The Takt Time

Giving the Takt…

The takt time is probably most well known for the customer takt. The customer takt is
the available work time divided by the customer demand during this time.

Please keep in mind that this is of course an average time between customer orders. In
reality, the customer will order much more erratically. You can also calculate the takt for
a single process or an entire manufacturing system. It is important that this always
includes the losses! This is useful if you want to find out if your system is able to satisfy
demand.

You should also distinguish between the target value and the actual value. For example,
if you determine that your system has produced 6000 parts during the last week with 40
working hours, your system or line takt is 24 . If, however, you would have needed
7200 parts, then your target system/line takt is 20 , and your system is too slow. If
you have two machines in parallel producing parts, then your machine takt or process
takt is 48 , but your target machine takt or targetprocess takt is 40 .

Also, please be aware that quite a few practitioners call takt time for
processes cycle times! This has lots of potential for confusion! I strongly prefer to
use cycle time only for times without unplanned losses or delays – see more on cycle
timebelow. In any case, if discussion takt times and cycle times with someone else,
please verify what they are talking about! For more details see my posts How to
determine Takt Times and Pitfalls of Takt Times.

The Throughput

How many per hour?

The throughput is simply the inverse of the takt time, although usually only used for
actual or target production, and only rarely for the customer demand.

It also must include losses. Hence, you can also have a system or line throughput,
a target system/line throughput, a machine or process throughput, or
a targetmachine/process throughput. This naturally must be measured in .

The Cycle Time

Also a cycle, although the measurement RPM is closer

to a throughput
The cycle time is like the takt measured in . The important and often confused
difference, however, is that the cycle time does not include losses! The cycle
time is the fastest repeatable time in which you can produce one part. I.e. it is an
idealized time that you need per part if everything goes perfect, having no breakdowns,
quality defects, or other problems (for more on losses see my articles on OEE).

Hence, you cannot simply divide the production time by the number of parts, but you do
have to measure every part individually, and figure out what your system can do under
ideal circumstances. Here you may choose not to use a mean, but instead use a
median, or even a lower percentile, e.g. speed of the 10th percentile. Please note that
you can add means to get the mean of the lead time, but this does not work with
medians or percentiles.

Cycle times are usually measured for individual processes, where you have both
a cycle time for the current state and a target cycle time for the speed you actually
want. By the way, the difference between the cycle time and the takt time of a process
is the OEE.

It is also possible to calculate a system or line cycle time for an entire system. You
would have to figure out how fast the system would be if there are no losses. If you
have only sequential processes with each process cycle needed only once for the final
product, then the system cycle time would be the slowest/largest process cycle time.
Similarly, you can set a target system/line cycle time. However, due to the
interactions of the losses in the processes that slow down the system in reality in my
view it is difficult to use a system cycle time number in a meaningful sense.

If you have batch processes, you also would have to distinguish if you are measuring
the time per batch or the time per part. Depending on what you use the measurement
for either one may make sense. If you want to figure out how fast your batch process
should be, then of course you set the cycle time for the entire batch. If you want to find
out if your batch is fast enough for the customer, and your customer takt is in individual
pieces, then you would need the cycle time of an individual part, and see if it is fast
enough for the customer takt if you also include OEE losses.

Please be aware that this definition above is far from universally accepted. Some
practitioners define cycle time to include losses. However, based on a discussion on the
LinkedIn Group TPS Principles and Practice, cycle time is more often defined excluding
losses (Many thanks to all who contributed in this discussion).

For more on cycle times check my posts How to Measure Cycle Times – Part
1 and How to Measure Cycle Times – Part 2, as well as Cycle Times for Manual
Processes.

The Lead Time

 Use Little’s Law for the Lead Time

The lead time is the time it takes for a single part to go through the entire process or
system. Therefore, this way of measuring production speed is quite different from
the takt time, cycle time, and throughput above. The takt/cycle times is important if
you want to know if you can produce enough. The lead time is important if you
want to know if you can deliver on time.

If your cycle time is good but your lead time is not, then you will have enough but too
late. On the other hand, if your lead time is good but your cycle time is not, you will build
up unprocessed orders which increase your lead time and hence you will have neither
enough nor on time.

Similar as with the cycle times, we have a process or machine lead time, a system or
line lead time, and of course all of them also as target values: targetprocess/machine
lead time and target system/line lead time.

To measure the lead time of parts directly is in practice quite difficult. However, there is
a very cool fundamental law in production systems that allows you to determine the lead
time based on the throughput and the work in progress (WIP): Little’s Law, with

 L – Inventory, measured, for example, in units or quantity

 λ – Throughput, measured in units or quantity per time
 W – Lead Time, measured in time

This is actually one of my favorite equations in lean manufacturing, since it is

valid everywhere as long as you have a stable system (i.e. no ramp up or other system
changes). Read my Eulogy for Little’s Law for more details.

What about Process Time?

Another term often used is process time. However, here it gets a bit confusing. Some
see process time as the sum of the cycle times in a series of processes, i.e. excluding
losses. Others use it as a synonym to lead time. Yet other describe it as a synonym
to cycle time or sometimes also takt time. Again other definitions I have read in my view
confused more than clarified, calling e.g. the process time a part of the cycle time.
Overall, I tend to stay away from using the term process time since it is too often
confused.

Summary

These above are the most commonly used measures to express the speed of your
system. The way of measuring depends of course on what you want to do with the
measurement. However, there are more pitfalls when actually determining these
numbers, which can make or break your improvement project. Hence, I will go into more
details about measurements in the following posts. Please also be wary about the
confusion on the nomenclature, and lots of people have different names for the
times above! While these are a lot of different numbers, I hope this helps you to avoid
confusion on what is what, even though the terminology in the field is highly
inconsistent! So, do not get confused, but go out and organize your Industry!