01
One measurement
Simple or stable materials, low variation across the width.
RollL-C-RTraffic lightTolerance profilesBatch
Module · Production QCDMIx BulkControl - Color quality in mass production.
Controls color quality at roll and batch level. With left-center-right measurement, automated evaluation and instant traffic-light feedback, BulkControl catches deviations early and reduces claims, rework and follow-up cost.
Faire défiler
Avantages
Ce que BulkControl rend possible.
01Quality control at roll level
Every fabric roll is checked systematically, not only by spot sampling. Results are recorded per roll and stay linked to batch, supplier and production line.02Left-center-right measurement across the material width
Three defined measurement points across the material width (left, center, right) reveal shading and cross-roll deviations that a single mid-roll measurement would never catch.03Automated evaluation of measurement values
Measurement values are evaluated automatically against the standard and tolerance. Nobody has to interpret dE tables, the system delivers a clear result per point and per roll.04Instant feedback on the traffic-light principle
The traffic-light principle (green, amber, red) delivers a decision in seconds: approve, review or stop. Even without a color management background, the next step is unambiguous.05Early detection of color deviations, shading and uneven dyeing
Color deviations, shading within a roll and uneven dyeing between rolls are detected before the material moves to the next production step.06Systematic control across every batch
Every batch runs through the same process, with the same tolerances and the same documentation. Quality no longer depends on who happens to be on shift.07Fewer claims, less rework and fewer production delays
Defective goods are stopped before they are processed further or shipped. Claims, rework, sorting and shipping costs drop noticeably.08Objective decision basis directly in production
Decisions are based on measurement data, not on gut feeling. Conversations with suppliers and internal teams become shorter and more factual, because the facts are available right away.
Today, reality in the supply chain
Color problems are classically discovered far too late.
Goods are dyed at the Tier 2 partner and shipped to Tier 1. Only there does it become clear that color, shading or quality do not match. By then transports have run, delivery windows are at risk and escalations between brand, T1 and T2 begin.
Typical today
- ·Dyeing at Tier 2
- ·Transport to Tier 1, days later
- ·Spot check or visual inspection on arrival
- ·Deviations only become visible there
- ·Email and phone alignment after the fact
Consequence
- ·Transport cost already spent
- ·Garment planning under pressure
- ·Delivery windows at risk, retail intros slip
- ·Expensive air freight or re-dyeing
- ·Claims, rework, re-production
The Standard is the Standard is the Standard.
What BulkControl does
Measure color quality where the goods actually come into being.
BulkControl checks color quality during or directly after bulk production. The measurement logic adapts flexibly to material, risk and quality requirement. Evaluation runs automatically using a traffic-light system.
- 01Deviation from the original standard
- 02Shading within a roll
- 03Deviation across the material width
- 04Process variation within a lot
- 05Differences between lots
- 06Risks before further processing
Measurement logic along the roll
Across the width, at freely chosen intervals.
Measurement points are placed across the material width, classically left, center, right, so that shading and cross-roll deviations become visible. Along the roll, measurements can be taken at any interval, tuned to material, process stability and risk.
WidthLeft · Center · RightFreely chosen intervalsMaterial dependentRisk dependent
Live measurement (top view)
Roll 01 · Batch A
All three across-width points within tolerance.
Approved
L · Left
dE0.42
Approved
C · Center
dE0.51
Approved
R · Right
dE0.48
Approved
Number of measurement points
As detailed as needed, never too coarse, never overdone.
The number of measurement points per pass is not fixed. Depending on material and requirement, measurement can be exactly as detailed as color, production risk and quality requirement demand.
02
Three measurements
Classic left, center, right control for most bulk cases.
03
Ten or more
Complex, sensitive or particularly high-risk materials.
04
Adjustable per lot
Measurement logic adapts to the actual production, not the other way round.
Automatic evaluation
A traffic light, not a subjective debate.
BulkControl evaluates measurements automatically using colorimetry and returns instant feedback. Complex evaluation turns into a fast, clear decision basis.
Green
Within tolerance
No critical shading effects or relevant deviations. Goods can be shipped or further processed on the defined basis.
Yellow
Early warning
Process variation is visible. Goods may still be usable, but trends and changes should be watched.
Red
Decision needed
Relevant deviation. The buyer decides: commercial approval, rework or a new lot, based on objective data.
Multiple tolerance profiles
The thresholds are not a fixed value. A dedicated tolerance profile can be stored per brand, material or article. The traffic light always evaluates against the profile that applies to the order.
Real time at the production site
The brand sees production while it is happening.
Instead of reacting only at Tier 1, BulkControl answers the key questions right at Tier 2, in real time.
- 01Do the goods match the approved standard?
- 02Is there shading within a roll?
- 03Is there variation within a lot?
- 04Are there differences between lots?
- 05Can the goods be shipped?
- 06Is a decision needed?
Transparency and traceability
A solid data basis for any later clarification.
BulkControl documents measurements, evaluations and decisions end to end. When claims, questions or quality discussions arise, what happened is fully traceable.
- 01Lot and roll
- 02Measurement points set
- 03Measured values
- 04Traffic light evaluation
- 05Decision taken
- 06People involved
Reports and supplier performance
From single case to strategic view.
01
Supplier performance
How individual suppliers perform across lots and seasons, with hard numbers instead of anecdotes.
02
Issue isolation
Flagged lots are mapped to specific MPOs, materials or colors, named and tracked precisely.
03
Process stability
Where do recurring deviations appear, which materials are particularly critical, where is targeted intervention worth it?
Avoid claims
Issues are caught where they originate.
Without BulkControl
- Unnecessary transport and air freight
- Late issue detection at Tier 1
- Garment planning disrupted
- Missed delivery windows and retail intros
- Rework, re-dyeing, escalations
- Claims between brand, T1 and T2
With BulkControl
- Detection at the production site, at Tier 2
- Instant colorimetric evaluation
- Clear decision basis from the traffic light
- Goods do not keep moving uncontrolled
- Lower downstream cost in the supply chain
- Objective basis for every discussion
Who benefits
Value for every role in the bulk supply chain.
Brands
- +Early detection of deviations
- +Real-time transparency over lots and rolls
- +Clear traffic-light decision support
- +Robust supplier performance reports
Suppliers, dyehouses, Tier 2
- +Clear standards out of MatchBox
- +Defined tolerances, instant feedback
- +Fewer subjective discussions
- +Better documentation of own quality
Tier 1 and garment makers
- +Problem goods do not arrive here first
- +Fewer unplanned inspection efforts
- +Fewer production interruptions
- +More predictable garment making and delivery
Quality and management
- +Structured measurement data, not spot checks
- +Automatic evaluation and lot tracking
- +MPO mapping and issue isolation
- +Robust basis for escalation and decisions
Across every material
Bulk quality control for knit, woven, denim, print and more, in one system.
Business impact
Measurable value in bulk production.
01
Fewer claims
- ·Early detection
- ·Objective documentation
- ·Fewer brand / T1 / T2 conflicts
02
Lower cost
- ·Less air freight
- ·Less rework and re-production
- ·Fewer production interruptions
03
Faster decisions
- ·Instant traffic-light evaluation
- ·Clear escalation paths
- ·Decisions on data
04
More transparency
- ·Measurements and decisions documented
- ·Lot and roll level traceable
- ·Supplier performance visible
Connections
BulkControl never stands alone.
DMIx BulkControl is a digital quality control system for bulk production. It evaluates color deviations and shading effects at roll and lot level automatically, makes them visible in real time, and reduces claims, rework and supply chain risk.
En contexte
Cas d'utilisation associés
RollL-C-RTraffic lightTolerance profilesBatch
Prêt ?
Découvrir BulkControl en direct dans votre propre flux de travail.
Nous vous montrons DMIx sur vos données, sans présentation générique.