Telares (Weaving)

Overview

Telares (Process ID: 2) is the weaving process that converts polypropylene tape from extruders into circular woven fabric using high-speed circular looms. This process is critical in the production chain as it transforms raw tape material into the structural foundation for industrial bags.

Process Characteristics

Process Type: Order-based production
Production Unit: meters
Product: Circular polypropylene woven fabric
Machines: 13 looms (T01 through T13)
Order Pattern: 2\d{6} (e.g., 2000123)
Production Target: 1,000 meters per loom per shift

What This Process Does

The Telares process:

Receives: Polypropylene tape bobbins (warp and weft) from Extrusor PP (Process 1)
Transforms: Tape bobbins → Circular woven fabric rolls
Delivers: Identified fabric rolls ready for lamination (Process 3)
Method: High-speed circular weaving on dedicated looms

Production Flow

Upstream Dependencies

Telares consumes lots (lotes) from Extrusor PP:

Each loom must declare which extruder lots it’s consuming per shift
Multiple lots can be consumed simultaneously (e.g., two colors, or lot changeover mid-shift)
Lot consumption is tracked via telar_consumo_lote table

Downstream Consumers

Telares output feeds into:

Laminado (Process 3): Main downstream process for coating fabric

Production Tracking Method

Accumulated Counter Method (telares.service.js:159-166):

reglasProduccion: {
  metodo: 'diferencia_acumulado_contador',
  descripcion: 'Each loom has a meter counter that resets January 1st...',
  unidad: 'meters',
  resetAnual: true,
  registroPorCambioDeOrden: true
}

Production is calculated as the difference between:

Current accumulated counter reading
Previous shift’s accumulated counter
Counter resets annually on January 1st (or nearest restart date)

Data Structures

Key Tables

registros_trabajo

Tracks production output per shift per loom:

{
  linea_ejecucion_id: FK,
  bitacora_id: FK,
  maquina_id: FK (loom T01-T13),
  cantidad_producida: meters (calculated from counter diff),
  merma_kg: waste in kg,
  observaciones: text,
  parametros: JSON {
    acumulado_contador: integer
  }
}

calidad_muestras

Quality samples for critical parameters:

ancho_tela (fabric width): 4 samples per shift, tolerance ±0.25 inches
construccion_urdido (warp construction): threads per inch
construccion_trama (weft construction): threads per inch
color_urdido / color_trama: Pass/Fail verification

calidad_telares_visual

Visual defects tracked per roll:

DEF-01: Incorrect tapes (wrong denier, width, or color)
DEF-02: Torn fabric (breaks during weaving)
DEF-03: Poorly wound roll (deformations, irregular edges)

telar_consumo_lote

Lot consumption traceability:

{
  registro_trabajo_id: FK,
  maquina_id: FK (loom),
  bitacora_id: FK,
  lote_id: FK (from Extrusor PP)
}

Process Contract (`TelarContract.js:1-236`)

processId: 2
nombre: 'Telares'
unidadProduccion: 'metros'
patronCodigoOrden: '2\\d{6}'
maquinasPermitidas: ['T01', 'T02', ..., 'T13']

Quality Parameters

Critical Parameters

1. Fabric Width (ancho_tela)

Unit: inches
Tolerance: ±0.25 inches (fixed)
Sampling: 4 measurements per shift (hours 2, 4, 6, 8)
Nominal: From active production order
Input Format: Fractions of 1/8 (e.g., “12 1/8”, “12 1/2”)

2. Warp Construction (construccion_urdido)

Unit: threads per inch
Sampling: Once per shift or when order changes
Validation: Must match order specification exactly

3. Weft Construction (construccion_trama)

Unit: threads per inch
Sampling: Once per shift or when order changes
Validation: Must match order specification exactly

4. Color Verification

Parameters: color_urdido, color_trama
Type: Pass/Fail
Frequency: Per order change + once per shift
Critical: If color fails, mandatory stop until corrected

Sampling Frequency (`TelarContract.js:118-137`)

frecuenciaMuestreo: {
  ancho: {
    muestrasMinTurno: 4,
    distribucion: [
      { indice: 1, momento: 'hora_2_del_turno' },
      { indice: 2, momento: 'hora_4_del_turno' },
      { indice: 3, momento: 'hora_6_del_turno' },
      { indice: 4, momento: 'hora_8_del_turno' }
    ],
    omisionRequiereMotivo: true
  },
  construccion: {
    muestrasMinTurno: 1,
    momento: 'inicio_turno'
  }
}

Business Logic

Personnel Assignment Rules (`telares.service.js:146-156`)

Strict validation enforced:

reglasAsignacionPersonal: {
  pareja: { maxMaquinas: 5 },      // Operator + assistant: up to 5 looms
  personaSola: { maxMaquinas: 3 }   // Single person: up to 3 looms
}

The system blocks save if personnel limits are exceeded.

Annual Counter Reset (`telares.service.js:161-171`)

Validation logic for legitimate counter resets:

function esResetAnual(acumuladoNuevo, acumuladoAnterior, bitacoraFecha) {
  if (acumuladoNuevo >= acumuladoAnterior) return false;
  const esNuevoAño = añoActual > añoBitacora;
  const esValorPequeño = acumuladoNuevo < (acumuladoAnterior * 0.1);
  return esNuevoAño && esValorPequeño;
}

New counter value must be < 10% of previous to be valid reset.

Lot Consumption Validation (`telares.service.js:205-224`)

if (produccionTotal > 0 && lotes_consumidos.length === 0) {
  throw new ValidationError(
    'Debe declarar al menos un lote consumido cuando hay producción registrada.'
  );
}

for (const lc of lotes_consumidos) {
  const lote = await this.loteService.getById(lc.lote_id);
  if (lote.estado === 'cerrado') {
    throw new ValidationError(
      `El lote ${lote.codigo_lote} está cerrado y no puede declararse como consumido.`
    );
  }
}

Color Non-Compliance (`telares.service.js:226-229`)

const colorNoCumple = calidad.color.some(c => c.resultado === 'No cumple');
if (colorNoCumple && paros.length === 0) {
  throw new ValidationError('Un color fuera de especificación obliga a registrar un paro.');
}

If color verification fails, a downtime record is mandatory.

API Endpoints

GET `/api/telares/resumen`

Returns summary of all looms for a shift:

[
  {
    id: 1,
    codigo: 'T01',
    ordenActiva: '2000123',
    produccionTotal: 1050,
    estado: 'Completo',
    tieneAlertas: false
  },
  // ... T02 through T13
]

Implementation: telares.service.js:25-53

GET `/api/telares/detalle/:maquinaId`

Detailed data for a specific loom:

{
  maquina: { id: 1, codigo: 'T01' },
  estado: 'Completo',
  ultimoAcumulado: 125400,
  lotes_consumidos: [
    { lote_id: 15, codigo_lote: '1000056-003', proceso: 'Extrusor PP' }
  ],
  produccion: [
    {
      id: 42,
      orden_id: 123,
      codigo_orden: '2000123',
      acumulado_contador: 126450,
      cantidad_producida: 1050,
      desperdicio_kg: 5.2
    }
  ],
  calidad: {
    ancho: [ /* 4 width measurements */ ],
    construccion: [ /* warp & weft counts */ ],
    color: [ /* color verifications */ ]
  },
  visual: [ /* defect records */ ],
  paros: [ /* downtime events */ ],
  especificaciones_orden: {
    ancho_nominal: 22.5,
    construccion_urdido: 12,
    construccion_trama: 11,
    color_urdido: 'Blanco',
    color_trama: 'Blanco'
  }
}

Implementation: telares.service.js:55-142

POST `/api/telares/guardar`

Saves shift production data: Request Body:

{
  bitacora_id: 42,
  maquina_id: 1,
  produccion: [
    {
      orden_id: 123,
      acumulado_contador: 126450,
      desperdicio_kg: 5.2,
      observaciones: ''
    }
  ],
  calidad: {
    ancho: [
      { indice: 1, valor: 22.5, resultado: 'Cumple', valor_nominal: 22.5 },
      { indice: 2, valor: 22.625, resultado: 'Cumple', valor_nominal: 22.5 },
      { indice: 3, valor: 22.5, resultado: 'Cumple', valor_nominal: 22.5 },
      { indice: 4, valor: 22.375, resultado: 'Cumple', valor_nominal: 22.5 }
    ],
    construccion: [
      { parametro: 'construccion_urdido', valor: 12, resultado: 'Cumple', valor_nominal: 12 },
      { parametro: 'construccion_trama', valor: 11, resultado: 'Cumple', valor_nominal: 11 }
    ],
    color: [
      { parametro: 'color_urdido', valor: 'Blanco', resultado: 'Cumple', valor_nominal: 'Blanco' },
      { parametro: 'color_trama', valor: 'Blanco', resultado: 'Cumple', valor_nominal: 'Blanco' }
    ]
  },
  visual: [
    {
      orden_id: 123,
      rollo_numero: '47-T-05',
      tipo_defecto_id: 'DEF-02',
      observacion: 'Rotura de cinta en zona central del rollo'
    }
  ],
  paros: [],
  observacion_advertencia: '',
  lotes_consumidos: [
    { lote_id: 15 }
  ]
}

Response:

{
  produccionTotal: 1050,
  registroIds: [156]
}

Implementation: telares.service.js:144-406
Permission Required: MANAGE_QUALITY

Machine Status States

Calculated in: telares.service.js:365-384

Sin datos: No production or quality data recorded
Parcial: Some data recorded but incomplete
Completo: All required data present:
- Production OR downtime recorded
- 4 width measurements OR justification for omission
- 2 construction measurements
- 2+ color verifications
Con desviación: Complete data but quality parameters failed

Traceability

Roll Identification Format

{roll_number}-{loom_code} Example: 47-T-05 = Roll #47 from Loom T05

Lot Consumption Chain

Telares → Extrusor PP lots:

Extrusor PP produces lot: 1000056-003
          ↓
Telares consumes lot via telar_consumo_lote
          ↓
Produces fabric roll: 47-T-05
          ↓
Laminado consumes roll 47-T-05

Operational Rules

Production Scenarios

Normal operation: Register counter value at shift end
Order change mid-shift: Register counter at changeover, then again at shift end
Zero production (full downtime): Still register current counter (equals previous) + mandatory downtime justification
Annual reset: Counter resets to near-zero on January 1st or next startup

Stop Restrictions (`TelarContract.js:20-26`)

restriccionesInicio: [
  'Telar sin orden activa asignada',
  'Rotura de cinta en urdimbre o trama',
  'Falla mecánica del telar',
  'Falta de materia prima (conos de cinta PP)',
  'Cambio de orden en proceso'
]

Downtime Categories (`TelarContract.js:49-54`)

Operational: Order change, warp tying, roll change, cleaning
Mechanical: Broken shuttle, motor failure, sensor failure, cam misalignment
Quality: Width out of range, weaving defects, incorrect color
External: Material shortage, electrical failure, absenteeism

Impact of Variability (`TelarContract.js:60-63`)

impactoVariabilidad: [
  {
    condicion: 'Variación de denier',
    impacto: 'Afecta el gramaje de la tela y puede causar roturas frecuentes.'
  },
  {
    condicion: 'Alta temperatura ambiente',
    impacto: 'Afecta la elongación de la cinta y la estabilidad del tejido.'
  }
]

Upstream: Extrusor PP (Process 1)
Downstream: Laminado (Process 3)
Related: Production Orders, Lot Management

Get Started

Core Features

User Guides

Production Processes

Administration

​Overview

​Process Characteristics

​What This Process Does

​Production Flow

​Upstream Dependencies

​Downstream Consumers

​Production Tracking Method

​Data Structures

​Key Tables

​registros_trabajo

​calidad_muestras

​calidad_telares_visual

​telar_consumo_lote

​Process Contract (TelarContract.js:1-236)

​Quality Parameters

​Critical Parameters

​1. Fabric Width (ancho_tela)

​2. Warp Construction (construccion_urdido)

​3. Weft Construction (construccion_trama)

​4. Color Verification

​Sampling Frequency (TelarContract.js:118-137)

​Business Logic

​Personnel Assignment Rules (telares.service.js:146-156)

​Annual Counter Reset (telares.service.js:161-171)

​Lot Consumption Validation (telares.service.js:205-224)

​Color Non-Compliance (telares.service.js:226-229)

​API Endpoints

​GET /api/telares/resumen

​GET /api/telares/detalle/:maquinaId

​POST /api/telares/guardar

​Machine Status States

​Traceability

​Roll Identification Format

​Lot Consumption Chain

​Operational Rules

​Production Scenarios

​Stop Restrictions (TelarContract.js:20-26)

​Downtime Categories (TelarContract.js:49-54)

​Impact of Variability (TelarContract.js:60-63)

​Related Processes

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