O / LAY-HD

O/LAY-HD – IPC Controlled Automatic Heavy Material Spreading Machine

The spreading stage is where the production plans and material calculations—representing 60% to 70% of total garment cost—begin to take physical form. Although CAD systems optimize marker efficiency, they cannot address losses such as end-of-roll waste, overlaps, spreading and cutting tolerances, or fabric defects. These inefficiencies occur directly on the spreading table and require precise machine control to be managed effectively. Designed exactly for this purpose, O/LAY-HD, Özbilim’s Industrial PC (IPC)–controlled automatic fabric spreading machine for heavy materials, represents the next generation of cutting-room automation for demanding applications. Powered by an Industrial PC running CODESYS-based SoftPLC, O/LAY-HD delivers high-speed processing, adaptive control, and advanced system flexibility while being mechanically engineered to handle heavy fabrics such as denim, rigid woven materials, and high-GSM textiles. Its reinforced structure and high-torque drive system enable precise tension management, accurate edge alignment, and uniform fabric presentation across all plies, even under high material weight and resistance, while opening the door to continuous software evolution, remote maintenance and updates, and deep digital integration.
Unlike conventional PLC-based Özbilim spreading systems, O/LAY-HD features built-in Agent and BASE integration as a standard, not an option. Job orders can be received directly from BASE, eliminating manual data entry and ensuring that spreading operations remain fully synchronized with production planning. Through its IPC platform, O/LAY-HD supports automatic software updates and patching, allowing new features, performance improvements, and security updates to be deployed without machine downtime. Remote maintenance capabilities further reduce service response times by enabling diagnostics, configuration, and support directly through the system—keeping heavy-material production running with minimal interruption.

Agent & BASE – Material Intelligence for the Cutting Room

O/LAY-HD works seamlessly with Agent&BASE, Özbilim’s intelligent material management and reporting ecosystem. Through this integration, each spreading action is monitored, measured, and recorded in real time, allowing manufacturers to understand fabric usage with far greater clarity.

The Agent & Base System consists of a console for each spreading machine and a main software called BASE, which controls them. Agent receives work orders from BASE. It follows the entire series operation and generates detailed performance, time, and material consumption data, and transfers them to BASE software. BASE ensures that all Agents in the cutting room are controlled from a single point. It creates digital work orders, transfers them to spreaders, and enables total cutting room analysis and management with real-time feedback.

• Production Planning and Scheduling

• Integration with company infrastructure
• Load-balanced job distribution
• Predicting and updating uptime with real data
• Real-time production tracking
• Data Collection
• Time Tracking
• Spreading Start and End times, Working and downtime
• Cycle times and Production speed

• Operation Efficiency & Material Tracking

• Fastest defect marking and management with minimal material wastage
• Roll and Lot counters (Total, Consumed, Remaining)
• Wastage Counters (Roll start, roll end, roll splice, fabric errors, marker wastes)
• Reporting
• Line and Operator performances, Customer/Order production reports, Fabric consumption by Supplier/Party, and compare with historical data.
• Quality Control & Purchasing Planning: Traceability on material utilization enables the companies to evaluate their planning & purchasing decisions and suppliers in the long-run.

These reports allow production managers to identify anomalies, balance capacity, and improve decision-making across the cutting room.
Agent & BASE ultimately transforms spreading from a manual operation into a data-driven process, where decisions are informed by precise metrics rather than visual estimation.

C-CUT   – Patented Augmented Reality (AR) Assisted Interactive Cutting Simulataion & Defect Management

O/LAY-HD is compatible with C-CUT, Özbilim’s patented augmented-reality-based cutting simulation and defect-handling system by default. C-CUT uses digital overlays and synchronized tracking to show operators exactly how patterns will be placed on upcoming plies, enabling powerful real-time decision-making while spreading.

Why C-CUT Matters

In traditional spreading workflows, operators must stop and manage the splicing and overlaps within the marker manually whenever a defect appears. At this point, the defect’s position inside the marker is not numerically known, meaning it is also uncertain if the defect intersects with a pattern area to be cut and sewn later or the selvedge area. So, every time a defect is noticed by the operator, the process has to pause. This creates unnecessary downtime and production delays.

With C-CUT :

• If a defect falls inside a pattern, the operator instantly notices and uses the proper overlap adjustment using Agent’s splicing capabilities. A couple of touches on the screen is all it takes.
• If a defect falls into the waste/selvedge area, the operators immediately notice the marker is unaffected — allowing the spreading process to continue without interruption.

This automation eliminates guesswork, prevents production stops, thus dramatically increasing process efficiency, and ensures that no defective piece moves forward unnoticed.

To support full quality traceability, any defect observed on the fabric can be marked using an interactive wand that communicates wirelessly with the C-CUT  system. Once marked, the defect’s precise location and the corresponding affected pattern pieces are instantly identified and registered. This information is automatically transferred to labeling units, ensuring that each cut component receives the correct label with its layer number, defect type, and defect location. This seamless workflow ensures that no defective piece moves unnoticed into production, while enabling controlled re-cuts and providing full transparency from roll to final bundle.

By combining the computational power of an Industrial PC, the flexibility of CODESYS softPLC, the built-in intelligence of Agent and BASE, and the precision of optional C-Cut augmented reality guidance, O/LAY-HD transforms heavy-material spreading into a fully connected, data-driven production stage. The system generates detailed reports covering ply data, lay statistics, break times, wastage, and efficiency metrics, all of which can be stored, analyzed, and shared across the organization. With the ability to integrate directly into customer ERP systems, O/LAY-HD becomes a central node in the digital cutting room—ensuring complete visibility, traceability, and control even in denim and heavy-fabric operations. It is the ideal solution for manufacturers seeking premium automation, scalable software-driven performance, and long-term operational excellence in high-load, modern cutting-room environments.

Check in with your nearest Özbilim reseller or request more information on specifications at info@ozbilim.com