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AUTOMATION EMPOWERING PERFORMANCE & PROFITABILITY Matching with Textile 4.0 using old machines

AUTOMATION EMPOWERING PERFORMANCE & PROFITABILITY Matching with Textile 4.0 using old machines. A.T.E. Enterprises Private Limited. V2.1 Mar 2018. OLD MACHINE. DC Motors Slip ring motors. Maintenance Cost Break Down. Old PLCs Embedded cards Controllers. Spares availability

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AUTOMATION EMPOWERING PERFORMANCE & PROFITABILITY Matching with Textile 4.0 using old machines

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  1. AUTOMATION EMPOWERING PERFORMANCE & PROFITABILITY Matching with Textile 4.0 using old machines A.T.E. Enterprises Private Limited V2.1 Mar 2018

  2. OLD MACHINE DC Motors Slip ring motors Maintenance Cost Break Down Old PLCsEmbedded cards Controllers Spares availability Dependence on OEMs Contactor Logic Relay logic More breakdown More down time Less production time No Online Monitoring No Utility Monitoring NO Alarm Diagnostics Old HMIs Mimic Analog meters

  3. OLD MACHINE Lot of break downs Break down attending time is more Energy inefficient (consumes more energy compared with latest machines) Spare parts not easily available. Most of the spare parts are obsolete OEM support not available/ Expensive In short with these old machines race cannot be won ………….

  4. NEW MACHINE READY FOR NEW AGE Industry 4.0 AC Motors Servo motors Maintenance Cost Break Down Advance PLCs Speed Efficiency Profitability Drives Power Saving Spares Advance features Alert MessagesOnline Monitoring ( IOT and robotics) Graphical HMIs PC

  5. ANALYSIS • It is very clear that continuing the production with old technology machines will force company to remain behind in race which is not affordable. • At the same time purchasing new machines is very costly affair and everybody cannot afford. • Then what is the solution to remain in the race …? • Matching with Industry 4.0 standards with old machines • Automation is the key by which our old machines can be made to work like new machines and help the producer to remain in the race with little investments compare to the costs of new machines.

  6. AUTOMATION AND UPGRADES NEED OF TIME

  7. WHY AUTOMATE / UPGRADE For increase in energy efficiency.e.g. replacement of old DC motors, inefficient motors, installation of AC drives. For increase in production efficiency. e.g. increase in machine speed, reduction in manpower 3. For improvement in product quality.e.g. monitoring and control of quality parameters during Production. 4. For reduction in number of breakdowns and time to attend breakdowne.g. by way of visual monitoring like SCADA/HMIs etc. & interactive software

  8. WHY AUTOMATE / UPGRADE ? For online monitoring of complete production process.e.g. Alarms, logs, trends availability for analysis of quality and production. For spares management and increase machine life e.g. getting rid of old obsolete spares and making machine ready for next 10-15 years For remote monitoringe.g. IOT based apps and systems to get better from machine For safety of man machine and product.e.g. addition of different safety interlocks. Customer can customize some machine functions as per their process/production need ACTIVE LIFE CYCLE

  9. WHY AUTOMATE / UPGRADE ? • In short automation helps: • Making old machine compatible with new generation machines at much lower costs. • Increase machine life for 10-15 years. • Increase in production, quality and energy efficiency. • Interactive visual software like SCADA. • Visual process control by PC/HMIs. • Replacement of old technology parts by latest ones. • Readily available service support • Machine is ready for new age Industry 4.0 ,,,,,,,,,,,,,,,,,,,,,,,

  10. Automation Process & Selection of automation agency Additional Customer need Study Customer Discussion Identify obsolete parts Tuning Final execution Shutdown Planning Preparing BOM

  11. Automations / upgrades • Textile Weaving (Preparatory): • Direct and Sectional Warping Machines • Customers: • M/s PT Indahjaya(Benninger) • M/s Saranya Mills Ltd (SMH) • M/s Raymond UCO ( SMH)

  12. Automations / upgrades • Textile Weaving (Preparatory): • Sizing machines • Customers: • M/s Raymond UCO, M/s Raymond LtdM/s Soktas, M/s Premier mills,M/s Nahar Industries, M/s Suryalakshmi,M/s Bhaskar, M/s PT Indahjaya,Govt of Sudan Textile Mills • Machine makes: • Benninger, Sucker Muller , Morrison, Rotal

  13. Automations / upgrades • Textile Processing • Dyeing, Finishing, Bleaching, Washing, Mercerizing and other process machines (all makes) • Customers: • M/s Bhaskar, M/s Raymond Ltd,M/s Siyarams, M/s JCT,M/s Arvind Mills, M/s Astha creations,M/s Knitcraft,M/s Swan industries • M/s IPMC • Machine makes: • Benninger, Kuster, Goller • Morrison etc.

  14. Automations / upgrades • Synthetics • Winders, Fiber plants, Pressing machines, Extruders, BCF Lines Dryer and chip conveyors etc. (all makes) • Customers: • M/s Reliance, M/s Welspun,M/s AYM, M/s Indorama,M/s Shubhalakshmi, M/s Recron Malaysia • M/s PT Indorama, M/s PT Mutu Gading,M/s PT Universal Carpets,M/s Eleme Petrochemicals • Machine makes: • TMT,Barmag,Teijin,Toyodenki,Autefa,Swisstex etc.

  15. Automations / upgrades • Steel Plants: • 2HI/4HI Rolling mills, Sintering lines, Strip processing machines etc. • Customers: • M/s KSPG Automotive, Pune • M/s Bimetal Bearings,Chennai • M/s KSG Automotive Mexico

  16. Case Study 1 • Customer :- M/s PT Asia Pacific Project :- Barmag Extruders 32 Nos Advntages :- Got rid of Obsolete & Costly spares - Dependency on OEM is killed - New Technology Incorporation - Making system ready for new IOT technology • - All Data available on 1 PC OLD MONITORING SYSTEM NEW MONITORING SYSTEM

  17. Case Study 2 • Customer :- M/s JCTProject :- Continuous Dyeing Range)Advantages :- Obsolete & Costly spares - Dependency on OEM - New Technology incorporation - Making system ready for new IOT technology • - Increased machine speed • - improved product quality

  18. Case Study 3 • Customer :- M/s PT Indorama SyntheticProject :- Fiber Line • Reasons :- Old Control system • - Old Drives • Advantages :- 25% reduction in energy cost • - Latest technology - Brake down reduction - Low wastage - Alarm & Trends for better monitoring & diagnose - System ready for IOT technology, Industry 4.0

  19. Case Study 4 • Customer :- Different Textile PlantsProject :- Benninger & SMH sizing • Reasons :- Old machine are equipped with obsolete & embedded cards or PLCs & drives - Dependency on OEM - Spares are very costly • Advantages :- Latest technology- Brake down reduction- Readily available support - Spares are availability in local market- Alarm & Trends for better monitoring & diagnose- System ready for new IOT technology

  20. Case Study 5 • Customer :- Polyester PlantsProject :- Polyester winders • Reasons :- Old machine are equipped with • obsolete & embedded cards - Dependency on OEM - Spares are very costly • Advantages:- Break down reduction- Low wastage- Alarm & Trends for better monitoring & diagnose- System ready for new IOT technology

  21. THANK YOU

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