Overview:

Factory automation and digitalization were implemented in a weaving factory specializing in aviation carpets, fine wool broadloom, and quality floor coverings. The facility relied on imported machines, which posed significant maintenance challenges once the annual maintenance contract (AMC) expired. During this period, the need for cost optimization and accessible service became increasingly critical, prompting the factory to seek innovative solutions to enhance operational efficiency and reduce downtime.

Problem:

1. Urgent need of Service accessibility of Imported LOOMs and its accessories

2. Proper weft count analysis for the end products

3. Improvement in operator efficiency

4. Automated technician alert system and Realtime maintenance log

Solution:

To tackle the urgent need for service accessibility at LOOM PLC, we developed a custom PLC system in collaboration with Mitsubishi. This system primarily focuses on monitoring weft activity within the LOOMs, addressing the critical issue of inaccurate weft count analysis in relation to the final products. By integrating data from the PLC and the Takemura weaving application, we established a real-time data transmission to a remote monitoring system. Additionally, an automation software was implemented to track operator break times and efficiency, requiring operators to log their reasons for breaks before resuming work. Furthermore, we created a cost-effective automated technician alert system that notifies the technician centre via SMS or calls when operators report issues. An escalation process ensures that any delays in technical assistance are communicated to higher authorities, while the application also captures the root causes of complaints and spare parts used, providing the factory with a comprehensive maintenance database.

Outcome:

Our solution enabled the client to:

Service accessibility & Cost optimization
Realtime & Remote data
Improves operator efficiency
Loom Maintenance and automated alert system for technicians ensures full transparency in operations.

SCHEDIO SCIENTIFIC PRIVATE LIMITED

Write a review for SCHEDIO SCIENTIFIC PRIVATE LIMITED

Please fill the form below

Budget

Quality

Schedule

Communication