relayr Case Studies Improving productivity and quality in Textiles

Improving productivity and quality in Textiles

relayr
Improving productivity and quality in Textiles
Equipment & Machinery
Discrete Manufacturing
Factory Operations Visibility & Intelligence
Ethernet
IO-Link
MQTT
Modbus
PROFIBUS

VISIBILITY - Currently unable to see amount of power consumed per machine or plant; need to account for energy used per batch. WASTE - 10% of product fails quality standards, unable to identify point of failure (initial spinning, weaving, final processing, etc). INACCURACY - Acquiring OEE measurements and compiling them is a manual process, which lacks visibility into all parts of the production process and is error-prone. LACK OF INTEROPERABILITY - Outdated machinery still has long, effective lifespans but needs to connect to newer, digital assets

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OVERVIEW: - Owner-operated company founded in 1997 - Mid-sized manufacturer with 5 plants in Europe - Each plant runs approx 150 production lines, running 800 spindles per production line - Produces high quality textiles across entire value chain (aerospace, hospitality, fashion) - €90 million annual revenue (approx.) OBJECTIVES: - Identify potential fault conditions to reduce unexpected downtime - Reduce waste due to quality issues - Reduce energy consumption, and enable reporting in accordance with legal standards and requirements (EEG-Umlage) - Improve effectiveness of maintenance planning - Identify future opportunities to improve the value chain with suppliers and operations

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Information transparency is key to get to the root cause of profit losses in manufacturing. The Industrial IoT unleashes the data silos in productions lines, and turns data into real insights. relayr’s Smart Manufacturing Solution allows you to collect, manage, and analyze data straight from production line machines, regardless of the level of automation. With relayr Smart Manufacturing you can easily change your current IT production line environment into a predictive model.

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Energy Consumption Rate, Energy Cost Per Unit, Power Consumption, Production Efficiency
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IOT
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Emerging (technology has been on the market for > 2 years)
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Full Visibility into the key metrics that are impacting the production line and need to be communicated per machine in real-time: right rotation of spindles, direction of rotation, and power consumption.

Real-time monitoring of dust and humidity levels, to ensure the environment does not exceed acceptable thresholds that impact yarn quality.

A 5% reduction in total waste.

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