Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 1

Statistical Process Control for Global Textile Markets

John McCombs12 October, 2006

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Quote from Hindustan Times 9 October, 2006

• Indian entrepreneurs have learnt to think big• Money not a problem, • Quality and management are

–The message is clear: Quality is non-negotiable. There is no dearth of capital. However, the core issue is: Does the management have the required mental bandwidth to face the challenges thrown up by globalization. By Uday Kotak

Repeatable Quality through Statistical Process Control is a Goal of Automation in the Textile/Fibers Industry

Repeatable Quality through Statistical Process Control is a GoalRepeatable Quality through Statistical Process Control is a Goal of of Automation in the Textile/Fibers IndustryAutomation in the Textile/Fibers Industry

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Textiles and Fibers Process

Copyright 1997 R ockwell International C orporation. A ll rights reser ved. Printed in USA

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Statistical Process Control for Textiles

• The Electrical Control Industry has grown with the Textile Industry into automation systems including Statistical Process Control

• Manual systems have become automated• Technical improvements have improved quality/repeatability

– Many of the steps in Textile production is to assure repeatable quality• Opening Blending, 1st sliver, 2nd Sliver, drafting –all aimed at repeatable quality• Dyeing variations are a certainty without repeatable quality

• Dyeing and Finishing have become an automated necessity for World Class Quality. Dye matching is a requirement even when runs are two months apart.

• Computer Scheduling Can add a layer of improved quality to normal automated systems.

Repeatable Quality through Statistical Process Control is a Goal of Automation in the Textile/Fibers Industry

Repeatable Quality through Statistical Process Control is a GoalRepeatable Quality through Statistical Process Control is a Goal of of Automation in the Textile/Fibers IndustryAutomation in the Textile/Fibers Industry

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Example 1 from Synthetic Fiber History

The controls grew as the process improvedThe controls grew as the process improvedThe controls grew as the process improved

Synthetic Spinning History

Automation the ProcessPartner

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Synthetic Fiber Progress Diagram

Analog regulators replaced in1970s by digital regulators, which

greatly increased repeatability

Analog regulators replaced in1970s by digital regulators, which

greatly increased repeatability

Inverters, synchronous motors one step process

Electrical Line Shaft

Inverters, synchronous motors one step process

Electrical Line ShaftMechanical Line Shaft

Two Step Process

Mechanical Line ShaftTwo Step Process

Phase 1Phase 1 Phase 2Phase 2

Phase 3Phase 3 Phase 4Phase 4

Single Motor Drives

controlled by hierarchal computers and plcs

Single Motor Drives

controlled by hierarchal computers and plcs

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• In the beginning a two step process • Machines were mainly mechanical

Draw

Winding

Unwind

The controls grew as the process improvedThe controls grew as the process improvedThe controls grew as the process improved

Form the fiber

Drawing the fiber Different draw ratios

required different gear sets

Quench

Wind

Phase 1Phase 1

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Inverters invented for this process 60’s

Meter

Pump

Drive

Hot

Chest

Drive

Godet

Drive

Winder

Drive

By changing the relative speed of the draw rolls different products could be made without time consuming gear

changes yielding a single step process

Inverters Synchronous Motors

Phase 2Phase 2

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Major Fiber Producing Chemical CompanySingle step process still meant same product on an entire machine – More Flexibility Required

– Motivated by JIT - Automotive Carpet CustomerDecided to replace bulk inverters with small single

motor inverters - Good Price, Good Performance- NO TOTAL AUTOMATION PLAN

Case Study Number 1

10Atlanta PVG 67

Typical BCFSingle Position Architecture

3 PHASE, 50HZ230V

*

AC FEED

ALLEN-

230V

PORTHIM

1336G

8A230V

PORTHIM

1336G

8A230V

PORTHIM

1336G

8A230V

PORTHIM

1336G

8A230V

PORTHIM

1336G

17A230V

PORTHIM

1336G

17A230V

PORTHIM

1336G

17A

2.9A 2.9A

METERPUMP B

FINISH

0.6A

FEEDWHEEL

5.2A 4.7A

TRAVERSE

4.5A 8.75A 8.75A

1336G

8A230V

HIMPORT

1DM 2DM 3DM 4DM 5DM 6DM 7DM 8DM

310VDC

DYNAMICBRAKE

310VDC

METERPUMP A

Bulking DRIVE ROLL A

DRIVEROLL B

BlackBox

RS 232Multidrop

RS 232

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Case Study 1

• 2 years later building an ASCII interface to a DCS is not complete (at least 1.5 man years wasted)

• In an attempt to connect the drives to the main control system a“black box device” to interface to the RS 232 port on each drive has 10 second update time to read all speeds and currents of 8 drives. 40 positions x 10 Seconds = Failed Network

1st operator interface for drives1st operator interface for drives

2nd DCS operator interface for the rest of the

machine = Errors

2nd DCS operator interface for the rest of the

machine = Errors

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METERING PUMP100 RPM

CHIMNEY AIR TEMP150 C

DRAW ROLLS

3500 MPMHOT

CHEST190 C

WINDERS3500 MPM

Godets

SINGLE SPINNINGPOSITION

Position 1 of 4

Extruder

Plant EtherNet

DeviceNet

MotionTurret

Position

1 of 4 Winder Panels

GodetHeaterControl

GodetHeaterControl

MMIM

Controller

Controller

PROFIBUS

2 Spiders

WinderBale Roll

Pulse p/u

9 Spiders

ControlNet

160’s AC fed

Winder drives are ac fed

6 Spiders are shared bus with fuses in the ac feed and dc link.

Zone heater Controlfor 3 extruders

BCF Machine

Four Position 3 Color BCF Machine ArchOne Common Data Base

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Example No. 2 Fabric Processing

• Processing Fabric– Better fabric through chemistry is achieved , delivering the quality customer’s desire.– The stages include washing, bleaching, shrinking, dyeing and adding stay pressed

finishes.• Automation has enhanced repeatable processes and enhances cost control• A common data base including line speed, concentrations of chemical and

temperatures insures repeatable higher quality. – For example by optimizing the bleaching process can reduce the amount of dye needed

to achieve the quality color desired in the dyeing process.

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Example No. 2

• In the past multiple data bases had to be coordinated• Processing fabric was often considered an art

– Time in the chemical was set by the speed of the line, which was controlled by one data base – a Drive system

Motors & Gears

Drives

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Chemical Concentrations often manually set by valves

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Multiple data bases yield multiple chances for errors

• Even when a control loop is used to set concentration or temperature, is it the right value for the product being run.

• Multiple data bases yield multiple changes for errors• Take Temperature Control – The easiest

– Sometimes Single Loop Controllers were used to maintain temperatures• Often set for wrong product being run

– Manual Controls with temperature read out• Cannot be monitored 100%

– Temperatures Drifted from beginning to end of the same lot of fabric– No Chance to repeat the next time a product is run

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19

20

21

22

23

24

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WEB Based Reports

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Reports can be show on the plant Email system

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Case No. 3

• Low cost

System Highlights:System Highlights:• Flexible system able to accommodate all new dyeing technology• Able to communicate with existing control systems and equipment• Data collection• Process monitoring• Friendly system easy to expand and configure

• Reduced process waste and rework• Cost savings• Process capable for all products

Process Benefits:Process Benefits:• Reduced process variation• Increased efficiency

ColorWorks Process Automation

Dyeing

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EthernetDH +

RSLinx

Automation Platforms

EOIMMIMMI

Enterprise / Control Integration

Ethernet

ERPERP AccessAccess ExcelExcelInternetInternet PDAPDA

Enterprise Systems

Remote I/O Control NetDevice NetEthernet

Automation Components

Plant Floor

Ethernet

Manufacturing Execution

RSSQLRSSQL

DCS

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DeltaV – SQL Integration

Communications between control and ERP networks via RSSQL OPC* technology

RSSQL OPC client was used to connect SQL to DCS and PLC* OPC: OLE for Process Control; OLE:: Object Linking and Embedding

Communication Standards Aid Implementation

Data Exchange System View

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Scheduler

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Enterprise / Control Integration

Process CultureIT CultureIT Culture

SupervisorySupervisoryControlControl

ControlControl

Setpoints,Limits

Analog,DigitalSignals

InventoryControl

ERPERP

Planning andScheduling

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What is S 95?

• A committee organized by ISA• Members from end users, vendors, integrators and consultants

– Dupont, Eli-Lilly, Hewlett-Packard, Dow Corning, Union Carbide, Lyondell Chemical, Honeywell, Bailey, Fisher Rosemont, Intellution, ABB, SAP, Moore, Yokogawa, OSI Software, Sequencia, Rockwell Automation

– AMR, PriceWaterhouseCoopers• Chartered with developing a standard for Enterprise System to Control System

Integration

• ISA.ORG

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S95 Three Categories of Information

Business Planning& Logistics Information

Plant Production Scheduling,Operational Management, etc

Manufacturing Operations& Control Information

Area Supervision, Production, Scheduling, Reliability, Assurance, etc

ProductDefinition

Information(How to make

a product)

ProductionCapability

Information(What is

available)

ProductionInformation

(What tomake andresults)

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Block Diagram Sample

• y

If you do nothave a plan

for Automation

you will neverachieve your goal

Adopt astep by stepapproach

one project at a time

Where dowe want to

be in 5 Years?

Where are wenow in TotalAutomation

Where arewe?

Where doWe WantTo be?

Step byStep Plan

Total Auto-mation

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. 35

The no. 1 result of automationIs repeatable, higher quality

Have a plan for automationand apply it on every project