Zircon InfoTech

Presents

Autoconer Automation System

Present WorkingEach Autoconer gives an Automatic

Report at each shift end. It prints report on thermal printer. If all the 30 items are printed (i.e. drum

no, red light, yellow right, cycle % etc) the length of report is 3 meters.

The style of report like this : -

SCHLAFHORST AUTOCONER 238 *Machine 205 (14604891663 ) USTER RoundMag RD2******* SHIFT REPORT *******D2 TH-02.01.03 14:45 A 480 Group 1 P Sec 1-1 W 1-10 A******* LOT PARAMETERS *******A LName P22325 Lot ID 100 Yarn gauge NE 17.7/1 Target yarn speed m/min 1400 Target package diam. mm 230 B******* LOT PRODUCTION *******B Production duration 468 % Efficiency Machine 80.2 Shift 75.4 kg Production total 160 /W * hour 2.13 Doffed packages 40 nDelPac Lot 253 Clearer cuts /100km 22.6 Clearer cuts /bobbin 0.39 Clearer cuts /kg 6.79 Thread breaks /100km 26.0 Yarn joints /100km 72.7 Duration / red light 1.72 % Red light / joint 3.21 % Repeaters / joint 19.8G**** DETAILED PRODUCTION *****G W %MA tRL tYL tCY tOFF %SF 1 75.7 43 2 67 3 1.90 2 78.0 27 1 58 78 1.63 3 77.5 27 8 60 44 2.11 4 81.8 17 8 59 6 2.30 5 80.1 14 13 65 5 2.62 6 81.3 12 14 61 5 1.50 7 82.6 10 19 51 4 1.22 8 81.9 9 17 58 5 0.55 9 82.0 20 2 60 9 1.11 10 80.4 13 13 64 8 1.90 -------------------------------- 80.2 9.64 16.6 19.3 60.3 1.69 W nBC nCC nTB/ nCS nCL nCT 1 316 119 0.86 45 44 30 2 278 74 1.75 21 26 27 3 272 114 2.07 34 62 18 4 301 92 1.00 21 42 29 5 278 128 1.43 43 42 43 6 259 89 1.19 47 18 24 7 251 95 0.59 40 35 20 8 247 119 1.19 42 50 27 9 278 124 0.80 42 56 26 10 279 132 1.23 52 49 31 -------------------------------- 2759 1.19 424 1086 387 275

PROBLEMS FACED BY WINDING DEPARTMENT • Compilation of voluminous data for long period is tedious.

• Loss of production in bad drums due to delayed reporting.

• Identifying abnormal drums failing in any of the multiple items.

• Limitations due to expensive thermal paper & thermal printer repairs.

• Focusing on abnormal drums with periodic failure tendency.

• Repetitive & boring manual calculation for statistical analysis.

• Frustration due to lack of previous day’s/week’s/month’s data. 

General Practice AdoptedEither do not print report at shift end or

print a very small report (i.e. limited 6 or 12 items).

Do not analyze all items for all machines at a glance.

What is AutomationPersonal Computer captures data from

Autoconer machines at every shift end automatically.

No need to print 3 meter long report.Analyze all the data within half an hour.Analyze all the 30 items.View different types of report.

System Architecture

A/c - 1 A/c - 2 A/c - 3 A/c - 4 A/c - 5

Interface

Box - 1

Interface

Box - 2

File Server

Application

Server

LAN LAN

LAN

Benefits of Automations• Highlights Abnormal/Rouge drums.• Increased efficiency due to reduced drum down–time and

hard waste.• Achieve better quality due to reduced number of cuts.• Eliminates expensive thermal paper and printers.• Lot to Lot comparisons.• Reduced typing & processing manpower.• Long term storage & easy recall of data.• Easy & faster reporting.• Faster decision making.• Elimination of duplicity.• Unlimited intangible benefits of computerization.

REPORTS Production : This report shows production duration, speed,

M/c efficiency, shift efficiency, Efficiency losses (Red & yellow lights, suction failure and cycling losses), Breakup of cycling losses, no. of cuts, yarn contents, total production, rate of production on the basis of standard production. etc. on a single sheet.

View report in different ways Lot wise Machine wise Machine wise Lot wise Lot wise Clearer wise Clearer wise Lot wise Winding Register

REPORTS….

Abnormal Drum : This report shows machine wise lot wise abnormal drums for a shift/day based on sigma value (select by user). Standard Abnormal drum report checks 12 items (i.e. toff, tRL, tYL, tCY, %SF, %CP, %AO, nTB/, nCC/, nCL, nCT, nCS) while periodical report shows report for a selected item for fortnight/month.

View report in different ways General Abnormal Drum for a Shift/Day Abnormal Drum Report for a Item for a Period

With Average Value Without Average Value

REPORTS….

Drum wise Day wise Original Values : This report shows machine wise drum wise actual value for a selected item for a month. This report allows you to select the normal value for the selected item and print report only either for normal value or abnormal values.

Drum wise Machine wise Values : This report shows drum wise machines wise actual value for a selected item for a given period. This report allows you to select the normal value for the selected item and print report only either for normal value or abnormal values.

REPORTS….

Summary : This report shows Cuts/100 Km and shift efficiency for a given period.

View report in different ways Count wise Lot wise Count wise Machine wise Machine wise Count wise Lot wise Machine wise Machine wise Lot wise Lot wise Clearer wise

REPORTS….

Daily Productivity Index : This report shows Lot wise M/c efficiency, shift efficiency, Cuts/100 Km, standard production per drum, rate of production, production in kg, % of losses, capacity utilization and productivity index for a shift/day for a given period.

REPORTS….

Machine wise Breakup : In this report user can divide all the drums in any machine into four groups based on their performance in a selected item. This helps to set and achieve the performance target.

Drum wise Analysis : in this user can apply his own conditions on 8 selected items on selected groups of a machine for a period/day. If the value of drums does not fulfill the defined conditions, it will highlights the values.

REPORTS….

Informator : This report shows the drum wise MIC report for all 30 items on a single line..

View report in different ways For a shift for a Machine Day wise Average values Week wise Average values Fortnight wise Average Values Month wise Average values

COST BENEFITS

Saving in Thermal Paper Cost

Increased Earning due to Increase in efficiency

Reduction in Hard Waste

Reduction in Manpower Costs

COST BENEFITS….

Saving in Thermal Paper Cost

Every Autoconer prints data for 60 drums for all 30 parameters per shift and it takes 3 meters of roll. It costs Rs. 3 per meter. The total paper cost for 11

11 Autoconers x 3 shifts x 365 days x 3 meters x Rs. 3 per meter = Rs. 1,08,405

COST BENEFITS….

Increased Earning due to Increase in Efficiency

Due to reduced drum down–time the expected efficiency increases by as much as 5%. Even if we expect a modest figure of 1%, which is not at all difficult to achieve, this will lead to a increased production of 1%. Each Autoconer produces 2000 Kg. of yarn @Rs. 10 per Kg i.e. Rs. 20,000 per day. The increased earning due 1% efficiency will be Rs. 200 per day per Autoconer. For 11 Autoconers and for 365 days, the additional earnings will be

Rs. 200 x 11 Autoconers x 365 days = Rs. 8,03,000

COST BENEFITS….

Reduction in Hard Waste

A nominal reduction of hard waste to final production ratio by 0.1 % gives us a saving as follows –

Rs. 80 per Kg x 0.1% x 2000 Kg x 11 Autoconers x 365 days = Rs. 6,42,400

COST BENEFITS….

Reduction in Manpower Costs

Since this automatic system saves the cost of 1 person @Rs. 10,000 per month, the annual saving is

Rs. 10000 x 1 person x 12 months = Rs. 1,20,000

The Total Cost Saving Saving in Thermal Paper cost = Rs. 1,08,405 Increased Earning due to Increase in Efficiency = Rs.

8,03,000 Reduction in Hard Waste = Rs. 6,42400 Reduction in Manpower cost = Rs. 1,20,000

The Grand Saving per Year = Rs. 16,73,805 (for 11 Autoconers)

For Further Details Contact :

Govind Garg

Zircon InfoTech

102,Trade Centre,18 South Tukoganj,

Indore-452001

Tel : 731-2523954 Cell no. : 98263-85954

e-mail: zirconinfo@gmail.com

Autoconer Automation System

The Beginning