Use Case

Smart Manufacturing: production lines

Improving productivity and quality in Textiles

CUSTOMER 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.)

CUSTOMER GOALS

  • 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

Challenges:

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Outdated machinery still has long, effective lifespans but needs to connect to newer, digital assets

Business outcomes:

Through relayr’s end-to-end Smart Manufacturing Solution, the customer was able to implement solutions that result in:

 

  • A 5% reduction in total waste
  • 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.

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