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Improving productivity and quality in Textiles

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 LACK OF INTEROPERABILITY - Outdated machinery still has long, effective lifespans but needs to connect to newer, digital assets

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  • SUPPLIER
  • relayr
    relayr is a rapidly-growing IoT company, delivering the most complete IoT solutions on the market for the Digital Transformation of industries. relayr’s protocol-agnostic IoT middleware platform, device management and analytics capabilities, open-source SDKs, and nimble professional services teams are trusted by hundreds of companies worldwide. With relayr, businesses are empowered to implement fully interoperable IoT solutions guaranteed to achieve their target business outcomes.Smarter connectivity. Better business outcomes. Guaranteed.
  • INDUSTRIES
  • Equipment & Machinery
  • FUNCTIONS
  • Discrete Manufacturing
  • CONNECTIVITY PROTOCOLS
  • Ethernet
    IO-Link
    MQTT
    Modbus
    PROFIBUS
  • USE CASES
  • Factory Operations Visibility & Intelligence
    Visualizing factory operations data is a challenge for many manufacturers today. One of the IIoT initiatives some manufacturers are pursuing today is providing real-time visibility in factory operations and the health of machines. The goal is to improve manufacturing efficiency. The challenge is in combining and correlating diverse data sources that greatly vary in nature, origin, and life cycle. Factory Operations Visibility and Intelligence (FOVI) is designed to collect sensor data generated on the factory floor, production-equipment logs, production plans and statistics, operator information, and to integrate all this and other related information in the cloud. In this way, it can be used to bring visibility to production facilities, analyze and predict outcomes, and support better decisions for improvements.
  • 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.) 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

  • SOLUTION
  • 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.

  • DATA COLLECTED
  • Energy Consumption Rate, Energy Cost Per Unit, Power Consumption, Production Efficiency
  • SOLUTION TYPE
  • SOLUTION MATURITY
  • Emerging (technology has been on the market for > 2 years)
  • OPERATIONAL IMPACT
  • Impact #1
    [Data Management - Data Visibility]
    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.
    Impact #2
    [Process Optimization - Real Time Monitoring]
    Real-time monitoring of dust and humidity levels, to ensure the environment does not exceed acceptable thresholds that impact yarn quality.
    Impact #3
  • QUANTITATIVE BENEFIT
  • Benefit #1

    A 5% reduction in total waste.

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