Zircon InfoTech

1. Zircon InfoTech Presents Autoconer Automation System

2. Present Working • Each 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 : -

3. SCHLAFHORST AUTOCONER 238 * Machine 205 (14604891663 ) USTER RoundMag R D2******* 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 19.8 G**** 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

4. 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.

5. General Practice Adopted • Either 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.

6. What is Automation • Personal 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.

7. System Architecture A/c - 1 A/c - 2 A/c - 3 A/c - 4 A/c - 5 Interface Box - 1 Interface Box - 2 LAN LAN File Server LAN Application Server

8. 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.

9. 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

10. 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

11. 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.

12. 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

13. 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.

14. 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.

15. 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

16. COST BENEFITS • Saving in Thermal Paper Cost • Increased Earning due to Increase in efficiency • Reduction in Hard Waste • Reduction in Manpower Costs

17. 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

18. 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

19. 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

20. 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

21. 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)

22. 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

23. Autoconer Automation System The Beginning