1. AUTOMATION EMPOWERING PERFORMANCE & PROFITABILITY
Matching with Textile 4.0 using old machines
A.T.E. Enterprises Private Limited
V2.1 Mar 2018

2. OLD MACHINE DC Motors Slip ring motors Maintenance Cost Break Down
Old PLCs Embedded cards
Controllers
Spares availability
Dependence on OEMs
Contactor Logic
Relay logic
More breakdown
More down time
Less production time
Old HMIs
Mimic
Analog meters
No Online Monitoring
No Utility Monitoring
NO Alarm Diagnostics

3. OEM support not available/ Expensive
OLD MACHINE
Energy inefficient (consumes more
energy compared
with latest machines)
Lot of break downs
Break down attending
time is more
Spare parts not easily available. Most of the spare parts are obsolete
OEM support not available/ Expensive
In short with these old machines race cannot be won ………….

4. NEW MACHINE READY FOR NEW AGE Industry 4.0
AC Motors
Servo motors
Maintenance Cost
Break Down
Advance PLCs
Speed
Efficiency
Profitability
Drives
Power Saving
Spares
Advance features
Graphical HMIs PC
Alert Messages Online Monitoring ( IOT and robotics)

5. ANALYSIS
It is very clear that continuing the production with old technology machines will force company to remain behind in race which is not affordable. At the same time purchasing new machines is very costly affair and everybody cannot afford. Then what is the solution to remain in the race …? Matching with Industry 4.0 standards with old machines Automation is the key by which our old machines can be made to work like new machines and help the producer to remain in the race with little investments compare to the costs of new machines.

6. AUTOMATION AND UPGRADES
NEED OF TIME

7. WHY AUTOMATE / UPGRADE
For increase in energy efficiency. e.g. replacement of old DC motors, inefficient motors, installation of AC drives.
For increase in production efficiency.
e.g. increase in machine speed, reduction in manpower
3. For improvement in product quality. e.g. monitoring and control of quality parameters during Production.
4. For reduction in number of breakdowns and time to attend breakdown e.g. by way of visual monitoring like SCADA/HMIs etc. & interactive software

8. WHY AUTOMATE / UPGRADE ?
For online monitoring of complete production process. e.g. Alarms, logs, trends availability for analysis of quality and production.
For spares management and increase machine life e.g. getting rid of old obsolete spares and making machine ready for next years
For remote monitoring e.g. IOT based apps and systems to get better from machine
For safety of man machine and product. e.g. addition of different safety interlocks.
Customer can customize some machine functions as per their process/production need
ACTIVE LIFE CYCLE

9. WHY AUTOMATE / UPGRADE ? In short automation helps:
Making old machine compatible with new generation machines at much lower costs.
Increase machine life for years.
Increase in production, quality and energy efficiency.
Interactive visual software like SCADA.
Visual process control by PC/HMIs.
Replacement of old technology parts by latest ones.
Readily available service support
Machine is ready for new age Industry 4.0 ,,,,,,,,,,,,,,,,,,,,,,,

10. Automation Process & Selection of automation agency
Additional
Customer need
Study
Customer Discussion
Identify obsolete parts
Tuning
Final execution
Shutdown Planning
Preparing BOM

11. Automations / upgrades
Textile Weaving (Preparatory): Direct and Sectional Warping Machines Customers: M/s PT Indahjaya (Benninger) M/s Saranya Mills Ltd (SMH) M/s Raymond UCO ( SMH)

12. Automations / upgrades
Textile Weaving (Preparatory): Sizing machines Customers: M/s Raymond UCO, M/s Raymond Ltd M/s Soktas, M/s Premier mills, M/s Nahar Industries, M/s Suryalakshmi, M/s Bhaskar, M/s PT Indahjaya, Govt of Sudan Textile Mills Machine makes: Benninger, Sucker Muller , Morrison, Rotal

13. Automations / upgrades
Textile Processing Dyeing, Finishing, Bleaching, Washing, Mercerizing and other process machines (all makes) Customers: M/s Bhaskar, M/s Raymond Ltd, M/s Siyarams, M/s JCT, M/s Arvind Mills, M/s Astha creations, M/s Knitcraft,M/s Swan industries M/s IPMC Machine makes: Benninger, Kuster, Goller Morrison etc.

14. Automations / upgrades
Synthetics Winders, Fiber plants, Pressing machines, Extruders, BCF Lines Dryer and chip conveyors etc. (all makes) Customers: M/s Reliance, M/s Welspun, M/s AYM, M/s Indorama, M/s Shubhalakshmi, M/s Recron Malaysia M/s PT Indorama, M/s PT Mutu Gading, M/s PT Universal Carpets, M/s Eleme Petrochemicals Machine makes: TMT,Barmag,Teijin,Toyodenki,Autefa,Swisstex etc.

15. Automations / upgrades
Steel Plants: 2HI/4HI Rolling mills, Sintering lines, Strip processing machines etc. Customers: M/s KSPG Automotive, Pune M/s Bimetal Bearings,Chennai M/s KSG Automotive Mexico

16. Case Study 1
Customer :- M/s PT Asia Pacific Project :- Barmag Extruders 32 Nos Advntages :- Got rid of Obsolete & Costly spares - Dependency on OEM is killed - New Technology Incorporation - Making system ready for new IOT technology - All Data available on 1 PC
OLD MONITORING SYSTEM
NEW MONITORING SYSTEM

17. Case Study 2
Customer :- M/s JCT Project :- Continuous Dyeing Range) Advantages :- Obsolete & Costly spares - Dependency on OEM - New Technology incorporation - Making system ready for new IOT technology - Increased machine speed - improved product quality

18. Case Study 3
Customer :- M/s PT Indorama Synthetic Project :- Fiber Line Reasons :- Old Control system - Old Drives Advantages :- 25% reduction in energy cost - Latest technology - Brake down reduction - Low wastage - Alarm & Trends for better monitoring & diagnose - System ready for IOT technology, Industry 4.0

19. Case Study 4
Customer :- Different Textile Plants Project :- Benninger & SMH sizing Reasons :- Old machine are equipped with obsolete & embedded cards or PLCs & drives - Dependency on OEM - Spares are very costly Advantages :- Latest technology - Brake down reduction - Readily available support - Spares are availability in local market - Alarm & Trends for better monitoring & diagnose - System ready for new IOT technology

20. Case Study 5
Customer :- Polyester Plants Project :- Polyester winders Reasons :- Old machine are equipped with obsolete & embedded cards - Dependency on OEM - Spares are very costly Advantages :- Break down reduction - Low wastage - Alarm & Trends for better monitoring & diagnose - System ready for new IOT technology

21. THANK YOU