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Factory Automation

133

Factory automation and digitalization were implemented in a weaving factory specializing in aviation  carpets, fine wool broadloom, and quality floor coverings. The facility relied on imported machines, which  posed significant maintenance challenges once the annual maintenance contract (AMC) expired. During this  period, the need for cost optimization and accessible service became increasingly critical, prompting the  factory to seek innovative solutions to enhance operational efficiency and reduce downtime.

Problem
Solution

To tackle the urgent need for service accessibility at LOOM PLC, we developed a custom PLC system in  collaboration with Mitsubishi. This system primarily focuses on monitoring weft activity within the LOOMs,  addressing the critical issue of inaccurate weft count analysis in relation to the final products. By integrating  data from the PLC and the Takemura weaving application, we established a real-time data transmission to  a remote monitoring system. Additionally, an automation software was implemented to track operator  break times and efficiency, requiring operators to log their reasons for breaks before resuming work.  Furthermore, we created a cost-effective automated technician alert system that notifies the technician  centre via SMS or calls when operators report issues. An escalation process ensures that any delays in  technical assistance are communicated to higher authorities, while the application also captures the root  causes of complaints and spare parts used, providing the factory with a comprehensive maintenance  database.

Outcome

Our solution enabled the client to:

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