EXCELLENCE

IN
MANUFACTURING
THROUGH
AUTOMATION

BY H.K. CHATTERJEE
Works Director
Raymond Ltd. Vapi Unit 1
 In today’s Global Scenario manufacturing
Efficiency and Agility is not an option , but it is
a strategic requirement

Metrics, including
RETURN ON NET ASSETS
(RONA),
are increasingly scrutinized.
2
 In today’s scenario production cost is increasing rapidly.
The labour cost, raw material cost, power cost, etc. are not in
our control. Hence to increase the productivity and reduce
the production cost we can only have controls on:

 Manpower cost – by reducing manpower

 Utility cost – by power saving
 Quality improvement – Through good control
 High production – Through state of art machine
 Keeping proper record – Through systems

All these can be possible only by implementing

Automation

3
 What is Automation?

Monitoring and controlling of any process with

the help of latest technologies like software,
ladder and logic controls, Robotics, ERP system
and incorporating central computer is called
Automation.

4
WHY AUTOMATION

Achieve more with less.

Elimination of human error

Cleaner Technology

Consistency of product

Minimize Energy consumption

Easy diagnosis of fault

5
 WHY AUTOMATION

Reduction in Resources
(Chemicals ,water , energy etc.)

Reduce manpower.

Data collection and consolidation.

Effective application for Complex tasks

Trending and Report generation.

6
WHY AUTOMATION

Reduction of Peak Loads

Reduction in Effluent

 Environment Protection.

Improve Safety and Health.

Reduce Maintenance.

7
 EFFECT ON PRODUCTIVITY

Automation effects the productivity in following

aspects
a) Increasing production by avoiding manual
delays.

b) Improving productivity by achieving the optimum

efficiency of the machine.

c) Avoiding reprocessing and improving the

productivity.
8
 EFFECT ON PRODUCTIVITY

d) Automation improves the power saving

possibilities and hence the cost of product goes
down.

e) By avoiding manual error it improves the quality

of product and hence productivity.

f) Automation can give useful data of the machines

which increases the possibility of analyzing the
cause of low or poor productivity.
9
 SCENARIO OF INDIAN TEXTILE
INDUSTRY
Most of the textile plant in India are still having old
technologies and running their plants in very low
efficiency.

Automation can improve the productivity of even old

machinery and enhance the quality of the product. For
example-

a) Ring frame automation can improve the doffing time,

reduce unnecessary breakdowns because of power
fluctuation and record the exact running procedure by
avoiding manual interference. It can reduce the
production cost by reducing manpower.

10
 SCENARIO OF INDIAN TEXTILE
INDUSTRY
b) Automation of weaving machineries can improve to analyze the
reason of breakdowns, improves the life of the machine by controlling
all critical mechanical settings and provide accurate data of the
machine.

c) The very important area for Automation is the dyeing process,

because it involves lot of minute parameters which are very critical.
Even in milligrams variation of recipe can change the shade of the
fabric. All the parameters for dyeing like temperature, pressure,
water level, water flow, circulation and time of treatment are most
important.

Automation of the dyeing process can improve the productivity by

controlling the above parameters very accurately.

11
 SCENARIO OF INDIAN TEXTILE
INDUSTRY
d) The finishing process is very critical and all the
parameters of the machine needs to control
preciously. Chemical dozing should also needs
accurate measurement. Automation helps to
improve all these parameters and improves the
productivity and quality in a great extent.

e) Even the folding and warehouse operation can

improve by Automation of the process.

12
 How to proceed for
automation
 Do you know where you are?
 Do you know where you want to be one years
from Now?
 Do you know where you want to be five years
from Now?

13
 How do we start
 It is very important to identify the need and the
feasibility of the system to be automated

 The production cost, the complicity of the

machines, the utility requirement of the
machines, quality parameters of the products are
most important factors to consider while
planning for Automation.

14
Select The System which has
Flexibility
 Ease of Programming
 Adaptability to change
 Expandability
 Enhancibility of function.
 Ruggedness in system.
 Service Back up.

15
 PERFORMANCE FACTOR
 Response Time
 Reliability
 Maintainability To perform the
 Availability desired task.
 Capability

16
REQUIREMENT OF AUTOMATION

PLC
Sensors
Actuators
Drives
SCADA
Networking

17
 Automation In Textile Industry

The textile manufacturers were having problems with the controls

on Textile Machinery as they were having proprietary
communication and programming standards. Therefore the
American Textile Manufacturing Institution along with the
Computer Instruments Manufacturing sub-committee have designed
a open communication standard. Use of this will help significantly
in implementing Integration and Automation strategies.

18
The o p e n de fina ble sta nd a rd s fo r c o m m unic a tio ns a nd
p ro g ra m m a b ility will g ive te xtile m a nufa c ture rs the
a bility to im ple m e nt pla nt wide stra te g ie s, witho ut
a sking the OEM fo r so urc e c o d e a nd e xp e nsive
re p ro g ra m m ing .

19
 Case Studies
I will show you some case studies where
Raymond Limited has improved their
productivity in a great extend by Automate their
existing machines and process.

20
 ROPE SCOURING
AUTOMATION
 APPLICATION

 We have Rope Scouring m/c for secondary

washing & softening of fabric. The fabric gets
stiffed after the process of singeing and heat
setting. This fabric is treated with chemical in
the rope scouring machine to remove stiffness as
well as stains.

21
 NEED
Earlier Operation of machine was manual. There were lot of
problems/negligence during operation of the machine and it is not traceable
easily. The whole system was studied by group of engineers. The study
reveled that the inconsistency in fabric was due to the following points

 Cycle Time.

 Quantity of chemical added

 Quantity of water taken.

 Speed of machine.

 Temperature of m/c.

22
 SOLUTION
 To automate the m/c it was decided to use distributed control
system, and then all the m/c were connected to central SCADA
system. Individual m/c is automated and connected through
Ethernet link. For automation the hardware used were DP
transmitter, Temperature sensor and transmitter, Level switch
etc. The electrical panel for this automation was Designed and
built In house.

 Total 50 nos of programs are made to fulfill the requirement of

process according to quality of fabric. According to lot data and
program number the m/c runs in auto mode and the chemical
request is send to dispenser accordingly.

23
 ADVANTAGES
 Consistent quality is maintained.
 The water consumption is reduced by 2 lacs lit/day.
 Manpower is reduced by 27 workmen out of 38 workmen
 Chemical saving is achieved up to 12%.
 The track of process and record keeping is easier.
 The energy consumption is reduced.
 The fault finding is easier due to which less downtime is
observed.
 The manual error is avoided.

24
 Automation of Chemical Dispensing
System
 The Application
 We have rope scouring m/c for secondary washing of Fabric.
After the Singing and Heat setting the fabric gets stiff so the
fabric is treated and washed here for wool setting and soft touch.
Four types of chemicals are used for this purpose.
 Non Ionic Detergent
 Non Ionic Softener
 Soda
 Acetic Acid

25
 The Ne e d
Pre vio u sly th e m / c w e re ru n n in g in m a n ua l m o d e a n d
th e c h e m ic a l w e re a d d e d th ro u g h Ja rs a n d Bu c ke ts .
C h e m ic a ls w e re a d d e d a c c o rd in g to sla b o f 50 kg
lo t. Th is w a s c ru d e m e th o d . Du e to th is th e re w a s lo t
o f va ria tio n in Q u a lity o f fa b ric .

Also there was very high

potential of saving the
chemicals. So to
optimize the resources
Automatic Dispensing
System was a good
option.

26
 The Solution
 A team of engineering comprising of
Mechanical ,Electrical, Instrumentation as
well as Process engineer studied together
and came out with a solution which was very
accurate and user Friendly.
 The system is divided into 2 Parts.
 Chemical Preparation and Loading
 Dispensing system
27
 Lo a d ing Sta tio n

Th e Q u a n tity o f c h e m ic a l to b e lo a d e d in Sto ra g e ta n ks is
e n te re d in to th e C o m p u te r a n d a u to m a tic a lly th e w a te r
to b e lo a d e d is c a lc u la te d . Th e c h e m ic a l a nd w a te r
lo a d in g is d o n e th ro u g h c o n sta n t flo w g e a r p u m p . Th e
m a g n e tic flo w m e te r is in sta lle d in d e live ry o f g e a r p u m p
w h ic h m e a su re s th e q u a n tity to b e lo a d e d a c c u ra te ly.

28
 Disp e nsing Syste m
As p e r th e p ro g ra m n o . a n d th e w e ig h t o f th e lo t,
c h e m ic a ls re q u ire m e n t is c o m p u te d a n d a re q u e st is
se n d to th e PLC o f d isp e n se r b y th e PLC o f m / c . Wh ic h in
tu rn s se n d th e re q u ire d q u a n tity o f c h e m ic a l to th e
d isp e n sin g PLC . O n c e th e PLC g e ts c a ll fro m th e m / c th e
va lve o f th e p a rtic ula r c h e m ic a l ta n k d o se th e c h e m ic a l
to th e o p e n ta n k. Th e o p e n tra n sm itte r m e a su re s m a ss o f
th e c h e m ic a l a nd g ive s fe e d b a c k to th e PLC . DP
Tra n sm itte r o n th e th e o ry o f “Bu b b le r Syste m ” in o p e n
Ve sse l d o e s th e m e a su re m e n t o f c h e m ic a l.

As soon as the measurement is over, the water flushing

valve flushes the entire System. This chemical and water is
transferred to m/c through Centrifugal Pump. After
dispensing the chemical & water, the air is blown in the
pipe so that no residuals remain in pipe.
29
 AIR WASHER TOWER
AUTOMATION

CONCEPT of automation was to centralize the monitoring

and control of all the towers from one place and keeping in
view of the Energy conservation aspect. All the systems,
available in the market at present use the custom built
controller. Energy conservation aspect is also not
considered whereas in our system, we have used PLC and
the software logic with a view to conserve energy without
compromising the departmental requirement for Relative
Humidity and temperature.

30
 Central Monitoring and control
In this system all the towers are connected to the central
control room through Ethernet LAN. All the towers are
monitored and controlled from one computer.

SCADA software is loaded in the PC to acquire and store

the data of various towers. This data is processed and then
displayed on the screen. Different screens are developed to
view the status like Trend, settings etc. The settings for
different process parameters and the Dampers Position of
all the Towers can be changed from the central control
Room. Also reports are generated to give the status of
individual user departments. On the mimic page, we can
view the actual running of the tower.
31
 EXAMPLE OF ENERGY SAVINGS DUE TO AUTOMATION
OF AWT

AWT – 1 AWT – 2
Capacity – 2,40,000 CMH Capacity – 2,40,000 CMH
Unit Consumption for AWT - 1 Unit Consumption
(For 1 month) For AWT – 2 (For 1 month)

Before automation 75360 kwh 86160 KWH

After automation 65744 KWH 76864 KWH
Net savings 9616 KWH 9296 KWH
*Annual Saving 70000 KWH 70000 KWH

*considerable saving is in the period of Aug to March.

32
 AUTOMATION OF DYEING PROCESS

Dyeing process whether it is piece dyeing, top

dyeing or cheese dyeing the time factor, the
cooling - heating cycle and correct quantity of
chemicals and dyes is very important. Dyeing
process consists of many different steps. The
process also differs from lot to lot. As the system
was totally manual the rate of human error and
wastage is very high leading to variation in shed.

33
To avoid these all it is decided to have automatic
color and chemical dispensing system. In the first
phase all the machines were automated in-house
by multiprogramming. For the automation, we
have changed the internal piping system and the
safety requirement. The complete process is
studied for the programming.

34
After completion of all machine automation, the
color service system is installed. Color Service
system handles the chemical & dyes and dispenses
as per the exact requirement of machine. All the
machines were connected with color service
through pipe line

35
 ADVANTAGES

 Reduction in water consumption.

 Consistency in quality.
 Saving in chemical & dyes
consumption.
 Manpower reduction.
 Elimination of reprocessing.
 Recording is easier.

36
 NEED OF THE DAY
 Automation is a need for today’s competitive
market where quality, cost and availability is
playing major role.

 Through Automation only we can achieve these

parameters and compete in the market.

37