Client Need

One of the large textile manufacturing brand in India with a legacy of 100+ years has embarked on their automation journey a few years ago. Given the competitive landscape and the large amount of data that was being collected from various sources, it was time to implement the Real Time corrective measurements to improve their throughput for one of their flagship manufacturing units.
The client experienced a double digit rejection ratio of 11.84% in the Finishing process.
  • The specific ask was to reduce the rejection ratio using automation
  • In addition, the client required a mechanism to implement the Material Management System to track the real time location of the fabric

The Solution

ARGES GLOBAL IPA framework used for pattern recognition and detect anomalies using AIOps for self-correction and self-healing for manufacturing machines to eliminate rejection
  • Using 6 months of data from SAP ERP system a co-relation was established between the fabric rejection to the machine problems
  • Data from a total of 71 machines used for 17 different finishing processes were captured using SCADA / PLC interface for vital information
  • Material Movement solution was conceptualized using existing assets

Client Impact

  • Targeted reduction of Rejection ratio by 3.5%
  • Real time tracking of the fabric on the floor and build the correlation with the processing machine

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