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Process Automation & Control System (PACS) Ventura Automation Services Inc Chennai.

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Presentation on theme: "Process Automation & Control System (PACS) Ventura Automation Services Inc Chennai."— Presentation transcript:

1 Process Automation & Control System (PACS) Ventura Automation Services Inc Chennai

2 Objectives of the Project Management Perspective Eliminate all Manual Data Entries of Process House Reduce Manpower for Data Entry Track time based movements of fabric for better delivery forecasting Structured feedback on quality issues Fix responsibility on individual performance 0% Error data or 100% Accurate Data Upload & Download information Automatically to CAMS Online or Real-time information to Management One time automation & life long benefits 5/9/2015All Rights Reserved - Ventura Automation Services Inc

3 Objectives of the Project Floor Level Perspective Find LOT whereabouts Identify LOT-wise Elongation & Shrinkage Reduce manual errors on batching  Style wise grouping  Automatic length Measurement per batch Machine wise production & utilization report Machine Stoppage Report Employee wise production report Employee Wise Efficiency Report RPM/MPM Data 5/9/2015All Rights Reserved - Ventura Automation Services Inc

4 The Flow Acquire Process Work Center details from CAMS Allocate “BATCH & LOT” details to Work Center DATA Received from CAMS are as follows BATCH # # of LOTS Required for Particular BATCH # Grey Rolls Required for LOT Work Center Allocated for LOT Grey Roll Details Such as Roll # Roll Meter Total Meters for LOT Work Center Allocated for LOT Work Center Allocated for BATCH 5/9/2015All Rights Reserved - Ventura Automation Services Inc

5 The Flow Continued Ist Process - Batching Group Similar Process styles/Work Order /Based on Work Center for grey fabric jumbo roll batching Batch May contain multiple LOTS Display “BATCH#” while batching in touch screen Option to Select LOT# would be provided Once “LOT” is selected Show “ALL ROLL#” in Touch Screen Now “ ROLL#” need to be selected under a “LOT” Control 1: Wrong Roll # Cannot be Selected under a LOT Control 2: Cannot Exceed Maximum Allowance in Meterage of ROLL meter Control 3: Wrong Roll Selection is not possible since roll# for the batch is decided by ERP 5/9/2015All Rights Reserved - Ventura Automation Services Inc

6 The Flow Continued Measure each Roll length Derive LOT Meters Add multiple LOTS & derive Batch Meter Store Batch Meters in CAMS Server with Following details # of LOTS in BATCH # Rolls in LOT Batch Start Time Batch End Time This meterage could be later verified with Grey Inspection End Batching Make Two RFID Cards on System Provided near batching machine RED for BATCH & GREEN for LOT Tie the RFID Cards with BATCH & LOT Cards Update LOT information to CAMS Database 5/9/2015All Rights Reserved - Ventura Automation Services Inc

7 The Flow in Block Diagram Batch# LOT 1 Roll # LOT 2 Roll # Work Center 1 Work Center 2 Work Center 3 LOT 1 Work Center 21 LOT 2 Work Center 18 5/9/2015All Rights Reserved - Ventura Automation Services Inc

8 The Flow… Continued Process Flow 2: BATCH – WORK CENTER 1 Place the RED RFID card in the Slot Provided Then Select Emp. Code# (Kindly note: Without placing the card on the slot or without entering employee code the machine cannot be started) then START When the machine is stopped for more than 30 seconds the relay would be triggered & user cannot start the machine without entering the stoppage To end the batch, press end doff key Remove RFID Card and use it for NEXT Process Upload DATA to Server Do similar for All following processes 5/9/2015All Rights Reserved - Ventura Automation Services Inc

9 Work Flow…. Splitting LOTS A computer would be provided in Process House with RFID writer Multiple computers with RFID writer need to be provided in case of multiple sheds In case a LOT is split a new LOT# to be created in Sync with CAMS with following details Original LOT# Meters in Original LOT# Wastage Meters Meters in newly created LOT# Authorized person name 5/9/2015All Rights Reserved - Ventura Automation Services Inc

10 Components of PACS Process Automation & Control System This is required At Each Machine Except Batching Machine Programmable Logic Controller Rotary Encoder (To Measure Linear Length of Fabric) Relay 1 (To identify Machine Run/Stop status) Relay 2 (To forcibly send stop signal to machine to get stoppage information) RFID Scanner Control 1: Prevent LOTS/BATCHES loaded in wrong work center Control 2: Which LOT/BATCH is under production process RFID Cards – (# of A Frames + # Trolleys * 5 times) Wireless Module (Optional) Machine – Human Interface To get Employee Code To get Stoppage Code Defect Code Sheet 5/9/2015All Rights Reserved - Ventura Automation Services Inc

11 How Does it Work? As soon as A LOT/BATCH is received from earlier process RFID Card to be placed on holder Enter the employee # Press Start button You can set Hinging Time (Assume 45 Seconds) If the machine is stopped beyond Hinging Time a Relay would be triggered by PACS. The machine cannot be started without entering valid stoppage code. One or Two encoders or Proximity Sensors would be fixed in starting & delivery point to measure linear length of fabric. 5/9/2015All Rights Reserved - Ventura Automation Services Inc

12 Exceptions Handling Making BATCH / LOT Stitch Joints Aluminium Sticker Foils need to be pasted on fabric before making a joint & to be stitched on top of the foil. To ensure this foil is not peeled of due to wetness Proximity sensor would sense the joint and sends information to the PLC & signal would be generated to place the LOT/BATCH card on the SLOT Beep Alarm RED Light indication Hi – Sound indication Machine can be stopped based on configuration if the Card is not placed within mentioned timeframe 5/9/2015All Rights Reserved - Ventura Automation Services Inc

13 Product Specifications Process House Data Acquisition System All products supplied would be IP65 grade products Industrial Graded Open Standards Based Ports Provision assuming 30% Expansion SMPS power supply Memory backup of information in case of power failure Option for Joint Software Development Option to provide source code for internal use Seamless integration with CAMS & NOW 5/9/2015All Rights Reserved - Ventura Automation Services Inc

14 Software Specifications Kindly Note: This would be extension of FIDAS for end to end data integration purposes. Hence no separate server or operating system or database required. Separate software module need to be developed for style based segregation & display of Grey inspected rolls for selection in touch screen monitor in batching machine. Unique 5 digit batch# generation & storing in database Create a Work Center flow module for Mercerized & Non-mercerized fabrics Make LOT# available till final inspection. Generate multiple reports Integration with CAMS Kindly Note: This generic specification outline only. Complete specifications will be known after discussing with the production & IT teams 5/9/2015All Rights Reserved - Ventura Automation Services Inc

15 Communication Architecture ‘ CAMS Database Server PACS Server Process 1 Process 2 Process 3 Process ‘N’ LOT Splitting Node Final Inspection BATCHING Node 5/9/2015All Rights Reserved - Ventura Automation Services Inc

16 Details to be Acquired & Sent Acquired from CAMS  Batch #  Work Center  LOT#  Work Center  Grey Roll#, Roll Meters Acquired & Sent from Machine  Batch Meters  Stoppages  Production  Employees  Start Date/Time & End date/time of each BATCH/LOT 5/9/2015All Rights Reserved - Ventura Automation Services Inc

17 Reports Machine wise production report Machine wise utilization report Employee Performance Report Batch wise Shrinkage & Elongation reports Style behavior Analysis Reports Batch Split Reports CAMS Integration Reports Other specific reports as asked by End Users 5/9/2015All Rights Reserved - Ventura Automation Services Inc

18 Other features Auto Generation Auto SMS Alerts Machine wise Real-time production Display through LCD Screen Plan Change at Floor level management Machine Stoppage control through system Forward & Backward integration with fabric inspection Software 5/9/2015All Rights Reserved - Ventura Automation Services Inc

19 Perceived Benefits Avoid manual Entries & human data entry errors for CAMS Reduce manual entry operators for CAMS Standardized methodology for identifying elongation & Shrinkage Online information on batch whereabouts Helps in production planning based on style behavior End to end data flow starting from roll doffing in loom shed till dispatch. Avoid style mixing while batching Identify pending grey rolls waiting for batching 5/9/2015All Rights Reserved - Ventura Automation Services Inc

20 For Enquiry & Clarifications Contact : O. Regis Xavier Ventura Automation Services Inc Hand Phone: Website: 5/9/2015All Rights Reserved - Ventura Automation Services Inc


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