1. Presents Autoconer Automation System
Zircon InfoTech
Presents
Autoconer Automation System

2. Present Working
Each Autoconer gives an Automatic Report at each shift end.
It prints report on thermal printer.
If all the 30 items are printed (i.e. drum no, red light, yellow right, cycle % etc) the length of report is 3 meters.
The style of report like this : -

3. SCHLAFHORST AUTOCONER 238 *
Machine ( )
USTER RoundMag R
D2******* SHIFT REPORT *******D2
TH :45 A
Group P Sec W 1-10
A******* LOT PARAMETERS *******A
LName P22325
Lot ID
Yarn gauge NE /1
Target yarn speed m/min 1400
Target package diam. mm
B******* LOT PRODUCTION *******B
Production duration
% Efficiency Machine
Shift
kg Production total
/W * hour
Doffed packages
nDelPac Lot
Clearer cuts /100km
Clearer cuts /bobbin
Clearer cuts /kg
Thread breaks /100km
Yarn joints /100km
Duration / red light
% Red light / joint
% Repeaters / joint
G**** DETAILED PRODUCTION *****G
W %MA tRL tYL tCY tOFF %SF
W nBC nCC nTB/ nCS nCL nCT

4. PROBLEMS FACED BY WINDING DEPARTMENT
Compilation of voluminous data for long period is tedious.
Loss of production in bad drums due to delayed reporting.
Identifying abnormal drums failing in any of the multiple items.
Limitations due to expensive thermal paper & thermal printer repairs.
Focusing on abnormal drums with periodic failure tendency.
Repetitive & boring manual calculation for statistical analysis.
Frustration due to lack of previous day’s/week’s/month’s data.

5. General Practice Adopted
Either do not print report at shift end or print a very small report (i.e. limited 6 or 12 items).
Do not analyze all items for all machines at a glance.

6. What is Automation
Personal Computer captures data from Autoconer machines at every shift end automatically.
No need to print 3 meter long report.
Analyze all the data within half an hour.
Analyze all the 30 items.
View different types of report.

7. System Architecture A/c - 1 A/c - 2 A/c - 3 A/c - 4 A/c - 5 Interface
Box - 1
Interface
Box - 2
LAN
LAN
File Server
LAN
Application
Server

8. Benefits of Automations
Highlights Abnormal/Rouge drums.
Increased efficiency due to reduced drum down–time and hard waste.
Achieve better quality due to reduced number of cuts.
Eliminates expensive thermal paper and printers.
Lot to Lot comparisons.
Reduced typing & processing manpower.
Long term storage & easy recall of data.
Easy & faster reporting.
Faster decision making.
Elimination of duplicity.
Unlimited intangible benefits of computerization.

9. REPORTS
Production : This report shows production duration, speed, M/c efficiency, shift efficiency, Efficiency losses (Red & yellow lights, suction failure and cycling losses), Breakup of cycling losses, no. of cuts, yarn contents, total production, rate of production on the basis of standard production. etc. on a single sheet.
View report in different ways
Lot wise Machine wise
Machine wise Lot wise
Lot wise Clearer wise
Clearer wise Lot wise
Winding Register

10. REPORTS….
Abnormal Drum : This report shows machine wise lot wise abnormal drums for a shift/day based on sigma value (select by user). Standard Abnormal drum report checks 12 items (i.e. toff, tRL, tYL, tCY, %SF, %CP, %AO, nTB/, nCC/, nCL, nCT, nCS) while periodical report shows report for a selected item for fortnight/month.
View report in different ways
General Abnormal Drum for a Shift/Day
Abnormal Drum Report for a Item for a Period
With Average Value
Without Average Value

11. REPORTS….
Drum wise Day wise Original Values : This report shows machine wise drum wise actual value for a selected item for a month. This report allows you to select the normal value for the selected item and print report only either for normal value or abnormal values.
Drum wise Machine wise Values : This report shows drum wise machines wise actual value for a selected item for a given period. This report allows you to select the normal value for the selected item and print report only either for normal value or abnormal values.

12. REPORTS….
Summary : This report shows Cuts/100 Km and shift efficiency for a given period.
View report in different ways
Count wise Lot wise
Count wise Machine wise
Machine wise Count wise
Lot wise Machine wise
Machine wise Lot wise
Lot wise Clearer wise

13. REPORTS….
Daily Productivity Index : This report shows Lot wise M/c efficiency, shift efficiency, Cuts/100 Km, standard production per drum, rate of production, production in kg, % of losses, capacity utilization and productivity index for a shift/day for a given period.

14. REPORTS….
Machine wise Breakup : In this report user can divide all the drums in any machine into four groups based on their performance in a selected item. This helps to set and achieve the performance target.
Drum wise Analysis : in this user can apply his own conditions on 8 selected items on selected groups of a machine for a period/day. If the value of drums does not fulfill the defined conditions, it will highlights the values.

15. REPORTS….
Informator : This report shows the drum wise MIC report for all 30 items on a single line..
View report in different ways
For a shift for a Machine
Day wise Average values
Week wise Average values
Fortnight wise Average Values
Month wise Average values

16. COST BENEFITS Saving in Thermal Paper Cost
Increased Earning due to Increase in efficiency
Reduction in Hard Waste
Reduction in Manpower Costs

17. Saving in Thermal Paper Cost
COST BENEFITS….
Saving in Thermal Paper Cost
Every Autoconer prints data for 60 drums for all 30 parameters per shift and it takes 3 meters of roll. It costs Rs. 3 per meter. The total paper cost for 11
11 Autoconers x 3 shifts x 365 days x 3 meters x Rs. 3 per meter = Rs. 1,08,405

18. COST BENEFITS…. Increased Earning due to Increase in Efficiency
Due to reduced drum down–time the expected efficiency increases by as much as 5%. Even if we expect a modest figure of 1%, which is not at all difficult to achieve, this will lead to a increased production of 1%. Each Autoconer produces 2000 Kg. of 10 per Kg i.e. Rs. 20,000 per day. The increased earning due 1% efficiency will be Rs. 200 per day per Autoconer. For 11 Autoconers and for 365 days, the additional earnings will be
Rs. 200 x 11 Autoconers x 365 days = Rs. 8,03,000

19. COST BENEFITS…. Reduction in Hard Waste
A nominal reduction of hard waste to final production ratio by 0.1 % gives us a saving as follows –
Rs. 80 per Kg x 0.1% x 2000 Kg x 11 Autoconers x 365 days = Rs. 6,42,400

20. COST BENEFITS…. Reduction in Manpower Costs
Since this automatic system saves the cost of 1 10,000 per month, the annual saving is
Rs x 1 person x 12 months = Rs. 1,20,000

21. The Total Cost Saving Saving in Thermal Paper cost = Rs. 1,08,405
Increased Earning due to Increase
in Efficiency = Rs. 8,03,000
Reduction in Hard Waste = Rs. 6,42400
Reduction in Manpower cost = Rs. 1,20,000
The Grand Saving per Year = Rs. 16,73,805
(for 11 Autoconers)

22. For Further Details Contact :
Govind Garg
Zircon InfoTech
102,Trade Centre,18 South Tukoganj,
Indore
Tel : Cell no. :

23. Autoconer Automation System
The Beginning