Ever-growing costs, never-ending market demands, incalculable expenditures, changing customer demands, untraceable production line, failure in locating the errors, and a lot more; it is obvious that textile wet processing is getting only tougher, and we know there is a lot to be improved.
Considering the need for transformation of the textile industry within the framework of sustainable production, we can evaluate that in the next decade, the challenge will be a lot more than today, and the success will be based on three main steps.
– Textile enterprises that do not perform sustainable clean production management, will not be able to continue their lives.
– If they would not perform real-time cost and deadline management, they will fall behind the competition.
– The importance of predictive and intelligent production management will provide textile enterprises the strength for production efficiency.
Digitalization is The Key to Achieving Sustainable and Clean Production Goals
Today, it is no longer enough for your factory only to be productive and profitable. The use of energy, chemicals, dyestuffs, and water you need while producing both consumes limited natural resources and harms the environment by generating CO2 emissions and wastes. A digitalized production process in your factory provides instant monitoring of each stage of your production in a transparent and backward traceable manner integrated with your supplier channels. It helps you to keep your consumption in a minimum level by optimizing your production.
It also helps you to check your compliance with MRLSL (Restricted Substance Production List) and ZDHC (Zero Waste in Hazardous Chemicals) instantly. Digitalization of textile processes also provides instant data and reports for International Audit Institutions on Cleaner Production and detects and reports anomalies.
The Strength of Real-Time Cost and Production Analysis
Flying a massive aircraft, the captain makes many decisions by looking at a few critical key indicators generated from thousands of data on the plane. You must look to the hundreds of reports and data to make sure that the machines, human resources, energy, and raw materials in your factory are used effectively. Most of the time, these reports are too late; it reaches you as the aircraft engine catches fire and stall towards the sea. Whereas a digitalized factory by Eliar instantly shows you the most critical data you need, for seeing the major picture.
Today, OEE is the most basic indicator used to measure the efficiency of all factories. It expresses the capacity of your factory, how much you can produce using this capacity, and how much of your production is of the expected quality as a single number. Digital Factory, if your capacity decreases for some reason (inoperative machines, decreased energy capacity, raw material, human deficiencies, etc.), if you become unable to use your current capacity (downtimes, losses, wastages, breakdowns, etc.), if you experience errors in production (repairs, additions, re-operations, etc.) shows you all these instantly and provide you with an in-depth analysis to reach the source of the problem.
The Effectiveness of Instant Trend and Anomaly Analysis
While thousands of transactions are carried out in your factory, hundreds of thousands of data are generated. Raw material and energy consumptions, downtimes, repairs, errors, losses, wastages, malfunctions. Thousands of transactions that you cannot control cause increased costs, delayed products, and thus customer dissatisfaction. The ELIAR Digital Factory instantly monitors every single process, from the cabin temperatures of a night shift of stenter to the motor chain speed, or from the tower speeds in your dyeing machine to your heat exchanger efficiencies. It checks the accuracy of the processes, and consumptions, predicts malfunctions before they occur and informs you if there is an abnormal situation. It predicts the production orders that will exceed the planned cost or the ones that do not reach the deadline and inform you before any burden being faced.
Aggregating all the improvements, the picture of the annual saving of automation and digitalization is simply amazing. Thanks to the optimizations provided by ELIAR for the textile industry, while doing all these by automation systems, it also reveals how your customers can express the benefits they provide to their consumers and supply chain by reducing the resource consumption of the products offered to their customers, by using their resources correctly, and how they stand out from their competitors with this method they prefer. As so, the future will be a period of innovative and idealistic enterprises that provide sustainable production.
Eliar Elektronik San. A.Ş. was founded in Istanbul, Turkey in 1984. ELIAR has strengthened the Turkish industry and economy with many devices, systems, and software, and has made many important contributions to automation with its R&D exclusively for the textiles industry.
Since 1984, the textile industry focus has been expanded and ELIAR has started to work on mechatronic weighing and dispensing systems. Today, Eliar, while continuing to develop liquid and powder chemical weighing and distribution systems, on the other hand, to develop control devices and automation software that can work integrated at the machine level, which is for fabric, yarn, dyeing, and garment washing, or else the factory level. Eliar also provides, for these projects, fully automatic control and recording of the entire dyeing process. Besides, with the central monitoring, planning, and reporting software it has developed, ELIAR delivers integrated systems from the processing machine level to the factory management level.
Today, thousands of control devices and integrated automatic dispensing systems, which has designed and manufactured by ELIAR, are installed and in active use in addition to Turkey, many other regions like the Far East, Europe, North–Central & South America, Asia, Middle East, and Africa. www.eliar.com