Few years back , we had shortage of winding capacity in our units situated in different locations. We used to transport Spinning Bobbins between units to manage the situation with compromise on Spin Plan. Our Spinning production was affected by this mismatching winding capacity. To tide over the situation, we started collecting key performance indicators of Automatic Winders every one hour manually and carried out the corrective action. Manual data collection was time consuming and caused hardship to our team.
At this juncture, Muratec introduced MSS to us. MSS started giving our required key data and additional details as well on real time basis.
The Technicians were able to concentrate on their core maintenance activities. The real time corrective actions resulted in the improvement of AEF by about 10%.As an immediate effect, the winding capacity became surplus and we couldincrease the Ring Spinning production by about 3000 Kg per day (production value of about Rs.9 Lakhs per day). Thanks to “Visual Manager” that we got rid of the investment towards new Automatic Winding machine.
Machine performance continuously improved. MIS% got reduced from 12 % to 5-7% level, Tension breaks got reduced from 5% to 3%, YLM got reduced from 1% to 0.2%, Cop rejection reduced from 1.2% to 0.6%. Back process could be corrected due to the availability of continuous data and diagnostic reports from MSS portal.
Apart from diagnostic reports, Visual Manager suggests solutions through its trouble shooting guide function. Maintenance activity became very easier and dependency on skilled person has come down. Hence, machine troubles could be set right by the semi-skilled technicians available in the night shifts. Job List info is available on the machine VOS display and hence the corrective action could be taken immediately. Communication is not being lost. The daily Visual Manager report, Weekly report and monthly report are discussed internally with all our units and the identified shortcomings by the team are listed and resolved. The MSS Portal provides latest information about updated parts, dispatch of FOC parts and hence our teams always stay updated and are able to plan their maintenance perfectly.
The data of all our Units could be visualized and compared in the MSS portal screen and thereby the overall group performance improved. Our position in the World ranking moved from bottom 1/3 to top 1/3 (iMW Index). The system has trained and refined us to retain this status. Visual Manager is a Wonder Gadget at an affordable cost. We are grateful that Muratec has implemented IOT, AI towards Industry 4.0 a long time ago and even before the Industry started talking about it.
Sri Kannapiran Mills wishes Muratec to continue with their unblemished service to the user industry.