MSS is helping us in achieving best possible utilization of Auto winders through 24 x 7 monitoring of deviations in terms of machine performance / quality data.
Monitoring of machine performance results in detecting abnormalities in early stages of any issue and take corrective action.
In terms of quality data, we are checking quality alarms trend and taking necessary actions in back process. This helps us in reducing 2nd quality and optimize back process for achieving desired quality.
Earlier we used to engage one person per unit to note down the data of Link coner machines taking around 1 hr for writing 4-5 data by going machine to machine. Now for our 100+ winders without Visual Manager, it would have been very tedious task to get these data timely & analyzing these data will take much more time.
In terms of cost of maintenance, without Visual Manager and analyzing data we can only rely on physical checking of critical parts, but if those parts are affecting performance of machines we can decide if any new activity related to maintenance is to be taken or parts replacement should be done. Since we are
getting data of problematic spindles, Auto-Doffers, CBF directly without much effort of searching through machine to machine which results in manpower saving and fast action.
By daily attending rogue spindles, low efficiency auto-doffers, CBF efficiency & alarms it improves overall productivity of machines & we can run link coner at optimum speed.
We have reduced our MIS (Mis Splicing Ratio) data from 6-8% to 4-5% by continuous monitoring of MIS Data and regularly optimizing the settings and attending the drums/machines with abnormal data.
By using Visual Manager, we have reduced paperwork in Winding Department. Earlier there were 14 Registers for noting down various data, which are now eliminated and with the help of Tablet we are maintaining all data in digital form.
It helped us in reducing load on supervisors to note down the data manually and now data for very long term can be seen since it is stored in digital form.