7th April 2006

J P Singh President, AIA

Indias Position

The Indian textile industry occupies an important place in the global economy
Sector
Production of Jute Producer of cellulosic fibre / yarn Production of cotton yarn Silk production Production of raw cotton Production of synthetic fibre / yarn

Rank
1 2 2 2 3 5

The contribution of this industry to gross export earnings is about 17%

Textile Industry Growth

Indias Share of Global Textile trade could go up to $ 40billion..

5000 4500 4000 3500 3000 2500 2000 1500 1000 500 0
RM Co G n tto M an M e ad en l oo W lk Si c di n Ha fts ra i Co r te u J

2005-06 2004-05
l& o o W

2004-05 2005-06

Key areas for automation

Fibres

collecting and cleaning natural fibres, extruding synthetic fibres, finishing fibres, mercerizing and of blending fibres. spinning, assembling filament yarns, folding, cabling, and the fabrication of fancy or textured yarns weaving, knitting, braiding, stitch bonding, laminating, or nonwoven techniques. dyeing, printing, and mechanical finishing such as raising, pleating or shrinking.

Yarns

Construction

Finishing

Automation Levels

Enterprise Integration
MES Growth & flexible production systems ROE (FS only)
ROIC or

Tier 4

Asset and Inventory Management

Tier 3

Key Performance Drivers

Special Purpose Machines Inspection Systems

Testing Systems
Tier 2

Automation Capabilities
PLCs / Control Systems HMI Robotic Systems

Manufacturing Infrastructure
Communication buses Servo and motion control Instrumentation & Sensors Inverter drives and power conditioning equipment

Tier 1

Advantages of automation

Computerised control of processes and machinery

+
Automated testing

10-30% saving in water and energy usage 5-15% saving in dyes and chemicals Significant saving in labor Meeting environmental regulations

Reduction in testing time by 90% machines & multi- Major reduction in set-up times axis motion controls Improvements in quality

Modernization And Consolidation For creating a Globally Competitive industry

+
Variable speed drives

Improvement in quality and productivity by 20-

30% Saving in energy consumption typically by 15-30%

+
Automated material handling

Significant productivity improvements Eliminating human error Reduce waste and inventory

Empowering a leading Indian polyester firm

Challenge ability to manufacture PFY through highspeed spindles, while providing final product with a minimum of yarn breakage and maintaining high uptimes Situation experienced several problems, including daily power supply dips caused by improper Plant co-gen & grid synchronization. These events usually resulted in two-hour production losses, therefore extremely high revenue losses occurred while the plant was being reestablished

Solution

Automated Load Management solution based on PLC, HMI incorporating features like Load Shedding, Control of DGs and Synchronization with grid, limiting grid power drawn & penalties , sharing of active and reactive loads Alarm summary for each fault occurrence tracks incident dates and times for data tracking and maintenance needs.

Case Study

Benefit The system provided a high-quality, uninterrupted power supply, allowing the customer to operate smoothly and achieve the highest quality PFY production ever in a continuous operating environment.

Standing out by maintaining Quality

Challenge To achieve a perfect quality thread, exactly maintaining the rotation speed set point is necessary. Situation Experienced less than optimum quality, because the existing legacy control system was not fully capable to perform complicated process calculations and provide reliable synchronized control of position and torque.

Solution

A high speed PLC used for the head controller which constantly monitors the spindle speed as well as the basic data for the rollers and the ring rail. High performance controlled drives & converters with dynamic and precise servo motors are used as a drive system for rollers and ring rail. The data are passed on to the drives via Profibus DP. Benefit End customers are very pleased with the exact positioning accuracy, high availability and fast response time of the machine.

Case Study

Robot Minimizes Product Damage and Labeling Errors

Challenge To minimize damage and labeling / processing errors Situation There are inefficiencies associated with excessive handling of the raw POY. The raw POY packages are extremely susceptible to contamination and/or damage. Each additional handling operation increases the risk of turning good product into waste and scrap.

Solution

The system deployed 8 AGVs (Automated Guided vehicles) to pick up completed POY packages from the spinning machines (in blocks of 3 consecutive spindles at a time) and deliver the 3-spindle blocks to one of three Adept Palletizer Robots. Each Palletizer is designed to receive the POY from the AGVs and place them into horizontal arrays on the conveyor-transported pallets (pucks) for subsequent processing. . Benefit eliminated several phases of handling, minimizing product damage and labeling errors which increased quality

Case Study

Conservation for the environment

Challenge Reduce excess utility consumption Situation The Yarn dyeing plants were consuming more hot water than their boilers could supply. As a result, dye procedures were extended to ensure adequate dyeing, which in turn used more water and natural gas.

Solution

A large hot water heater was added to each boiler to ensure a significant supply of hot water would always be available. PLC monitoring and control systems were installed which monitored and controlled all water system flows, storage tank levels, and water temperatures. The control system also monitors all water in the plant and determines, by temperature, which tank should be used for heated water storage. Benefit Wastages Reduced, water usage and natural gas usage per pound of yarn dyed has drastically decreased. Cycle times for yarn dyeing procedure were optimized and allowed all existing equipment to dye more product.

Case Study

Thank you