artisan task 1.3

1ARTISAN 1st ARTISAN 1st Plenary MeetingPlenary MeetingMay 8th – 9th 2012

ARTISAN 1st ARTISAN 1st Plenary MeetingPlenary MeetingMay 8th – 9th 2012

Artisan Task 1.3

Mapping of enterprise [email protected]


• Mapping to Data Structure – Scenarios• Structure of a textile ERP• DS-S 1: online monitoring• DS-S 2: mapping to production orders• DS-S 3: model for produc groups: total• DS-S 4: time profiles by group• DS-S 5: allocation for energy consumption• DS-S 6: allocation of embodied energy

Agenda


• Scenarios were agreed in the kick off meeting• Each scenario defines a data structure– Seven of them defined– They cover different areas in energy consumption

• Main objectives of Task 1.3– Map existing data to scenarios• Showing the structure of textile companies• Explaining if and where data are available

Mapping to Data Structure – Scenarios


• Textile companies are not all the same– Weaving mills– Spinning mills– Third party finishing / dyeing– Others...

• The main concepts are similar – Generic structure

• We will ignore thousands of customizations

Structure of a textile ERP


Structure of a textile ERPArticles may be fabrics, twisted or simple yarns, raw

material

Bill of Material says which yarns

compose a fabric, which raw material

composes a yarn

A generic workflow is

associated to the article

Order rows will feed the

production management

module

The batch table contains all

pieces in production

The actual Workflow and Bill

of Material are updated while

processing


DS-S 1: online monitoring

The plant

department

department

department office office

department

heating

engines

lamps

refrigerators

dryers

Heat suppliers Heat dispersors

walls

windows

air exchange

Introduce or dispose heat ?


Department Process


Machine 1(loom)

Stage 1(weaving)

Stage 2

Stage 3

Machine 2

Machine 3

Ind. energy

Direct energy

Direct energy

Direct energy

Processes (examples)

Transformation from Yarn to FabricWet finishingPieces dyeing

RaisingStenter

Dry finishingFinal control and shipping


NAME PLACE UNIT DATA FORMAT CORR.

Electric power Sensors on machine, counter

KWh Sent on requestxml 15 minutes

+/- 2%

Gas Not categorized but no peaks

Cube meters per Hour

Xml (1 hour) +/- 5%

Steam Secondary. Measure of primary source

V[m3], P[bar], t[°C]

Water Consumption for heating and purification

V[m3], t [°C]

Compressed air

Consumption for production

V[m3]

Air conditioned

Offices, closed rooms V[m3] , t [°C] , humidity (%)



• Total energy splitted in – Direct Energy (used in production)– Indirect Energy (used in the infrastructure)

DS-S 2: mapping to production orders

E(U) = EDir(U) + EInd(U)

• Direct Energy:– Sum energy of stages: Etot = E(f1)+ E(f2)+...+ E(fn)– Divide by total amount: EDir(U) = Etot / Qta

• Indirect energy– [EInd(u)] = (EInd department/working time)*Unit

production time


• Divide articles in groups:– Begin from commercial groups defined in ERP• Similar stages• Similar machines

– Refine grouping by «macro process»• Similar stages in process

• Example: group products having similar stages in «textile transformation from yarn to fabric»

DS-S 3: model for product group: total


ID Process Elapsed time

A Transformation from yarn to fabric

8.6 min

B Wet finishing 9.7 min

C Piece dye-works 4.3 min

D Raising 0

E Stenter 2.7 min

... 0.5 min

Y Dry finish 3.1 min

Z Final check and shipping 1 min

DS-S 4: time profiles by group

• Compute the average time of permanence of each macro process for a unit of product:


DS-S 5: allocation for energy consumption

Generic model of energy consumption.

Energy consumer

Energy provider

Tells the provider how much energy is needed or stops the consumer

The workflow, a set of stages, generate

the energy consumption


• Energy used for maintenance and emissions– Solid emissions

• Fibers• Plastic• Packaging• ...

– Liquid emissions• Water• Oil• Chemical products• ...

– Gas emissions• CO2

DS-S 6: allocation of embodied energy


Q & A

artisan task 1.3

Documents