automation in home textile

Atomization in Home Textile

GHCL Limited -Information Technology


System Simplification –Complex to user-friendly

Accuracy- Eliminate Data entry mistake. Speed- Improve user activity speed Reduce paper work and Duplicate entry Reduce IT cost –SAP Licence and other Quality improvement in IT service

Agenda

GHCL Limited -Infromation Technology

Before Implemented• Data collection from shop

Floor • Paper copy preparation• Paper copy covert to Excel

document• Data Entry in SAP• SAP document generation• Skill User requirement • Report & Analysis • More time and manpower

engagement

After Implemented

• Shop floor data entry by work man

• On Shop floor document Printing

• Update data in SAP• More System validation• Less skill person require


Std SAP Steps V/s IT Automated steps


?• Data entry in SAP… ?• Duplication of data entry…? • Real time data in system……?• IT cost reduction …?• Skill user ….?


Why this Requirement ?


Weaving

Inspection

Cutting

Madeups

Implemented Project-Interface


Weaving Automation

• TsudoKama M/c data transfer to SAP• Weaving performance online Display• Auto message for Performance to

Manager


Weaving Automation

Looms Shed


• Earlier 162 loom data collection by manually • Time required for this activity – 4 hrs /Shift/Per Deo• Tsudo Kama to TLM data transfer then convert to

Excel and Upload in SAP• Online data performance monitor for loom shed• SMS system to Highlighted Production data • After implemented time require 10 min/ Shift /Per Deo• More data accuracy ,less time consumption • Hardware cost-62K +1.63 Lacs=2.25 Lacs

Weaving Automation


Inspection Automation


• More than 1L meter , 450 Rolls data need to update in SAP

• Per roll required 20 Min Entry time • Manpower Utilization -2 Deo/Shift required to finish this

entry But data accuracy ?• Now on Inspection machine operator entre data with In-

house developed software • VB Data FTP SAP• Online data for analysis, More accuracy• Now 1 Deo / Shift Handle this activity• Implemented cost- Hard ware -4.50 Lacs

Inspection Automation


Cutting Automation


• More than 1L meter , 40 Batch Production data need to update in SAP

• Per roll required 15 Min Entry time • Manpower Utilization -1 Deo/shift• Now on shop floor operator entre data with

validation• Online data for analysis, More accuracy• No requirement of Deo• Implemented cost- Hard ware -1.2 Lacs

Cutting Automation


Madeups Automation


• More than 1L meter , 15,000 Sets data need to update in SAP

• 4/5 SAP entry screen required Book Production • Manpower requirement -1 Deo/shift/Location• Now on shop floor operator entre data• Data update in sap with automation system • Under Implementation- Hard ware cost-60k

Madeups Automation


• Shop floor Data entry – VB software • Data Fetching – FTP server• Hard ware – Touch screen monitor,Barcode

scanner ,Tvs Printer • SAP- Bapi

Technical Specification


Benefits …..In glance

Sr No Dept Implement cost

Benefit cost Manpower

Before DEOManpower

After Imp DEO Manpower

Time Saving

1 Weaving 2.25 2 4 2 3.50 Hrs Shift/DEO

2 Inspection 4.50 2 6 4 3 Hrs shift/DEO

3 Cutting 1.2 2.40 3 0 8 Hrs /shift

4 Madeups 60K - - - -


Thank You


Question …..

automation in home textile

Small Business & Entrepreneurship