Ever-growing costs, never-ending market demands, incalculable expenditures, changing customer demands, untraceable production line, failure in locating the errors, and a lot more; it is obvious that textile wet processing is getting only tougher, and we know there is a lot to be improved.
Considering the need for transformation of the textile industry within the framework of sustainable production, we can evaluate that in the next decade, the challenge will be a lot more than today, and the success will be based on three main steps:
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Textile enterprises that do not perform sustainable clean production management, will not be able to continue their lives
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If they would not perform real-time cost and deadline management, they will fall behind the competition.
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The importance of predictive and intelligent production management will provide textile enterprises the strength for production efficiency.
Digitalisation is The Key to Achieving Sustainable and Clean Production Goals
Today, it is no longer enough for your factory only to be productive and profitable. The use of energy, chemicals, dyestuffs, and water you need while producing both consumes limited natural resources and harms the environment by generating CO2 emissions and wastes. A digitalised production process in your factory provides instant monitoring of each stage of your production in a transparent and backward traceable manner integrated with your supplier channels. It helps you to keep your consumption in a minimum level by optimising your production.
It also helps you to check your compliance with MRSL (Restricted Substance Production List) and ZDHC (Zero Waste in Hazardous Chemicals) instantly. Digitalisation of textile processes also provides instant data and reports for ınternational audit ınstitutions on cleaner production and detects and reports anomalies.
The Strength of Real-Time Cost and Production Analysis
Flying a massive aircraft, the captain makes many decisions by looking at a few critical key indicators generated from thousands of data on the plane. Similarly, you must look to the hundreds of reports and data to make sure that the machines, human resources, energy, and raw materials in your factory are used effectively. Most of the time, these reports arrive too late; they reach you just as the aircraft engine catches fire and stalls, plunging towards the sea. Whereas a digitalised factory by Eliar instantly shows you the most critical data you need, for seeing the major picture.
Today, OEE is the most basic indicator used to measure the efficiency of all factories. It expresses the capacity of your factory, how much you can produce using this capacity, and how much of your production is of the expected quality as a single number. Whether your capacity decreases for some reason (inoperative machines, decreased energy capacity, raw material, human deficiencies etc), you become unable to use your current capacity (downtimes, losses, wastages, breakdowns etc), or you experience errors in production (repairs, additions, re-operations etc), the ELIAR Digital Factory shows you all these instantly and provide you with an in-depth analysis to reach the source of the problem.
The Effectiveness of Instant Trend and Anomaly Analysis
While thousands of transactions are carried out in your factory, hundreds of thousands of data are generated. These include raw material and energy consumptions, downtimes, repairs, errors, losses, wastages, malfunctions. Thousands of transactions that you cannot control cause increased costs, delayed products, and thus customer dissatisfaction. The ELIAR Digital Factory instantly monitors every single process, from the cabin temperatures of a night shift of stenter to the motor chain speed, or from the tower speeds in your dyeing machine to your heat exchanger efficiencies. It checks the accuracy of the processes, consumptions, predicts malfunctions before they occur and informs you if there is an abnormal situation. It predicts the production orders that will exceed the planned cost or the ones that do not reach the deadline, and informs you before any burden being faced.
Aggregating all the improvements, the picture of the annual saving of automation and digitalisation is simply amazing. Thanks to the optimisations provided by ELIAR for the textile industry, while doing all these by automation systems, it also reveals how your customers can express the benefits they provide to their consumers and supply chain by reducing the resource consumption of the products offered to their customers, by using their resources correctly, and how they stand out from their competitors with this method they prefer. As so, the future will be a period of innovative and idealistic enterprises that provide sustainable production.
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