Process Automation & Control System (PACS) Ventura Automation Services Inc Chennai.

Process Automation &

Control System (PACS)

Ventura Automation Services IncChennai

Objectives of the Project

Management Perspective

Eliminate all Manual Data Entries of Process House Reduce Manpower for Data Entry Track time based movements of fabric for better delivery forecasting Structured feedback on quality issues Fix responsibility on individual performance 0% Error data or 100% Accurate Data Upload & Download information Automatically to CAMS Online or Real-time information to Management One time automation & life long benefits

04/18/23 All Rights Reserved - Ventura Automation Services Inc

Objectives of the Project

Floor Level Perspective Find LOT whereabouts Identify LOT-wise Elongation & Shrinkage Reduce manual errors on batching

Style wise grouping Automatic length Measurement per batch

Machine wise production & utilization report Machine Stoppage Report Employee wise production report Employee Wise Efficiency Report RPM/MPM Data


The Flow Acquire Process Work Center details from CAMS Allocate “BATCH & LOT” details to Work Center DATA Received from CAMS are as follows

BATCH # # of LOTS Required for Particular BATCH # Grey Rolls Required for LOT Work Center Allocated for LOT Grey Roll Details Such as

Roll # Roll Meter

Total Meters for LOT Work Center Allocated for LOT

Work Center Allocated for BATCH


The Flow Continued

Ist Process - Batching Group Similar Process styles/Work Order /Based on Work Center for grey

fabric jumbo roll batching Batch May contain multiple LOTS Display “BATCH#” while batching in touch screen Option to Select LOT# would be provided Once “LOT” is selected Show “ALL ROLL#” in Touch Screen Now “ ROLL#” need to be selected under a “LOT” Control 1: Wrong Roll # Cannot be Selected under a LOT Control 2: Cannot Exceed Maximum Allowance in Meterage of ROLL meter Control 3: Wrong Roll Selection is not possible since roll# for the batch is decided by ERP


The Flow Continued Measure each Roll length Derive LOT Meters Add multiple LOTS & derive Batch Meter Store Batch Meters in CAMS Server with Following details

# of LOTS in BATCH # Rolls in LOT Batch Start Time Batch End Time This meterage could be later verified with Grey Inspection

End Batching Make Two RFID Cards on System Provided near batching machine

RED for BATCH & GREEN for LOT Tie the RFID Cards with BATCH & LOT Cards Update LOT information to CAMS Database04/18/23 All Rights Reserved - Ventura Automation

Services Inc

The Flow in Block Diagram


The Flow… Continued

Process Flow 2: BATCH – WORK CENTER 1 Place the RED RFID card in the Slot Provided

Then Select Emp. Code#(Kindly note: Without placing the card on the slot or without entering employee

code the machine cannot be started) then START

When the machine is stopped for more than 30 seconds the relay would be triggered & user cannot start the machine without entering the stoppage code

@De-Sizing, To end the batch, press end doff key Remove RFID Card and use it for NEXT Process Upload DATA to Server Do similar for All following processes04/18/23 All Rights Reserved - Ventura Automation

Services Inc

Work Flow…. Splitting LOTS A computer would be provided in Process House with RFID writer

Multiple computers with RFID writer need to be provided in case of multiple sheds

In case a LOT is split a new LOT# to be created in Sync with CAMS with following details Original LOT# Meters in Original LOT# Wastage Meters Meters in newly created LOT# Authorized person name


Components of PACS

Process Automation & Control System

This is required At Each Machine Except Batching Machine Programmable Logic Controller Rotary Encoder (To Measure Linear Length of Fabric) Relay 1 (To identify Machine Run/Stop status) Relay 2 (To forcibly send stop signal to machine to get stoppage information) RFID Scanner

Control 1: Prevent LOTS/BATCHES loaded in wrong work center Control 2: Which LOT/BATCH is under production process

RFID Cards – (# of A Frames + # Trolleys * 5 times) Wireless Module (Optional) Machine – Human Interface

To get Employee Code To get Stoppage Code

Defect Code Sheet04/18/23 All Rights Reserved - Ventura Automation

Services Inc

How Does it Work? As soon as A LOT/BATCH is received from earlier process RFID Card to be placed on holder Enter the employee # Press Start button You can set Hinging Time (Assume 45 Seconds) If the machine is stopped beyond Hinging Time a Relay would be triggered by

PACS. The machine cannot be started without entering valid stoppage code. One or Two encoders or Proximity Sensors would be fixed in starting & delivery

point to measure linear length of fabric.


Exceptions Handling

Making BATCH / LOT Stitch Joints Aluminium Sticker Foils need to be pasted on fabric before making a joint & to be

stitched on top of the foil. To ensure this foil is not peeled of due to wetness

Proximity sensor would sense the joint and sends information to the PLC & signal would be generated to place the LOT/BATCH card on the SLOT

Beep Alarm RED Light indication Hi – Sound indication

Machine can be stopped based on configuration if the Card is not placed within mentioned timeframe


Product Specifications Process House Data Acquisition System

All products supplied would be IP65 grade products Industrial Graded Open Standards Based Ports Provision assuming 30% Expansion SMPS power supply Memory backup of information in case of power failure Option for Joint Software Development Option to provide source code for internal use Seamless integration with CAMS & NOW


Software SpecificationsKindly Note: This would be extension of FIDAS for end to end data integration

purposes. Hence no separate server or operating system or database required. Separate software module need to be developed for style based segregation &

display of Grey inspected rolls for selection in touch screen monitor in batching machine.

Unique 5 digit batch# generation & storing in database Create a Work Center flow module for Mercerized & Non-mercerized fabrics Make LOT# available till final inspection. Generate multiple reports Integration with CAMSKindly Note: This generic specification outline only. Complete specifications will be

known after discussing with the production & IT teams


Communication Architecture

‘

CAMS Database Server

PACS Server

Process 1

Process 2

Process 3

Process ‘N’

LOT Splitting NodeFinal Inspection

BATCHING Node


Details to be Acquired & Sent Acquired from CAMS

Batch # Work Center LOT# Work Center Grey Roll#, Roll Meters

Acquired & Sent from Machine Batch Meters Stoppages Production Employees Start Date/Time & End date/time of each BATCH/LOT


Reports Machine wise production report Machine wise utilization report Employee Performance Report Batch wise Shrinkage & Elongation reports Style behavior Analysis Reports Batch Split Reports CAMS Integration Reports Other specific reports as asked by End Users


Other features Auto Email Generation Auto SMS Alerts Machine wise Real-time production Display through LCD Screen Plan Change at Floor level management Machine Stoppage control through system Forward & Backward integration with fabric inspection Software


Perceived Benefits Avoid manual Entries & human data entry errors for CAMS Reduce manual entry operators for CAMS Standardized methodology for identifying elongation & Shrinkage Online information on batch whereabouts Helps in production planning based on style behavior End to end data flow starting from roll doffing in loom shed till dispatch. Avoid style mixing while batching Identify pending grey rolls waiting for batching


For Enquiry & Clarifications

Contact :

O. Regis Xavier

Ventura Automation Services IncHand Phone: 0 99629 36356

Email: [email protected]: www.venturaautomation.com


Process Automation & Control System (PACS) Ventura Automation Services Inc Chennai.

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