Automation in Home Textile

1. Atomization in Home Textile
GHCL Limited -Information
Technology

2.  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
GHCL Limited -Information Technology
Agenda

3. 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
GHCL Limited -Infromation TechnologyGHCL Limited -Information Technology
Std SAP Steps V/s IT Automated steps

4. ?
• Data entry in SAP… ?
• Duplication of data entry…?
• Real time data in system……?
• IT cost reduction …?
• Skill user ….?
GHCL Limited -Infromation TechnologyGHCL Limited -Information Technology
Why this Requirement ?

5. Weaving
Inspection
Cutting
Madeups
GHCL Limited -Information Technology
Implemented Project-Interface

6. GHCL Limited -Information Technology
Weaving Automation
• TsudoKama M/c data transfer to SAP
• Weaving performance online Display
• Auto message for Performance to
Manager

7. GHCL Limited -Information Technology
Weaving Automation
Looms Shed

8. • 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
GHCL Limited -Information Technology
Weaving Automation

9. GHCL Limited -Information Technology
Inspection Automation

10. • 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
GHCL Limited -Information Technology
Inspection Automation

11. GHCL Limited -Information Technology
Cutting Automation

12. • 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
GHCL Limited -Information Technology
Cutting Automation

13. GHCL Limited -Information Technology
Madeups Automation

14. • 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
GHCL Limited -Information Technology
Madeups Automation

15. • Shop floor Data entry – VB software
• Data Fetching – FTP server
• Hard ware – Touch screen monitor,Barcode
scanner ,Tvs Printer
• SAP- Bapi
GHCL Limited -Information Technology
Technical Specification

16. GHCL Limited -Information Technology
Benefits …..In glance
Sr No Dept Impleme
nt cost
Benefit
cost
Manpo
wer
Befor
e
DEO
Manp
ower
After Imp
DEO
Manpow
er
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 - - - -

17. Thank You
GHCL Limited -Infromation TechnologyGHCL Limited -Information Technology
Question …..