The Textile industry fulfills one of the basic needs of humankind and is centered on long-term value creation for its consumers. Though the textile industry is involved in converting fibers into yarn through various machinery, it frequently faces a setback in its manufacturing process, incurring an annual loss of 2.6%.
For a fabric industry, profitability is a concurrent execution of efficiency and potency of the equipment. According to the recent survey conducted by the International Textile Manufacturers Federation, approximately 80% of the garment industries implement Total Preventive Maintenance strategy in their plants to boost their production, decrease downtime and ensure the fall in production rejection by 20%.
The comprehensive preventive maintenance strategy blurs the specific maintenance needs of the specialized equipment and authorizes a mandatory planned shutdown every three months or 1000 hours of operations. This implies loss of equipment uptime, ensuring a stock of spare parts, and streamlining communication between departments to establish actionable protocols. Regular supervision in the textile plant complies with the regulations and certifications but may result in improper resource allocation and outrage of employees.
Maintenance of critical equipment that moves with relatively high speed must be recorded and documented for auditing purposes. They are carding elements, flat to cylinder setting, bearing locations, front auto leveler surroundings, couplings, engineering rotating components, rotary tubes, mechanical fittings, filters, flow regulators, auto-lubricators, textile finishing machinery, dryers, dyeing, and sizing machines
Moreover, the depiction of the degradation of textile machines involves some degree of uncertainty and unreliability. Remote and instantaneous inspection of the performance of a pump that pumps hazardous chemicals confirms safety in the plant and assures the lowest pollution level. Further, blowing compressed air is one of the essential requirements of the textile industry, particularly in the process-machines from blow rooms, carding, spinning, winding, weaving, etc. Monitoring the vibrations of these blowers, detecting the variation, predicting the need for servicing, diagnosing the exact root cause of misbehavior, and recommending a corrective action can avoid air leakage, conserve loss of Rs. 60-72 Lacs per annum and prevent an unexpected breakdown in the plant. Each modern machine in the textile plant is complex in design and functioning. Predictive maintenance bundled with Diagnostic Services eases and prioritizes Maintenance activities.
Infinite Uptime’s Diagnostic services integrated with a Predictive Maintenance Solution with a Patented Vibration Monitoring System is a complete end-to-end solution for textile industries. The system comprises plug-and-play hardware for data acquisition, AI-driven analysis based on the data interpretation displayed on the user-friendly software dashboard, and actionable remedial actions to maintain the reliability of the equipment and stop the machine failure. The adherence of an edge-computing technology in its hardware further enhances and improves the KPIs of the equipment.
The real-time insights with detailed Observations, apt Diagnosis followed by executable Recommendations (ODR) demonstrated on the Dashboards with drill-down views of machinery encourages equipment-users to anticipate the health of the asset and schedule diagnostic services accordingly. The independent IoT platform not only notifies the registered authorities about the steps to be taken for maintenance but also maintains a history of such activities. It can be accessed from the comfort of their homes on the PC, Laptop, mobile, or other gadgets.
The holistic approach supported with diagnostic algorithms eliminates the requirement of expert knowledge and experience. This pioneering service significantly simplifies the machinery audit and leverages machine learning-led predictive maintenance solutions to reduce asset downtime.