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Energy Consumption,
Production Reports and Cost Analysis with Real Data
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The production amounts such as length,
counts and weight received immediately by the Eliar
control devices and the consumption amounts such as
raw materials, electricity, water and vapor received
from counters connected to the main lines are recorded
into the system.
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Monitoring
and reporting of consumption amounts and costs on the
basis of job orders, shifts and machines |
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Monitoring
and reporting of production unit costs on the basis of
job orders, shifts and machines |
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Comparison
of consumption costs between machines |
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Monitoring
and reporting of production amounts on the basis of job
orders, shifts and machines |
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Daily
total dyeing amounts on Kg |
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Total
production report on the basis of date, machine no, job
orders |
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Summary
report on dyehouse production |
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to beginning >>> |
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Error Free
Batch Starting and Production Area Monitoring
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By the reading of the barcodes in
the accompanying cards, data such as program information
on the work order, operator code, weight and machine
speed are automatically loaded to the programmer.
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Starting
of planned work in the right machine with correct parameters
according to job orders |
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Blocking
of starting of unplanned work |
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Blocking
of passage to manual mode during automatic operation |
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Being
aware of errors in the dyeing parameters |
| The job order of
each party to be processed in the workplace are read by
the barcode readers assembled to the production machines
(boiler, ram, open width pre-shrinking, peaching etc).
Thus which party is at what stage and how long they have
been waiting at that stage can be monitored. |
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Graphical
monitoring of which parties are in the machines |
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Monitoring
and getting reports on the last condition of each party
and which stages they have passed through an how long
a time |
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to beginning >>> |
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Increasing
Quality and Ensuring Repeatability
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When a party is being processed in
the dry section, it can be monitored and recorded whether
the process variables such as pH, temperature, pressure,
humidity, flow, level, speed related to that process
are within the defined upper and lower limits. These
archived data form a very important source for both
increasing and repeating the quality in future processes.
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Graphical monitoring
of in-process variables such as pH, temperature, pressure,
humidity, flow, level and speed for each party |
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Warning when the
process variables pass the defined upper and lower limits |
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Storing, for each
party, of the process variables together with data related
to that party |
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Forming of a data
bank in time for the ensuring of the same quality |
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The reading and
recording of the real machine set values related to a
party and using of the same machine set values in a future
similar order |
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to beginning >>> |
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Follow-up of
Auxiliary Installations
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| The breakdowns in
auxiliary installations are immediately acknowledged through
signals received from the breakdown contacts. |
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Warning in machine
or device breakdowns |
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Data monitoring
for pressure, temperature and flow in auxiliary installations
and alarm or warning in critical levels |
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- Climate control
- Compressor pressures - Boiler pressure and temperature |
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- Cooling towers
temperatures - Hall temperature and humidity – External
environment temperature and humidity |
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to beginning >>> |
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Analysis of
Stopping Causes and Speed Optimization
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With the stopping time, period and
cause data received from the breakdown contacts and
sensors in various places of the machines in the dye
house or with the data entered via the hand terminals,
the conditions of all machines can be monitored in a
single display and stopping and productivity reports
on machines can be produced.
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Machine stopping
periods and causes received from the field |
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Entrance of data
that have to be entered manually via hand terminals or
barcode readers |
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Monitoring stopping
with causes (idle, cleaning, breakdowns etc) |
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to beginning >>> |
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Energy Automation
System
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No-problem passage
between the network and generator |
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Monitor and command
of generator, UPS and compressor |
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The Bucholtz and
thermic alarms of transformers |
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Monitor of current
and circuit breaker positions, command of powered circuit
breakers and recording of position changes |
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Fast and easy access
over the Ethernet depending on authority |
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On-line monitoring
of energy analyzers and protection relays in the AG and
OG panels and changing of parameters over the computer |
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Inclusion of the
water counter, vapor counter and natural gas counter consumptions
in the workplace in the system |
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A structure that
can be integrated to the ERP System in the workplace |
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Back
to beginning >>> |
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| REFERENCES |
|
AKKİM
ARÇELİK (Eskişehir)
BAYDEMİRLER
CAMELYAF
CAMELYAF
ÇAYIROVA GLASS
DEMİRDÖKÜM
ECZ.BAŞI - BAXTER
ECZACIBAŞI - VİTRA
EGE CERAMIC
ELİDA
İSKO ÇORLU
KÜÇÜKER TEKSTILE
MARSHAL
MONSANTO FOOD
PAŞABAHÇE GLASS
PAŞABAHÇE GLASS
POLİYA POLYESTER
SODA INDUSTRY
TEKNİK GLASS
TRAKYA GLASS
|
Central Monitoring
System
Test Rooms Humudity and Temp. Cent. Monitoring and SCADA
Sys.
Production Following and Reporting System
Drying and Reporting SCADA System
Central Monitoring and Alarm Recording SCADA System
2, 3 and 4. Furnaces Data Acqusition and Evaluating System
Central Data Acqusition and Reporting SCADA System
Central Data Acqusition and Reporting SCADA System
Monitoring System for Lavatory Bowl Test System
Monitoring System for Lavatory Bowl Test System
Central Data Acqusition and Reporting SCADA System
Dyehouse Data Acqusition and Reporting System
Continue Machines Tank Monitoring and Chemical Demand
Term. Sys.
Central Data Acqusition and Reporting SCADA System
Furnace Monitoring SCADA System
Product Counting and Production Control System
Cooling Monitoring and Control System
Tank Product Monitoring System
Data Acqusition and Reporting System
Furnace and Invertion Data Acqusition and Evaluating System
Furnace/Bath/Cooling Data Acqusition and Reporting System |
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