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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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Viewing and reporting
of consumption amounts and costs on the basis of work
orders, shifts and machines |
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Viewing and reporting
of production unit costs on the basis of work orders,
shifts and machines |
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Comparison of costs
between machines |
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Viewing and reporting
of production amounts on the basis of work 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, work orders |
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Summary report on
dye house production |
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| Error
Free Batch Start 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 work 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 work 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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| 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 |
| • |
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 |
| • |
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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| 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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| 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 |
| • |
Monitoring stopping
with causes (idle, cleaning, breakdowns etc) |
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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 |
| • |
Inclusion of the
water counter, vapor counter and natural gas counter consumptions
in the workplace in the system |
| • |
A structure that
can be integrated to the ERP System in the workplace |
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| REFERENCES |
|
AKKİM
ARÇELİK (Eskişehir)
BAYDEMİRLER
CAMELYAF
CAMELYAF
ÇAYIROVA GLASS
DEMİRDÖKÜM
ECZACIBAŞI - 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
Fýrýn/Bath/Cooling Data Acqusition and Reporting
System |
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Industrial
Automation Dep.- eo@eliar.com.tr |
