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MONITORING LINE EFFICIENCY USING IOT
PRESENTED BY - SHELCY S ALEX
MENTOR - S.PRABHAKAR
METHODOLOGY
AT A GLANCE
LITERATURE REVIEW
OVERVIEW
INTRODUCTION
- The conventional method of monitoring efficiency in garment industry is to collect the number of pieces produced per hour by each line manually and entered in the website
Human interaction
Time consuming
IOT
IOT
No Human to human interaction
No Human to computer interaction
OBJECTIVE
To collect the real time data from end of the production line ie; number of pieces passed at each line
To develop a visual interface which displays the real time information from each line for finding the efficiency.
73%
REAL VIEW
DEFECT PIECES
ADC & NODE MCU
PASS PIECES
WI-FI
How it is calculated?
For example,
If 3 garments are put into the bin of size XXS,M and XXL.
Change in weight =(350+390+430)/350=3.3 ~ 3 garments
Efficiency calculation
- Garment : Men's trouser
- SAM of the garment : 30
- Number of operators : 60
- Target = (Number of operators *total man minutes)/SAM = 960 pcs per day
- Pieces produced per min = 960/480 = 2 pcs per min
Efficiency=(16/22)*100=76%
2 pcs
4 pcs
20 pcs
21 pcs
22 pcs
1 min
2 min
10 min
11 min
12 min
SENSOR
Literature review
IOT Based Water Quality Monitoring System
Analysis on Production Efficiency of Lean Implemented Sewing Line
Efficiency
EFFICIENCY=(PRODUCED QUANTITY/PRODUCTION TARGET QUANTITY)*100
PRODUCTION TARGET QUANTITY = (TOTAL MAN POWER*TOTAL WORKING MIN PER DAY)/SAM
The above values can be obtained from
Produced quantity - from sensors
Total man power & SAM -from input data through website
Total working min per day -480min
METHODOLGY
PROBLEM IDENTIFICATION
AFTER
BEFORE
PROBLEM IDENTIFICATION
SYSTEM DESIGN
NODE MCU
ADC
SYSTEM ARCHITECTURE
WEIGHT SENSOR
LOAD CELL
CAPACITY
CALCULATION
SENSOR
CAPACITY : 350kg
WORKING
WORKING
ANALOG SIGNAL
(VOLTAGE)
WEIGHT (FORCE)
GARMENT WEIGHT
800
*For XL size
CALCULATION FOR SELECTING CAPACITY OF THE SENSOR
- AVERAGE SAM = 25
- NUMBER OF OPERATORS = 60
- TARGET = (480*60)/25 = 1152 PCS
- FACTORY EFFICIENCY = 75%
- PIECES PRODUCED PER DAY= (1152*75)/100= 864 PCS
- MAXIMUM WEIGHT OF THE GARMENT = 800gm
- TOTAL WEIGHT =(864*800)/2+EXTERNAL WEIGHT(BIN & SETUP WEIGHT) ~350kg
ADC
ANALOG TO DIGITAL CONVERTER
MODEL : HX711
WORKING
DIGITAL SIGNAL
(BINARY)
ANALOG SIGNAL
(VOLTAGE)
POWER TO LOAD CELL
NODE MCU
MICROCONTROLLER
MODEL : ESP8266
OPEN SOURCE IOT PLATFORM
FEATURES
TYPE
SINGLE BOARD
FEATURES
MEMORY
128 KB
STORAGE
4 MB
POWER
USB
WIFI ENABLED
CIRCUIT DIAGRAM
CIRCUIT DIAGRAM
Algorithm
Algorithm
STEP 1: Enter the weight of smallest garment and the target per hour
STEP 2: Check the reading from the weight sensor
STEP 3: If change in weight divided by the weight of smallest size of garment the given value is added as the number of pieces for pass as well as defect pieces
STEP4: Number of pieces produced divided by the target per min will give the efficiency of line
STEP5: Store the value in the local memory of microcontroller
STEP6: The value is send to the thing speak cloud
STEP7: The value is displayed in the thing speak website
WEBSITE VIEW
MOBILE VIEW
PROJECT TIMELINE
COST
RETURN ON INVESTMENT
Bulk costing
- Setup cost for one line = Rs.3,062
- Cost for 8 line =Rs.24,492
- Operator's Salary =Rs.8400
- Other stationary=Rs.500
- ROI= 2.6 months
Scope
Advantages
Disadvantages
Advantages
Reduce manpower
Cost effective
No training required
Easy to monitor efficiency
Disadvantages
- If weight is increased due to falling of other than garment into the bin can give wrong efficiency
- Sensor is very sensitive in case the weight exceed the premsible limit it can get damaged
SCOPE
- The data stored in cloud can be used for predicting the learning curve, so the efficiency can be improved and learning curve period can be reduced which is application of artificial intelligence
- Can be used in finishing floor to find the number of pieces produced by each operator