Technology, and the breathtaking pace at which it has evolved, has brought a new reality: Industry 4.0. Trends such as Cloud Computing, Big Data and the Internet of Things offer industrial managers unprecedented possibilities for increasing productivity, differentiating their offering and controlling every process that takes place in the factory.

Of all these trends, IoT (Internet of Things) is particularly interesting. It is the term used to define the network in which any type of device or object is connected to the virtual world through the internet, with information exchanged bilaterally between machines.

When associated with industry, this concept is called the Industrial Internet of Things (IIoT), and it emerged with the use of ethernet on the factory floor at the level of sensors and IP-addressed technologies that combined information technology (IT) with operational technology (OT).

IIoT makes it possible to connect all the information from every process taking place in an industrial unit, coming from machines, products, services, systems or people. By analysing this information, it is possible to achieve more efficient production, increased productivity and operational excellence. According to a study carried out by TCS, industrial managers using IIoT solutions saw revenues increase by 28.5% between 2013 and 2014.

IoT technology in the clothing industry

Using the latest IoT technologies and sensing devices installed on the factory floor throughout the production process, Openlimits implemented a continuous Just-in-Time Monitoring System on the production lines of a leading company in the clothing industry.

Production orders and all operations in progress are controlled through a Web Dashboard, with critical information presented in real time. This data is communicated directly from the sensing devices on the factory floor, which are connected to a factory wireless network and have a numeric interface and a barcode label reader that identifies the production orders in progress.

Building on this integrated IoT-based monitoring platform, Openlimits implemented an integrated Manufacturing system that involved Production configuration, Execution modelling and Production Analysis. The implementation of this system was also a critical step towards potential optimisation developments in "Supply Chain Management".

Production requirements

In detail, the System implemented by Openlimits meets the following Production requirements:

Production Configuration:

• Structuring of item technical sheets with colours and sizes;
• Classification and structuring of components in the technical sheets, in order to group the information to be printed when the production order is issued (interior, exterior, trims, packaging);
• Costing and quotation.

Execution Modelling:

• Requirements Calculation - Material reservations/supplier orders - confirmation of production orders;
• Recording of raw material and component consumption, and finished product receipts by colour and size;
• Changing the quantities to be produced when fabric runs out, adjusting reservations/new supplier orders for additional material requirements;
• Packing List.

Production Analysis:

• Stock inventory and forecast stock;
• Production analysis by production order - reservations/orders/consumption relationship;
• Estimated and actual costing;
• Periodic production analysis by: operation, production order, colours and sizes.

Conclusion

The new industrial revolution is completely transforming the secondary sector, and IIoT is one of its technology trends. The experience and knowledge of the Openlimits technical team ensures that all the ICT components in your organisation work in harmony, in a whole that extends to cyber-physical systems, communication networks, virtualisation and simulation, digitalisation, energy and environmental efficiency, artificial intelligence, and smart & new materials, applicable across a wide range of sectors and activities.

Written by:
Openlimits

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