Sagar Manufacturers implemented Rieter’s ESSENTIALmonitor in 2021, combining it with the individual spindle monitoring ISM premium on their ring and compact- spinning machines
Digitisation is front and centre in Sagar Manufacturers’ relentless mission of continuous improvement. Based in India, the company has made a name for itself in just over a decade of operations and now exports to more than 20 countries and partners with more than 200 brands. Since using ESSENTIALmonitor, a module of the Rieter Digital Spinning Suite, Sagar Manufacturers recorded a noticeable increase in mill productivity of 1.5 per cent.
Sagar Manufacturers implemented Rieter’s ESSENTIALmonitor in 2021, combining it with the individual spindle monitoring ISM premium on their ring and compact- spinning machines. ESSENTIALmonitor provides real-time monitoring of machine parameters so that the company can always keep an eye on the performance of their machines. The system keeps track of interruptions on the ring spinning machines as well as machines and spinning positions that require adjustments.
ESSENTIAL displays the data in a cockpit where each user can see information that is customized to their role. Data tiles can be selected and re-arranged to meet individual requirements. The mobile app enables decision makers to get a 24/7 overview of the performance of their spinning mills. The mill managers have access to all data in a user-friendly cockpit on their desktop and can drill down to every detail, identifying areas that require improvement. The overview on the dashboard in the spinning mill helps operators and shift supervisors to identify the root cause of production disruptions (Figure 1).
The implementation of ESSENTIALmonitor with ISM premium brought numerous benefits to Sagar Manufacturers:
⦠An increase in productivity of 1.5 per cent,
⦠A reduction in manpower requirements of 10 per cent,
⦠A decrease in hard and soft waste of 10 per cent and 2.5 per cent, respectively, and
⦠An expected improvement of plant utilisation amounting to 0.1 per cent.
The features ‘Improvement suggestions’ and ‘Threshold trigger’ in particular have helped the company to avoid stoppages and maintain quality. ‘Improvement suggestions’ enables intelligent mill maintenance. It analyses sensor data from critical machine components and identifies deviations. With ‘Threshold trigger’, the user sets threshold values and is informed by e-mail or SMS when these are missed or exceeded.
A K Saini, Chief General Manager (Operations) of Sagar Manufacturers stated, “We appreciate the support from the Rieter team very much and feel that our needs are understood. The full utilisation of ESSENTIALmonitor has allowed us to optimize the performance over the entire process. We are excited to see what the future of the system holds†(Figure 2).
About Sagar Manufacturers
Sagar Manufacturers is a leading Indian textile manufacturer established in 2012, operating in the fields of spinning and knitting. They produce ring yarn from Ne 20 to Ne 44 under the brand ‘Sagar Yarn’. The company exports to over 20 countries and partnerships with more than 200 global brands. Their commitment to using the finest fibres and the latest technologies has earned the company a reputation as a trusted brand in the global textile market.
About Rieter
Rieter is the world’s leading supplier of systems for manufacturing yarn from staple fibres in spinning mills. Based in Winterthur (Switzerland), the company develops and manufactures machinery, systems and components used to convert natural and
man-made fibers and their blends into yarns in the most cost-efficient manner. Cutting-edge spinning technology from Rieter contributes to sustainability in the textile value chain by minimizing the use of resources. Rieter has been in business for more than 225 years, has 18 production locations in ten countries and employs a global workforce of around 5 600, about 16 per cent of whom are based in Switzerland.