Schneider Electric Case Studies Seamless digitization of light industry

	Seamless digitization of light industry Schneider Electric

Seamless digitization of light industry

Schneider Electric

Technology Category	Platform as a Service (PaaS) - Connectivity Platforms Analytics & Modeling - Real Time Analytics Functional Applications - Remote Monitoring & Control Systems
Applicable Industries	Apparel
Applicable Functions	Discrete Manufacturing Quality Assurance
Use Cases	Predictive Maintenance Factory Operations Visibility & Intelligence Inventory Management Edge Computing & Edge Intelligence
Services	System Integration Cloud Planning, Design & Implementation Services
Challenge	ROSO Automation Technology Co., Ltd. is a high-tech enterprise specializing in the research and development, production, and sales of zipper dyeing production lines. The company faced challenges in digitizing their machines and transforming from simple to smart manufacturing. Traditional zipper production was labor-intensive, incurring high labor costs with low product added value. The company also had to deal with the dual challenges of manufacturing and operation due to its business model of providing operating services to zipper manufacturers. The lack of digital systems in production and operation at the factory led to errors and omissions during material handover, inconvenient management of onsite logistics, and confusion regarding the locations of finished and semi-finished products. There was also no adequate mechanism for managing the dyeing formulas, which are central to the dyeing process. Read More
About Customer	ROSO Automation Technology Co., Ltd. is a high-tech enterprise based in Chengdu, China. The company specializes in the research and development, production, and sales of zipper dyeing production lines, providing the most complete production lines in the industry. For years, its cloth belt shaping technology has been helping domestic zipper enterprises greatly improve product quality and effectively reduce production costs. ROSO operates in a highly competitive industry, with China being the world’s largest manufacturer and exporter of zipper products. The company has adopted a unique business model by offering their operating services to zipper manufacturers, in addition to providing customers with a complete set of production line equipment for zipper dyeing. Read More
Solution	To address the cost, efficiency, and management challenges at the factory, ROSO implemented a zipper dyeing production line using Schneider Electric’s EcoStruxure Machine solution. The hardware system, including Modicon PLCs, frequency converters, Lexium servo drives, Harmony touchscreens, and low-voltage power distribution products, ensures the stability and reliability of the production line equipment. On the software side, EcoStruxure Machine Advisor and AVEVA’s System Platform provide support for the long-term operation of the production line. The jointly developed solution is based on AVEVA’s System Platform. The software can quickly develop a tailor-made information system on demand to complete order management, scheduling, warehouse management, and quality inspection. EcoStruxure Machine Advisor makes remote equipment maintenance convenient and efficient. Staff can also implement automatic parameter adjustments through Machine Advisor’s analysis center function to improve yield. Read More Log in to view content
Contents

Technology Category

Platform as a Service (PaaS) - Connectivity Platforms

Analytics & Modeling - Real Time Analytics

Functional Applications - Remote Monitoring & Control Systems

Applicable Industries

Apparel

Applicable Functions

Discrete Manufacturing

Quality Assurance

Use Cases

Predictive Maintenance

Factory Operations Visibility & Intelligence

Inventory Management

Edge Computing & Edge Intelligence

Services

System Integration

Cloud Planning, Design & Implementation Services

Challenge

ROSO Automation Technology Co., Ltd. is a high-tech enterprise specializing in the research and development, production, and sales of zipper dyeing production lines. The company faced challenges in digitizing their machines and transforming from simple to smart manufacturing. Traditional zipper production was labor-intensive, incurring high labor costs with low product added value. The company also had to deal with the dual challenges of manufacturing and operation due to its business model of providing operating services to zipper manufacturers. The lack of digital systems in production and operation at the factory led to errors and omissions during material handover, inconvenient management of onsite logistics, and confusion regarding the locations of finished and semi-finished products. There was also no adequate mechanism for managing the dyeing formulas, which are central to the dyeing process.

About Customer

ROSO Automation Technology Co., Ltd. is a high-tech enterprise based in Chengdu, China. The company specializes in the research and development, production, and sales of zipper dyeing production lines, providing the most complete production lines in the industry. For years, its cloth belt shaping technology has been helping domestic zipper enterprises greatly improve product quality and effectively reduce production costs. ROSO operates in a highly competitive industry, with China being the world’s largest manufacturer and exporter of zipper products. The company has adopted a unique business model by offering their operating services to zipper manufacturers, in addition to providing customers with a complete set of production line equipment for zipper dyeing.

Solution

To address the cost, efficiency, and management challenges at the factory, ROSO implemented a zipper dyeing production line using Schneider Electric’s EcoStruxure Machine solution. The hardware system, including Modicon PLCs, frequency converters, Lexium servo drives, Harmony touchscreens, and low-voltage power distribution products, ensures the stability and reliability of the production line equipment. On the software side, EcoStruxure Machine Advisor and AVEVA’s System Platform provide support for the long-term operation of the production line. The jointly developed solution is based on AVEVA’s System Platform. The software can quickly develop a tailor-made information system on demand to complete order management, scheduling, warehouse management, and quality inspection. EcoStruxure Machine Advisor makes remote equipment maintenance convenient and efficient. Staff can also implement automatic parameter adjustments through Machine Advisor’s analysis center function to improve yield.

Impact #1	The digitized production line has transformed the factory in Fujian, making the zipper dyeing process fully automated from order placement to end-product.
Impact #2	The scheduling system meticulously calculates order priority, equipment status, and order date, ensuring optimized equipment use and reducing production conflicts and delays.
Impact #3	A digital verification system ensures that the correct raw materials are delivered from the warehouse per the automatically generated work orders, preventing errors and increasing efficiency.

Impact #1

The digitized production line has transformed the factory in Fujian, making the zipper dyeing process fully automated from order placement to end-product.

Impact #2

The scheduling system meticulously calculates order priority, equipment status, and order date, ensuring optimized equipment use and reducing production conflicts and delays.

Impact #3

A digital verification system ensures that the correct raw materials are delivered from the warehouse per the automatically generated work orders, preventing errors and increasing efficiency.

Benefit #1	Overall efficiency of ROSO’s production lines has improved by 10%-20%
Benefit #2	Energy usage has dropped by 20%

Benefit #1

Overall efficiency of ROSO’s production lines has improved by 10%-20%

Benefit #2

Energy usage has dropped by 20%

Download PDF Version

Overview

Seamless digitization of light industry

Operational Impact

Quantitative Benefit