Upgrading from Manual Transcription to Real-time Monitoring with Advantech’s Industry 4.0 Capabilities
Company Size
1,000+
Region
- Asia
Country
- China
- Indonesia
- Vietnam
Product
- Advantech’s process visualization solution
- iFactory Solution Ready Package (SRP)
- WebAccess/SCADA software
- WISE modules
Tech Stack
- Real-time manufacturing visibility system
- Wireless data acquisition
- Embedded automation platform
Implementation Scale
- Enterprise-wide Deployment
Impact Metrics
- Cost Savings
- Digital Expertise
- Productivity Improvements
Technology Category
- Application Infrastructure & Middleware - Data Exchange & Integration
- Platform as a Service (PaaS) - Connectivity Platforms
Applicable Industries
- Apparel
Applicable Functions
- Discrete Manufacturing
- Quality Assurance
Use Cases
- Manufacturing System Automation
- Process Control & Optimization
- Real-Time Location System (RTLS)
Services
- Software Design & Engineering Services
- System Integration
About The Customer
The Ching Luh Group is one of the world’s leading sports footwear manufacturers with manufacturing locations in China, Vietnam, and Indonesia. The firm has won the favor of some of the world’s leading sports brands, producing major sneaker lines for them. Moreover, to maintain its cutting-edge reputation, the firm has been quick to optimize its traditional manufacturing processes with the help of Industry 4.0 solutions from Advantech. The Ching Luh Group understood that it was imperative to build a mature ICT infrastructure with a practical management platform to rapidly and efficiently integrate machines and their data. Such comprehensive, real-time integration makes key manufacturing information highly transparent, enormously increasing opportunities for optimization and improvement.
The Challenge
The Ching Luh Group, a leading sports footwear manufacturer, was facing the challenge of automating the collection of real-time production information from manual transcription. The traditional approach of manually recording and entering data into a computer system was cumbersome, slow, and prone to errors and inconsistencies. This outdated method prevented managers from having a firm grasp of the real-time production status, hindering the ability to make meaningful improvements. In today’s fiercely competitive market with rapidly changing customer demands, a shoemaker that persists with this outdated approach risks devastation at the hands of competitors. With the advent of Industry 4.0 and associated smart factory technologies, shoemakers and other textile manufacturers must adapt or die, sink or swim.
The Solution
In early 2017, the Ching Luh Group introduced Advantech’s process visualization solution at its factory in Vietnam in order to build a real-time manufacturing visibility system for the factory floor. Based on Advantech’s iFactory Solution Ready Package (SRP), this solution allowed the firm to develop its own specifically developed application functions. The iFactory SRP drastically reduced system development time, allowing intelligent applications to be implemented with ease and simplicity. It also efficiently integrated Advantech’s embedded automation platform, WebAccess/SCADA software, and wireless data acquisition WISE modules, shortening the implementation schedules for real-time equipment monitoring, manufacturing processes, and energy consumption systems.
Operational Impact
Case Study missing?
Start adding your own!
Register with your work email and create a new case study profile for your business.
Related Case Studies.
Case Study
Fire Alarm System and Remote Monitoring Sytem
Fire alarm systems are essential in providing an early warning in the event of fire. They help to save lives and protect property whilst also fulfilling the needs of insurance companies and government departments.Fire alarm systems typically consist of several inter-linked components, such as smoke detectors, heat detector, carbon monoxide, manual call points, sounders, alarm and buzzer. The fire alarm system should give immediate information in order to prevent the fire spread and protect live and property.To get maximum protection a shoe manufacturer in Indonesia opted for a new fire alarm system to monitor 13 production sites spread over 160 hectars. Although the company had an existing fire alarm system, it could not be monitored remotely.It was essential that the new system would be able to be monitored from a central control room. It needed to be able to connect to the existing smoke detector and manual call point. Information should be easily collected and passed on to the Supervisory Control and Data Acquisition (SCADA) system. Furthermore, the system should have several features such as alarm management, auto reporting, being connected to many client computers without additional cost, and run 24/7 without fails. The company also needed a system which could be implemented without changing the architecture of the existing fire alarm system.
Case Study
IoT Applications and Upgrades in Textile Plant
At any given time, the textile company’s manufacturing facility has up to 2,000 textile carts in use. These carts are pushed from room to room, carrying materials or semi-finished products. Previously, a paper with a hand-written description was attached to each cart. This traditional method of processing made product tracking extremely difficult. Additionally, making sure that every cart of materials or semi-finished products went to its correct processing work station was also a problem. Therefore, the company desired an intelligent solution for tracking assets at their factories. They also wanted a solution that would help them collect process data so they could improve their manufacturing efficiency.
Case Study
Retailer Uses RFID Scanner to Improve Efficiency
Patrizia Pepe wished to improve the logistics of their warehouse: accepting incoming goods from their production sites, movement of items throughout
the warehouse, and packaging of goods for distribution to the retail locations. They initially tried to use barcodes for this function. Because barcodes must be individually scanned within a line-of-sight, the acceptance of goods coming into the warehouse was too time consuming. Working with the University of Florence, Patrizia Pepe instituted a five-month pilot project beginning in August of 2009 to test the validity of an RFID solution. The pilot involved tagging of about 60,000 items for the second seasonal collection, and convinced the company to move forward with tagging all items.
Case Study
Monitoring and Controlling Automatic Mixing and Dispensing Machines
As technology advances, textile manufacturing has been transformed from a labor-intensive to a partially or fully automated industry. Automation is significant in all segments of textile production - from spinning to printing, and textile machinery manufacturers are constantly searching for new technologies and automation processes will increase the productivity of their machines. The color paste mixing and dispensing machine is an essential part of the printing and dyeing process. With the advantage of automatically computerized controls and database management, the system can significantly improve its dispensing precision, working efficiency and production quality as well as reducing material consumption.
