Industry 4.0 compliant shop floor scheduling of textile industry
Our project is an industry 4.0 compliant solution to automate industrial process and shop floors by real time communication of devices and integrated softwares and IoTs. Our industrial sector is lacking behind comparing to the smart and intelligent, fully automated and digiti
2025-06-28 16:33:07 - Adil Khan
Industry 4.0 compliant shop floor scheduling of textile industry
Project Area of Specialization Internet of ThingsProject SummaryOur project is an industry 4.0 compliant solution to automate industrial process and shop floors by real time communication of devices and integrated softwares and IoTs.
Our industrial sector is lacking behind comparing to the smart and intelligent,
fully automated and digitized industries abroad. Most of the work is done manually,
employing more and more manpower for less work. Most of the data keeping is done
on papers that is quite inefficient and unsafe in a sense that it can be either
lost or stolen or can easily be manipulated.
So we visited some industries to capture their processes and to come up with a
solution to automate and digitize their ecosystem to an extent that it could
compete to the outer world and also result in increased production of goods.
The system we propose to design is such that, we will build an IoT network of
devices which would be installed at various machines, working in industry that
will continuously monitor their state of work and show the respective output on
the dashboard. Once a task is done by a machine and sent to the next process,
the process done by previous machine is notified as completed on dashboard.
Hence the processes will be continuously monitored, scheduled and piplelined
resulting in decreasing idle time of machine and hence enhanced production.
Our main objective is to implement industry 4.0 compliant solution in a textile industry.
At first, we will design a software based model of the processes that were captured during the industrial visit and by proper understanding of the shop floor mechanisms. This software models helps to futher implement the desired intelligence system. We will be using bizagi studio framework for the management and monitoring system. The process flow of each shop floor will be designed at first and then using the information gathered from the aforementioned design, the data model will be designed. Also UI/UX will be designed using this framework and database and backend will be integrated to it.
Secondly , since our project includes an complete IoT network of sensors that
will be installed at various shop floors monitoring the jobs of that particular
shop floors.This network will aid in monitoring the performance of the installed
machine and the producing data for analysing the production of products. Also this
will aid in stock trafficking and employee work management.
Further addition to this project is integration of IoTs with control and monitoring management system and deploying services to a secure cloud infrastructure for real time service provision and effective data analysis.
Project Implementation MethodIndustry 4.0 not only means a change in technologies, it also provides an opportunity to consider and create new business models. Whether this change is optional or crucial will depend on the competitive environment – disrupt or be disrupted. A clear business model acts as a primary means of analysis, and provides clear gateways for progress.
For stakeholders, including employees, customers and suppliers, the use of a business model helps to drive understanding of the process, what is important and why.
The development of digitalisation-based business models impacts organisations across three key areas:
A. Optimisation – digitalisation can be used to enhance an existing business model. For example, the use of RFID/GPS to track the real-time status of components throughout the whole supply chain.
B. Transfer – taking a successful business model from one industry and applying it to another, where it was not used before. For example, load sharing resources between factories/businesses, in a similar fashion to the way in which car sharing works.
C. New model development – bringing together or developing new business models provides the opportunity for truly disruptive change.
What’s the current state in the plant and how connected are existing products? There are two aspects to consider and it’s important to establish how your new project will overlap in these areas.
Firstly, digital infrastructure can underpin a wide range of manufacturing activities, including data processing on the shop floor, machine-to-machine interfaces and company-wide networking within production. In each case, there can be distinct levels of maturity, for example machine-to-machine communication can vary from fieldbus interfaces, to machines that access the internet, and web services with M2M software.
The second area of maturity relates to products. Again, digitalisation touches upon many areas, including integrating sensors, connectivity, functionalities for data storage and exchange, and monitoring for performance assessment.
There are assessment tools and consultancy services available to assess and understand current levels, and help set readiness and maturity targets for the future. Digitalisation should be an evolution, not a revolution.
Benefits of the ProjectThis project is beneficial for industrial sector such that it will
excessivley reduce manpower and will digitize the processes and data collection techniques.
Though a few industries lies at the standards of industry 3.0 (we here focus on the
textile industries)but most of the industries are lagging quite behind in this
revolutionary development. This project will aid those industries those industries to
meet the industrial standards followed internationally.
Secondly , digitizing and automating the system will increase the efficincy of work
by reducing the manual work and thus increasing the production of materials.
Our country being an agricultural and textile enrich, requires that our export in this
should be increased so that more and more revenue can be generated. So main benefit
is that
Survey's and process identification and re-engineering: the first deliverable would be the initial businees model designed by using the information gathered from surveys and interviews of people of the specified industry.
Identification of IOT's and machines: After discussions with the industry officials, we will be evaluating the specific machinery, models and cloud connections necessary for the industry after which the final business model will be presented to the officials for review and finalization. The tools used during this time include MS project, MS Visio etc.
BPMN 2.0 complete shop floor simulation: After the business model is accepted, the software design of the complete shop floor will be designed using bizagi studio, a BPMN tool.
UI/UX: The andriod and web based User Interface of the project will be designed.
IOT framework implementation: Implementation of sensors and connection of the automated machines to the cloud, such that all of the important and necessary data of the company/ industry is constantly secured on cloud.
AI/ ML/ DL framework implementation: Implementation of data acquisition techniques, such that the training set for AI and machine learning algorithms is prepared and set forth in motion to be implemented to allow machines to take decisions independant of human involvement.
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 69760 | |||
| esp32 | Equipment | 3 | 500 | 1500 |
| rfid sensors | Equipment | 5 | 450 | 2250 |
| ble beacons | Equipment | 3 | 550 | 1650 |
| Temperature | Equipment | 4 | 440 | 1760 |
| Proximity sensors | Equipment | 2 | 5850 | 11700 |
| humidity | Equipment | 7 | 900 | 6300 |
| routers | Equipment | 3 | 4000 | 12000 |
| optical sensors | Equipment | 4 | 950 | 3800 |
| Cameras(image capturing) | Equipment | 3 | 5000 | 15000 |
| location | Equipment | 2 | 2000 | 4000 |
| fingerprint sensors | Equipment | 2 | 1650 | 3300 |
| stationary | Miscellaneous | 4 | 500 | 2000 |
| Printing | Miscellaneous | 5 | 100 | 500 |
| overhead | Miscellaneous | 3 | 500 | 1500 |
| PCB and electronic components | Equipment | 25 | 100 | 2500 |