Case

Client: A well-known textile printing and dyeing enterprise in Southeast China

Industry: Textile Printing and Dyeing

Project Timeline: Q1 2024

The Challenge: Inconsistent Process Control, High Defect Rates, and Inability to Trace Quality

A leading textile enterprise faced significant challenges in its dyeing workshop:
• Manual Process Reliance: Dyeing time, temperature, and chemical dosing were manually controlled, leading to process deviations and color shade variations exceeding 5% between batches.
• High Defect Rates: Inconsistent dyeing resulted in a fabric defect rate of around 8%, causing substantial material waste and rework costs.
• Non-Traceable Quality Issues: When color discrepancies occurred, it was impossible to trace back to specific process parameters or operator actions, hindering accountability and continuous improvement.
• Rising Labor Costs: Difficulty in recruiting and retaining skilled workers for round-the-clock shift operations increased operational costs and management complexity.

Xiamen Shun Ding Rui Solution: End-to-End Dyeing Process Automation and Data Visualization

We implemented a comprehensive “Precise Process + Digital Management” intelligent transformation solution centered around the Siemens platform.

1. Centralized Control System:
   • Utilized a Siemens S7-1500 series PLC as the core controller to manage all dyeing vats, achieving unified and precise control over the entire dyeing process.
2. Precision Execution Layer:
   • Equipped each dyeing vat with Siemens G120C compact frequency converters for precise pump motor control.
   • Deployed our “Shun Ding Rui Pro” series analog output modules to accurately control proportional valves for steam and chemical dosing, ensuring process consistency.
3. Data Acquisition and Visualization:
   • Integrated various temperature, pressure, and flow sensors via our “Shun Ding Rui Pro” distributed I/O stations.
   • Configured a Siemens TP2200 Touch Panel to display real-time process curves, formulas, and production status, providing operators with clear guidance.
4. Process Management Upgrade:
   • Developed standardized dyeing process recipes within the PLC, allowing one-touch initiation by operators, eliminating reliance on individual experience.
   • The system automatically records all critical process data for each production batch, enabling full traceability.

Quantifiable Results & Value Delivered

The solution delivered transformative results upon implementation:

• Significant Quality Improvement: Batch color shade variation was reduced to under 1.5%, and the defect rate dropped from 8% to 2%, substantially reducing waste and enhancing product grade.
• Boosted Production Efficiency: Automated control shortened dyeing cycle times and reduced manual intervention, increasing overall equipment effectiveness (OEE) by approximately 30%.
• Reduced Labor Dependency: The system simplified operations, lowering skill requirements and reducing the number of operators required per shift by 40%.
• Enabled Data-Driven Decisions: Comprehensive data recording allows for quick root cause analysis of quality issues, supporting continuous process optimization.

Client Testimonial:

— Production Manager, XXX Textile Co., Ltd.

“This collaboration with Shun Ding Rui has been a leap in quality and efficiency management for our dyeing workshop. Their solution, combining the robust Siemens platform with their flexible and cost-effective ‘Pro’ series modules, addressed our core issues perfectly. We’ve not only seen impressive quality and efficiency gains but have also established a solid foundation for our future smart factory planning. Their professionalism is commendable.”