Rieter Helps Sagar Manufacturers Increase Efficiency With Essential Monitor
Digitization is front and centre in Sagar Manufacturer’s 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 Essential monitor, a module of the Rieter Digital Spinning Suite, Sagar Manufacturers recorded a noticeable increase of 1.5% in mill productivity.
Sagar Manufacturers implemented Rieter’s Essential monitor in 2021, combining it with the individual spindle monitoring ISM premium on their ring and compact spinning machines. Essential monitor 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.
The ESSENTIAL dashboard provides a clear overview of machine parameters.
Essential monitor unleashes productivity
The implementation of Essential monitor with ISM premium brought numerous benefits to Sagar Manufacturers. These include:
- An increase of 1.5% in productivity,
- A reduction of 10% in manpower requirements,
- A decrease in hard and soft waste of 10% and 2.5%, respectively
- An expected improvement of plant utilization amounting to 0.1%.
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 analyzes 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, states: “We appreciate the support from the Rieter team very much and feel that our needs are understood. The full utilization of Essential monitor has allowed us to optimize the performance over the entire process. We are excited to see what the future of the system holds”.
