Initiatives affirming the power of digital transformation

Goal of overcoming shortcomings

According to Mr. Nguyen Van Minh (representative of the author group), during the production process at the Dyeing Workshop, the continuous operation of the excavator is mainly done by manual methods. Operating parameters such as speed, temperature, chemical pressure... are imported directly by workers and confirmed by hand. This causes problems such as not being able to immediately track the machine's operating status; lacking a history database for each product code, causing difficulties in tracing and analyzing; manual recording with many potential errors. Faced with this situation, the group of authors proposed and deployed a comprehensive digital solution for the operation of excavators to improve accuracy, traceability and management efficiency.

The solution is designed and deployed with main components such as building modules to manage travel documents, each product code is created with a separate QR code, scanning before being put into operation for identification and monitoring activation. Build modules to manage machine operation processes, manage parameters such as process codes, items, speed of stages, temperature of each cooking box (box1 to box15), chemical compression, lake temperature... Install a line scanning device at the excavator, workers just need to scan the QR code, the automatic system to identify the product code and record the process.

Automatically recording the operating data, the machine will automatically send real-life data ( Temperature, speed...) to the system every 5 minutes through PLC and HMI connection. Every 15 minutes, data is pushed to the Cloud system so that managers can remotely access it. Real-time data monitoring, managers can track the device's performance, performance, downtime... in real time on the phone, tablet or web interface.

The effect of digital transformation

Applied from August 2024, the theme "Online production process management and system monitoring, automatic reporting" is a practical step to modernize production management activities, contributing to increasing productivity, reducing costs and improving quality control capacity in the dyeing industry. This is the first time the unit has deployed a connection between the production data system and machinery equipment through PLC, HMI and the centralized data system. When successfully implemented at the Dyeing Workshop, many positive results have been achieved because it automatically stores data every 5 minutes, serving analysis, tracing, and quality reporting; improving accuracy in production management; supporting data tracing when there are errors or tracing requests from customers. Saving management costs and operating time, with a value of VND300 million/ machine/year. This solution is in line with the digital transformation orientation and smart production management of the Textile and Garment industry.

The model is expanded to apply to other lines in the factory such as: Bearing machines, seeds, coffee machines (applied from April 2025 as a program to celebrate the April 30 holiday with a profit value of 100 million VND/ machine/year), ponding machines, cutting machines, tenon drying machines, excavators, chemical pumps, temperature measurement machines, equipment performance... towards building a smart factory, sustainable development and integrating with the 4.0 industrial trend.

See the original here