Reliably and efficiently manufacturing superlative quality – that is the wish of every yarn, fiber and nonwovens manufacturer. However, optimally adjusting manufacturing with constantly-changing products is a huge challenge: because even small deviations can have a massive impact on the quality of the end product.

To better monitor and control production across all systems against this background, globally technologically-leading machine and systems constructor Oerlikon has expanded its Manmade Fibers segment portfolio to include new digital products and services. By integrating the know-how of the recently-acquired German industrial automation solutions specialist AC-Automation, Oerlikon now offers Industrie 4.0 systems solutions from a single source: the entire manmade fiber manufacturing plant is – step by step – being automated, digitalized and expanded to include new functions.

This starts with human machine interfaces (HMIs), which have enabled hugely interesting services – whether process monitoring via a service online app on smart phones and tablets or customer care and maintenance using the Microsoft HoloLens solution. The possibilities range from expanding the ‘From Melt to Yarn, Fibers and Nonwovens’ process chain to include upstream and downstream steps. Because it makes sense in the future to include those processes – such as automatic labeling or yarn package, fiber and nonwoven bale logistics – to date covered by means of third-party solutions.

Edge computing and cloud solutions

All these functions and services are – together with the Plant Operation Center (POC), which at Oerlikon assumes the function of a manufacturing execution system (MES), including the link to superordinate ERP systems – provided by the Oerlikon Digital Services platform. The machines, systems and third-party systems are networked and integrated by means of power edge computing and cloud solutions based on the OpenStack industry standard. This means that the data are utilized at the customer site as far as possible and only transferred to the central Oerlikon customer data center if required – and only following customer approval. Here, data security, data minimization and transparency are extremely important: “Needless to say, we process all data in accordance with the new European General Data Protection Regulation (GDPR), taking all further international data protection standards into account. Our customers always know which data we use and why”, explains Mario Arcidiacono, Business Intelligence & Data Warehouse specialist for the Oerlikon Manmade Fibers segment.