PIACENZA: textile - Production optimization by enhanced data collection and shared production model implementation

Improve the monitoring of production capability
Better exploitation of internal and external production capacity
Reduce the machinery exploitation costs and the production time
Reduce the quantity of energy used and gas supporting the production

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Description of the trial

The trial belongs to the Smart Factory domain and is applied in the Textile sector. Led by Piacenza (Italy), it aims at creating agreements between competitors to share production facilities, i.e. the first core of a “shared production model”. The current existing IT infrastructure and application is mostly derived by the iSurf117 FInES/FoF Project. Other related experiences come from Moda-ML, EBIZ and EBIZ-TCF , LEAPFROG IP and TEXWIN, iSurf, Artisan. With the adoption of FITMAN “cloud production” model, the trial intends to maximize the benefits for industrial end users production. Main objectives are: to improve the monitoring of production capability, have a better exploitation of internal and external production capacity, reduce the machinery exploitation costs, to reduce the production time, reduce the quantity of energy used for production, and reduce the quantity of gas supporting the production.

FITMAN Piacenza Trial fact sheet

Innnovative service and functionalities

  • Integration between legacy infrastructure and the FIWARE IoT chapter, by introducing a TSC that translates from legacy events to NGSI9 and 10

  • Addition of the new RFID technology to the existing infrastructure, that enables real-time monitoring of the production in crucial phases like the dry finishing

  • An innovative, web-based, dashboard that allow operators and managers to follow the production anywhere in the plant

  • The ability to share production capability that allows to sell and buy production capacity and reach a better machinery exploitation

Impact & benefits

The objective of the pilot is to demonstrate that, on the basis of FI technologies, textile “shared production” can become reality. To implement this scenario, the FI could support the integration of the above mentioned new textile industrial needs, the increased network capacity (above all new wireless transmission capacity) and the state of the art IoT new applications towards the implementation of the challenging concept of a real “shared production”. First of all FI-WARE can support the necessary integration with a more efficient sharing of product and production information, based on full RFID-IoT application to machinery and goods. Second, it could support the update of the software tools (materials and partner research), of the communication standards (Moda-ML, E-Biz) and of interoperability systems, exploiting the new and state of the art FI-Ware performances, is a critical step towards a renewed business ecosystem. In the end the full exploitation of the FI-WARE multi device platform performances can lead to a critical step towards their implementation into t/c full value chain and to the demonstration of FI-WARE intrinsic exploitation possibilities to support t/c business ecosystem towards a new, more efficient and flexible organization, which can exploit EU peculiar industrial organization of the textile/clothing sector.

Technical challenges

Piacenza textile trial uses a Smart Factory solution to enhance the production supervision and monitoring, and a cloud solution to export and import machinery availability, e.g. their capability surplus. The platform has been deployed in local and dedicated environment inside the Fratelli Piacenza company. The technical solution adopted some GEs from the FIWare IoT chapter such as the ContextBroker, the IoT-Broker, The ConfMan and the DataHandling and WireCloud for the presentation layer, and the cloud part of the project. RF-ID data have been collected by using the Shop-Floor-Data-Collection SE, and some specific components have been developed to get data from legacy system and to show data at presentation layer. Concerning the RF-ID, the challenge was to have a tag reading reliability, the great difference between the working mode from a machine to another required a meticulous analysis. Concerning the task specific components, the introduction of the DB trigger and the Event Manager allows to manage all the legacy, e.g. from the MES, and new, e.g. RF-ID, events in a common way, make them available on the IoT chapter and at the presentation layer.

Business challenges

Piacenza production organisation is vertical and typical of textile sector, with some key phases directly performed inside the industrial structure and other ones delegated to sub suppliers. Because of textile sector peculiarities (see above) and in particular the very short product life cycle, the unpredictability and variability of fashion demand and the length of the value chain (more than 70 sub-steps of production from spinning to weaving and finishing) and to keep quality, price and service under control Piacenza has decided to mix internal and external production. Nevertheless the exploitation of company infrastructure is still subject to under or over exploitation in relation with the erratic fluctuations and of demand. Piacenza objective is to improve in relation to AS-IS situation the exploitation of the production machineries and infrastructures involved in the project up to a potential 30% improvement in off peak production periods, with a related decrease of fixed costs per meter produced by the implementation of cloud manufacturing, with a proportional extension to all the subjects of the business ecosystem. The definition of proper information ontologies and contents and transfer protocol standards will be carried out on the basis of the experience by the industrial end user (Moda ML, e-biz, iSurf, Tex Win) and will be take into proper account the GE infrastructures and resources to support the implementation of this activity in a general environment.

IT PARTNER: Softeco Sismat

Softeco Sismat SrL (http://www.softeco.it), established in 1979, with its headquarters located in Genoa and branch offices in Milan, Naples and Catania, is a mid-size, highly innovative SME and a software systems provider in several business sectors, including industry, telecommunications, services, finance, security, and government. The company is a major supplier of software and automation systems for industry and research partners, operating in complex environments with advanced IT methodologies, hardware and software tools, in Italy and Europe. Company solutions, products and services, include applications in various market segments such as e-Business and e-Work/mobile-Work solutions in different industrial sectors (e.g., manufacturing, automotive, shipping, biotech, etc.) and service markets (e.g., info-mobility, transport, tourism and travel, logistics, health care, etc.). Softeco also develops specific, mission-critical, ICT solutions, adopting state-of-the art SO architectures, for industrial, public, and private organizations in various areas (e.g., energy production and distribution, telecommunications, traffic and transportation, finance).

END USER: Piacenza

Piacenza is a SME manufacturer of fine woolen fabrics, leader in the top segment of noble fiber fabrics for fashion and luxury markets. It is supplier of fabrics to all world-leading fashion brand manufacturers (Zegna, Gucci, Prada, Louis Vuitton, Hermès among the others). Based in Italian textile district of Biella, where all its production is realized, and it is one of the oldest textile industries of the world, founded in 1733 and from then on owned by the Piacenza family. Its production organization is fully performed in Italy and it is completely integrated from raw materials to finished fabric, except spinning phase which is performed on its behalf by sub suppliers. Piacenza provides its competence in its sector, supported by state of the art application of EU funded research in the fields of future internet technologies for manufacturing and IoT, advanced production management (genetic algorithm and CBR based), communication and interoperability standards, RF-ID technology and logistics, production optimization for energy efficient use. Piacenza also provides its IT infrastructure, updated on the basis of it past and ongoing EU participation into research projects since FP5. Its fully integrated supply chain, from direct raw material purchase in the market of origin to fabric and clothing sales by own shops, updated by research participation, offer Fitman a cover of the whole textile value chain and the related complete testbed