"Zyfra" has implemented the industrial monitoring system "Dispatcher" in "STK Production Company"

2024: Connection to the Dispatcher system of 60 looms

GK "Zyfra" introduced the industrial monitoring system "Dispatcher" in the "STK production company" engaged in the production of technical fabrics. This "Figure" reported on January 29, 2025. The purpose of the digitalization project is to assess the efficiency of the use of production facilities, control of operational activities within the workshop, compliance with the technology and quality of production by organizing digital traceability of equipment and technological processes, as well as obtaining information on the actual work performed.

At the first stage of the project, the Zyfras team connected 60 hydraulic looms to the Dispatcher equipment and personnel monitoring system. The system is expected to be replicated for another 60 machines in 2025.

We upgraded the fleet of our equipment and purchased Chinese-made machines. We had the opportunity to purchase machines with a built-in monitoring program and reporting function, but the supplied software was not Russified and was not accompanied by technical support. As a result, we began to look at the market of Russian developers of monitoring systems, - said Alexander Murtazin, General Director of STK Production Company.

We were faced with the task of giving the customer a tool in order to see the real load of equipment, to control the amount of products produced and its quality in the form of errors in breaking the thread. At the request of the company, we have developed a single analytical panel where data from all equipment is collected. In addition, our own competence center developed hardware for the implementation of the program specifically for the functional requirements of weaving production, "said Vasily Churanov, head of the Engineering and Metalworking Division, about the progress of the project.

Two analytical dashboards were introduced into the system:

• "Analysis of equipment operation." The panel provides information about the efficiency of the equipment, the material produced on the equipment, the number and type of thread breaks and the downtime for each of the breaks.
• "Production Time Analysis." The panel shows the detailed production time and a summary information of the duration of the equipment in one state or another. This panel serves as a tool for finding trouble spots in production.

With the help of the implemented functionality of the "Dispatcher" "Monitoring of equipment conditions/downtime," now in production you can track the occurrence of undesirable conditions that lead to the appearance of defects or variants of equipment downtime specified by personnel. When such an event occurs, the monitoring system sends notifications to responsible persons through PUSH notifications, SMS, email or chatbot in instant messengers.

As of January 2025, the enterprise is at a stage of rapid growth - the number of equipment and the volume of production are multiplied, while our task is not to increase the number of personnel servicing the machine, but to cope with the current human resources, increasing labor productivity due to the processes of digital transformation of production, - said Alexander Murtazin, General Director of STK Production Company.

Already in January 2025, STK Production Company can control the footage and quality of manufactured products for each machine, by shifts, articles and operators, which gives a real picture of the load of equipment and personnel. Implementation of monitoring system "Figure. The dispatcher "made it possible to reduce unscheduled downtime of equipment and increase its productivity by identifying working time reserves.