Real-time loom monitoring
Continuous tracking of spindle speed, runtime, stoppages and status across machines.
Textile
IoT-Based Loom Monitoring
Real-time loom intelligence for a textile facility, to improve productivity and reduce breakdowns.
31%Reduction in machine breakdowns
18%Increase in production output
22%Reduction in quality defects
Overview
Client Overview
The client operates a large textile unit with multiple weaving looms running across shifts. Consistent machine performance and fabric quality are critical to delivery commitments.
The challenge
Operational challenges
- Frequent loom stoppages due to yarn breakage
- No real-time visibility of spindle speed and runtime
- Manual production tracking with delayed reporting
- Fabric defects from undetected process variations
- Reactive maintenance leading to production losses
Solution
What was implemented
An IoT-based loom monitoring system collects real-time operational data, detects anomalies and gives production and maintenance teams actionable insight.
Yarn breakage alerts
Instant alerts on yarn breaks so operators can intervene quickly.
Production analytics
Production counts, efficiency and shift-wise performance.
Visibility
Dashboards and views
- Loom-wise and line-wise runtime status
- Spindle speed trends and stoppage analysis
- Yarn breakage frequency and patterns
- Shift-wise productivity and efficiency
Results
Benefits
- Improved loom uptime and stability
- Less fabric waste and rework
- Faster response to yarn breakage
- Better coordination between production and maintenance
Conclusion
The system gave the textile manufacturer real-time visibility of loom operations and supports expansion to more looms and plants.
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