Have you noticed the advantages of manufacturing in industry 4.0? The textile industry has evolved significantly in recent years, and automation has brought benefits to several companies.
With it, it is possible to optimize processes, increase productivity and even avoid waste.
Want to know how? Continue reading the article
Clothing in industry 4.0: a general context
Clothing in industry 4.0 generated one of the main changes to the production process: automation! With it, the clothing industry guarantees a series of benefits that contribute to competitiveness
. Transformando suas operações, as empresas se tornam mais ágeis para enfrentar os desafios do futuro.
After all, industry 4.0 is a concept that promotes the digitalization of industrial activities to optimize resources, increase production and improve relationships. In this model, physical and virtual components are interconnected by automation and digital systems, resulting in a more efficient operation.
Not surprisingly, according to data presented by CNN, industry 4.0 innovations can increase industrial productivity by up to 38%!
Not to mention that, for 80% of organizations, automation, together with other technologies, results in reduced costs related to the unavailability and quality of products and services. In fact, for a third of industries, the cost per hour of machine downtime is at least R$100,000
. Nesse contexto, a automação surge como uma solução eficaz.
Thus, manufacturing in Industry 4.0 becomes more strategic and intelligent, allowing the production of personalized items that meet the needs of the end consumer. Furthermore, by making decisions in real time, based on reliable data, the industry is able to respond to market changes with precision, standing out among the competition.
The real productive gain generated by clothing in industry 4.0
With the automation provided by manufacturing in industry 4.0, all these steps are now carried out faster and more precisely. Currently, 4.0 equipment offers a variety of solutions to problems associated with traditional mesh preparation and review methods.
Mesh Checker
For example, the Mesh Checker is capable of monitoring characteristics such as width and footage, in addition to having a synchronization and stretching system, and a system that guarantees the quality of the roll. To add on, it generates a defect map, indicating compromised areas in the tissues
. Os dados coletados por esse equipamento são armazenados, permitindo que os insumos reprovados sejam devolvidos ao fornecedor devido à não conformidade.
Mesh relaxer
Then, the fabrics that do not need relaxation are sent to storage, while those that require rest go through the process in a Mesh Relaxer. This equipment completely eliminates the need for a space dedicated to resting the mesh. And in less than ten minutes, it completes the roll relaxation process, air conditioning and also provides accurate data on length, width and side cutting area.
Data-driven decision
Therefore, like manufacturing in industry 4.0, in addition to accessing accurate information in an online database, it is possible to avoid removing the roll from the wrapping due to variations in measurements or manufacturing defects.
By controlling this information, you will be able to identify when the raw material does not meet the necessary quality standards, allowing the supplier to be replaced, if necessary.
This avoids the use of low quality mesh in production. As a result, it eliminates the production of second-line pieces, which end up being sold at lower prices, resulting in lost revenue.
Watch the video below to understand the productive gains of these solutions in practice!
The changes generated by manufacturing automation 4.0
Obtaining information about the raw material is essential for efficient quality control in the clothing industry!
The modernization of clothing in industry 4.0 brings the following natural results:
- Standardization of breaded products;
- Quality improvement;
- Failure reduction;
- Increased productivity.
However, for everything to work properly, it is essential not only to invest in machinery, but to ensure that suppliers offer excellent raw materials. It is also essential to train the team so that everyone understands the importance of automation in the textile industry. Finally, production must be continuously monitored, providing positive and corrective feedback on manufactured items, in order to increasingly optimize the process.
As in other sectors, technology has come to improve processes. Clothing manufacturers that do not follow this evolution will end up losing competitiveness, and their methods will gradually will become obsolete. Remember: consumers are increasingly looking for quality and value for money
. Com a concorrência crescente, não há mais espaço para falhas nos processos.
Investing in modernization and adopting manufacturing in Industry 4.0 has become essential to remain relevant in the market.
Reach new heights with manufacturing in industry 4.0!
Manufacturing in industry 4.0, driven by the automation of intelligent textile machines, such as the Reviser and the Relaxer, provides significant gains for the industry’s growth. the Delta Máquinas Têxteis revolutionized the textile sector
by offering these and other solutions guided by industry 4.0. To discover them, click the button below and download our complete catalog for free!
After all, what was the preparation and review of mesh before manufacturing 4.0?
In the clothing industry, traditionally, when purchasing a roll of mesh, it was enough to rely only on the information provided by the manufacturer.
However, qualifying and quantifying the material or performing a physical analysis of the quality standards of each roll manually can be time consuming. The fabric review process was not common in the sector before manufacturing in industry 4.0
. Isto é, muitas indústrias adquiriam suas peças sem conferir a qualidade e o acabamento da mesma.
This practice resulted in significant delays and bottlenecks during the baking process. Sizing errors were only detected after opening and stacking the fabrics in layers, which caused problems with cutouts and patterns.
Furthermore, the manufacturer himself recommends that some types of fabric undergo rest/relaxation of the mesh to return to its normal state. However, this operation takes 24 to 48 hours and requires adequate space on hammocks or tables so that the fabric can open properly during relaxation.
These hours represent a period in which production is at a standstill, in addition to increasing the risk of human error.
The inability to detect defects in fabrics is “normal” in this context, as they are noticed after the products are made, or the inadequacy in relaxing the mesh.
All these obstacles make manufacturing processes more complex, slower and prone to errors, resulting in great waste, increased costs and unproductivity.
