Textile Industry 4.0: controlling quality in the era of advanced manufacturing

With signs of resumption of production, clothing companies confuse the process loss with process error, and a very large volume of raw materials is wasted due to lack of information about Industry 4.0.

In general, companies are only concerned with the measurements of the finished/sewn pieces, but they do not analyze the root cause of the variables in their raw material. Reliable technical information on the raw material is essential for planning/scheduling wrapping and cutting in a garment factory, avoiding waste.

What would the day-to-day life of clothing manufacturers be like if they had real and stable information (width, meters, usable area, weight, yield) of each roll of mesh/fabric that is in their stock online?

Imagine being able to look at stock and select the best roll, with the best use for each cutting order. Imagine what it would be like not to have to collect a roll of wrapping due to manufacturing defects and measurement variations.

Industry 4.0: this is already possible

The standard process nowadays is to buy a roll of mesh/fabric and base it on the information on the label generated by the manufacturer. However, the manufacturer itself advises relaxing/resting these items so that they return to their normal state (without stretching).

Well, this means that there will be a change in the measurements of the mesh/fabric on the roll and understanding this behavior is the first step to adapting to the concept of Advanced Manufacturing or Industry 4.0.

Without the appropriate technology and a personalized plan to automate the entire process of quality control, relaxation and variable collection, it is difficult to have real information for good planning and resource management.

Efficient automation of textile processes achieves excellent results regardless of process variables.

With technology it is possible to predict different scenarios, machines with ready-made presets that adjust to each type of article, adjustments configured quickly and accurately.

Physical control of the mesh roll before use is essential. Today, it is now possible to automate this process with technology from Delta Equipamentos. In addition to an efficient process, it is important to have monitoring data.

Preventive quality analysis in the textile industry must guide the management of textile production, identifying in advance the drop in quality of its suppliers and acting preventively to reduce losses in its production.

+Learn more: Quality standardization: essential methodologies
+Learn more: Quality management: how to solve problems with RNC’s

From chaos management in textile production to Industry 4.0

In some sectors of the Brazilian industry, this process of automation and advanced manufacturing is far ahead of what is found in the textile industry.

In fact, experts claim that the national textile industry is technologically outdated, but it is not a question of buying a state-of-the-art machine and simply inserting it into the existing workflow, but rather of processes, management and efficiency in production, with control and data on all variables of textile production, measuring each stage of the process, and sending data to customer management systems (ERP).

It’s important to emphasize that high technology in machines and industrial automation optimize variables and allow for the creation of a database of extreme importance for the traceability of raw materials in clothing manufacturing, making the process safer.

+Learn more: How to modernize quality control in manufacturing?
+Saiba mais: What is quality control? How does it work in the textile industry?

Clothing that does not qualify the raw material can lose up to 50% of productivity

Discussing productivity is still a taboo for some factories, and the market can charge dearly for the lack of innovation and increase the loss of its own profit.

If you believe that your company’s production process can reach higher levels of efficiency with process control and accurate data for decision making, know that we share the same opinion.

If you are interested in understanding and improving the automation of your production processes, speak to our consultant and ask your questions.