Global connectivity has reached an unparalleled level over the past 10 years. Mobile devices, sensing technology, and digital networking have made seamless communication a norm. It has also spurred a global race to acquire valuable data, which manufacturing companies across sectors have exploited. First movers have spent years gathering and analyzing this data to understand their customers and operations better. Digital transformation initiatives have spurred innovation by combining AI, ML, IoT, and robotics. This confluence sparked the 4th industrial revolution encouraging industry 4.0 in garment manufacturing.
“Industry 4.0″—the 4th industrial revolution—integrates modern technologies like automation, AI, and the Internet of Things into Fully Automated Clothing Manufacturing. The first industrial revolution mechanized production using water and steam. The second development was large-scale power generating. The third introduced telecommunications and microprocessing, revolutionizing information technology. Industry 4.0, also known as the 4th industrial revolution, is the age when electronics and information technology integrate the physical, digital, and biological components of modern human life for seamless digital communication.What is transforming the industrial value chain includes:
- Advanced technologies like AI, ML, automation
- IoT
- 3D printing
- AR, VR
- Energy storage and generation
- Quantum computing, and
- Robots transforming the industrial value chain.
Industry 4.0 in Clothing Manufacturing
Industry 4.0 will transform manufacturing, especially clothing, fashion, and footwear. Smart Factories redefine manufacturing with cutting-edge, efficient production facilities. Industry 4.0 accelerates, expands, and transforms key production and manufacturing processes. Fully automated, self-servicing, and self-repairing factories due to industry 4.0 solutions need little human intervention. The advent of Industry 4.0 technologies has paved the way for the development of a really intelligent and smart factory.
Industry 4.0 in Garment Manufacturing for a Precise and Comprehensive Understanding
A fully integrated smart factory provides a precise and comprehensive understanding of production activities by using real-time processing and analysis of data from web-based IoT devices and sensors. A connected factory enables advanced functionalities such as predictive analytics, self-diagnostics, repair, and self-optimization. The Digital Twins strategy is a strategic way of digitization.
Digital twins enable the replication of production and manufacturing processes in a virtualized environment on a digital platform. Subsequently, factory managers may use this digital replica to conduct experiments and evaluate novel process solutions, therefore avoiding the costly expenses and potential risks associated with real-world adoption. Consequently, a smart factory may be progressively improved over time to achieve continual enhancement while minimizing expenditures.
Industry 4.0 in Garment Manufacturing for Intelligent Production of Clothing, Fashion, and Footwear
Integrated technologies inside the shop floor in the garment, fashion, and footwear industry are rapidly progressing towards Industry 4.0 norms, in response to the intense competition. The fast advancement of emerging technologies enables enhancements in manufacturing processes that not only improve current systems but also facilitate the creation of novel processes. An apparel smart factory has the potential to achieve significant advancements, such as making inexpensive mass customization a reality. This can be accomplished by completely transforming the Fully Automated Clothing Manufacturing process to become more flexible, adaptable, and cost-efficient.
Customization of Clothing is Gaining Momentum
Various companies are now conducting trials with different levels of implementation to develop new clothing manufacturing techniques in order to achieve this goal. Ministry of Supply, a clothing firm established in Boston, uses thermal imaging, 3D printing, and 3D knitting technology to produce customized blazers, shirts, skirts, and sweaters. These goods are tailored to the unique body heat mechanics of each consumer and generate no waste material throughout the manufacturing process. The trend toward widespread clothing customization may seem to be a specialized market, but it is already gaining momentum.
Automated Clothes Factories Operating on Demand
In 2017, Amazon submitted a patent application for an automated clothes factory that operates on demand and covers the complete value chain. Amazon’s forthcoming completely automated smart garment factory will efficiently handle customized orders, akin to the simplicity of one-click buying. This system utilizes a variety of contemporary technologies, including augmented reality and computer vision for design and fitting, 3D printing for manufacturing, computer vision and artificial intelligence for shop floor operations, machine learning for logistics, and robotics for packaging and distribution. Once the prevalence of intelligent factories increases; clients will get customized garments with the same speed as ordering birthday cakes.
A Smart Factory Provides a Wide Range of Advantages in Terms of Production and Efficiency
A smart factory provides a wide range of advantages in terms of production and efficiency. The system is designed to continuously gather and organize vast amounts of data produced by all systems. Companies are provided with a very useful collection of data that can be studied in real-time across many departments. Individuals in positions of authority who have the ability to access this data may acquire a crucial understanding of areas where performance is lacking and thus be in a more advantageous position to provide remedies. These observations guarantee a consistent manufacturing process while enhancing the operational availability of assets and output. The use of automation significantly lowers human involvement in almost all manual tasks, resulting in a substantial decrease in production costs and potential variations in quality.
Smart Factories can Autonomously Manage their Own Maintenance
Smart factories can autonomously manage their own maintenance, including scheduling regular repairs and addressing difficulties in a proactive manner. Smart factories may be readily enhanced with updated software and configuration, similar to how a smart vehicle like Tesla gets software upgrades. Digitizing industrial equipment provides firms with a comprehensive understanding of the operational environment inside the factory, enabling them to optimize various process activities ranging from product development to logistics. A smart textile factory not only obtains immediate knowledge of its fully automated clothing manufacturing process but also utilizes predictive and prescriptive solutions to achieve desired results.
Machine Learning-Enabled Smart Factories Can Control Temperature Fluctuations and Component Aging
Machine learning-enabled smart factories have the capability to monitor several aspects, including temperature fluctuations, output effectiveness, and component aging. By using real-time data, a smart factory may use machine learning algorithms to anticipate the point at which a certain component of the sewing system would deteriorate and need repair. Subsequently, this substitution might be executed with automated machinery, guaranteeing a seamless workflow with minimum interruptions.
Machine Operators May Enhance the Efficiency of Their Operations
Machine operators may enhance the efficiency of their operations. They can do it by using RFID tags on various fabric bundles, which automatically adjust the settings on the sewing machine. This significantly reduces the amount of time and effort required. By incorporating digital automation into the code of these industrial equipment, shop floor engineers may efficiently modify the configurations of all machines on the factory floor, resulting in cost reduction and improved productivity.
Factory Managers Can Visually See Their Process Analytics
Factory managers now have the ability to visually see their process analytics by merely observing a screen. For Juki sewing machines, the collection and analysis of operator data aids in optimizing production processes, resulting in significant time and resource savings. The system promptly dispatches notifications on any production line faults, enabling swift remedial measures to be taken, hence minimizing any damage or downtime.
Guesswork becomes Unnecessary when Using Juki Machines
Consider a scenario where your sewing machine is experiencing an elevated frequency of needle breakages. Several variables may contribute to this issue in a standard sewing machine setup. The reason might range from a loosely fastened screw clamp to a deformed needle, necessitating a meticulous diagnostic procedure. Guesswork becomes unnecessary when using Juki machines. Engineers can now swiftly diagnose the issue and identify the precise reason within seconds. These include the machine running at speeds higher than the ideal rate, resulting in frequent needle breakages. These systems let shop floor managers track productivity in real-time and identify performance issues.
Final Words
The potential of Industry 4.0 in Fully Automated Clothing Manufacturing is endless. A smart factory in the fashion and footwear sector is becoming more likely as manufacturing equipment and components integrate sensors and automation. Industry 4.0 systems improve intelligence, quality, cost-effectiveness, and speed. Thus, they should boost garment manufacturing and production efficiency, productivity, and competitiveness.
