Industry 4.0 is turning traditional garment factories into highly productive, interconnected smart systems.

The fashion world changes quickly, and global competition makes it hard for manufacturers to keep up. To stay relevant, they need to be fast and efficient, but this is expensive due to high labor and tech costs. "Industry 4.0" is a solution. It's about using computers and the internet to make factories smarter and more connected. This helps make production faster and brings together different parts of the manufacturing process. For clothing makers, this can be a game-changer. Let's explore how "Industry 4.0" can help the fashion industry.

What's new in garment making with industry 4.0?

Old factories had workers doing everything. Now, with Industry 4.0:

  • Robots spread and cut fabric with high precision

  • Machines help in sewing and remember how to improve

  • Packaging is faster with robots

  • Fewer mistakes, meaning better products

Why is industry 4.0 good for clothes makers?

  • 1. Better quality with smart machines

Smart machines and robots learn quickly and store information for future use, meaning that any mistakes will prompt reprogramming to ensure they’re not repeated. Where human workers are prone to error due to tiredness, sickness, or improper training, smart machines and robots never vary in their performance, providing accurately constructed, high-quality products every time. Moreover, image processing lends greater precision to quality control and production processes like cutting.

  • 2. Fast decisions with real-time data

Smart factories powered by Industry 4.0 are all about data. Machine sensors collect production line data in real time, allowing managers to analyze it at a glance and make important manufacturing decisions on the go. Collected data is used to monitor all factors impacting production speed, helping manufacturers streamline the entire manufacturing process.

  • 3. More orders, bigger profits

A more streamlined, accurate production line means that managers can start taking more orders. Built to withstand challenging factory conditions, heavy-duty machines are better equipped to take on an increased workload than manual workers. By sharing data and allowing closer monitoring of each production stage, interconnected machines free up staff time. Thanks to interconnected, smart machines, manufacturers previously stuck in domestic markets can now compete globally, increasing their productivity and profit.

  • 4. Customers stay informed

Manufacturers traditionally take orders and, aside from a few updates along the way, leave customers out of the production process. Smart machines enhance communication with customers, embracing them as an integral part of the process. Online systems allow customers to monitor manufacturing status and keep abreast of any changes to production timelines, enhancing convenience and affording them more accurate planning. Customers can also monitor real-time reports, and will maintain rapport with manufacturers knowing that the information provided is reliable, machine-generated data.

  • 5. Save money with automation

Kitting out an entire factory with new, interconnected machines comes with high start-up costs, but it’s a worthwhile investment. Automation reduces production errors, in turn reducing the risk of product recalls later down the line. This allows manufacturers to take on bulk orders without worrying about quality issues.

Aside from a management team, factory workers are replaced with smart machines, significantly reducing labor costs including wages, training, and sick days. Existing workers can be transferred to other departments to enhance productivity.

  • 6. Better training with augmented reality (AR)

Industry 4.0 is transforming the way we view garment manufacturing, and staff training is no exception. Augmented Reality harnesses smart machines and a digital environment to teach staff the skills they need to make clothing. This type of smart training can boost productivity by up to 50 percent, and significantly reduces the chance of defects caused by human error.

  • 7. Advanced quality Ccecks

Although machines do play a part in the traditional quality control process, manual inspections have a greater role. Human error due to fatigue or oversight means that some defective products end up slipping through the net, causing customer dissatisfaction or even injury. Industry 4.0 transforms quality control into a computer-aided process, using advanced image processing and machine learning to carefully scan items for defects. By removing human involvement, this highly accurate process in turn removes the risk of human error.

  • 8. Happier customers mean repeat orders

Big data and smart machines enable more comprehensive production data storage, improving machine accuracy and productivity. A leaner manual workforce means a more precise production line, as smart machines take over and standardize most areas of production. Smart machines also enable thorough quality control checks, using machines and image processing to scan items. In turn, this means fewer product defects and happier customers, resulting in repeat orders and a stellar factory reputation.

OSHIMA machines: the future of clothes making

OSHIMA’s range of smart machines helps garment factories keep up with consumer demand. A garment machine expert with decades of experience, OSHIMA continues to develop smart machines complete with the latest technological innovations. Smart machines from OSHIMA are interconnected and underpinned by data management systems, allowing managers to monitor production in real time.

Conclusion

Garment manufacturers wishing to remain competitive must transition to Industry 4.0. Although installing a new range of machines and systems may seem like a large investment, the benefits make it worthwhile. Smart systems help manufacturers cut costs and produce higher-quality goods, saving them the hassle of costly product recalls. Instead of employing a large workforce, manufacturers can deploy robots and smart machines to take over tasks, increasing efficiency and precision. OSHIMA’s outstanding range of smart systems allows garment factories to save time and money through automation. Do you want to create a smart factory but don’t know where to start? Talk to us today.

References
https://www.researchgate.net/publication/332410328_Industry_40_Revolution_in_Clothing_and_Apparel_Factories_Apparel_40
https://www.textiletoday.com.bd/will-industry-4-0-change-textiles/
Return to previous page