Real-time data collection is the next step in automating factory floors to help businesses grow.
In a large-scale industrial garment factory, meeting production deadlines is challenging. Managers have to take the time to collect accurate factory floor data, understand what’s happening when a problem arises on the production line, and ensure the same production standards are enforced everywhere, making it hard to produce enough to meet demand while maintaining the quality customers expect from garment manufacturers.
Competitive garment manufacturers have begun to embrace Industry 4.0, the current movement of embracing AI technology and automation in manufacturing, by upgrading to smart factories capable of real-time production planning. Garment manufacturers can get ahead of deadlines by leaving day-to-day production management to AI-powered integrated machinery, while they focus on their big-picture business goals.
What is real-time production planning?
In a factory with real-time production planning, production data is stored on a shared virtual platform that connects every smart machine in the factory to each other, even across multiple factory locations. Every step of the production process is automatically recorded, from how many products were made and how long it took to make them to the number of defects and more.
This kind of high-tech automation is part of Industry 4.0, the next evolution in manufacturing, where computers and AI play a major role in production. Industry 4.0 improves a garment manufacturer’s speed and productivity, and it starts with offloading menial tasks like data collection onto machines.
Garment manufacturing companies have traditionally relied on individual human workers to collect data about the production process on the factory floor. Not only does this take up a lot of time and manpower, but information collected in this way also quickly goes out of date.
According to a multi-industry survey, a factory floor can only run at 40 percent production capacity when workers manually report things like production stats and scheduling, because this information takes so much time to write up. Automated, smart technology made for real-time production planning fixes this problem.
Four key advantages of instant data collection
Real-time data collection for production planning helps garment manufacturers gain competitive advantage by improving their production process. Here’s how:
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Keep all information updated and in one spot
Real-time data collection means garment manufacturers know what’s happening on the production floor, as it happens. Constant access to up-to-date and past data, all on one convenient platform, can help factory managers better understand the source of the problem when an issue arises and make informed decisions without wasting time and resources.
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Make products quickly and with better quality using AI
Machines are more accurate than the human eye, so quality control that incorporates real-time production planning is faster and more efficient. In one study, a garment manufacturer saw a 30.5 percent increase in production efficiency after installing a real-time data collection monitoring system. By streamlining the data collection and analysis process by connecting AI-powered machinery to a central platform, garment business owners can make sure that their product quality is consistent across all areas of production.
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Easily handle machines and workers
Real-time production planning systems are perfect for helping garment factory managers standardize their production process so it’s easier for workers and machines to do their jobs. It also helps managers monitor employee activity. For example, managers can keep track of who made what garment and how long it takes employees or machines to complete certain tasks. Having a better understanding of how employees and machines work together and spend their time can help managers calculate employee incentives and plan tasks so they can be done as efficiently as possible.
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Keep your customers happy
More organized and accurate production planning means businesses can do more for their customers. A clearer understanding of exactly how long production tasks take can help companies deliver orders on time, keeping customers happy. At the same time, accurate data collection lets companies be more transparent about their work, helping them run honest and open business operations that customers can trust.
Who benefits from real-time manufacturing data?
Manufacturers of any size can benefit from using real-time data collection in their smart factories. The connectivity of real-time production planning is perfect for managing multiple operations at once. For large companies that are expanding their production capacity, being able to seamlessly manage all the moving parts involved in running several production facilities is crucial for lowering the production errors that can occur in expansive production operations.
A recent cross-industry survey found that on average for large companies (businesses with over 1000 employees), one hour of downtime a year costs the company over $100,000 USD. This means that wasting time by not running machines at their maximum efficiency affects your bottom line in a huge way. Real-time production planning helps businesses establish the most efficient manufacturing process possible, saving them time and, as a result, many thousands of dollars. Garment manufacturers can use the time and money saved to expand their business so they can compete with industry heavyweights.
Small- to medium-sized garment manufacturers looking to grow can also benefit from an automated real-time data collection system. More business means higher production demands, so smaller operations need to be ready to put out large orders on time while maintaining quality.
In a recent case study, researchers recorded the small garment manufacturer CV Indotas’ experience with integrating a real-time production planning system into their assembly line to meet growing demand from an increase in customers. They found that the new real-time data system helped the company reduce errors as more orders came in. It also had an 88.3 percent acceptance rate among employees, showing that workers found it easy to use and helpful for tracking orders.
Conclusion
A real-time production planning system is perfect for any garment manufacturer looking to grow their business and make orders more efficiently. Instead of wasting time figuring out how to make a product or correct an issue with out-of-date information, companies can let a smart, automated system do it for them. That way, they can deliver products at the quality their customers expect with greater transparency and quicker turnaround times. Contact us today to see which of our real-time data collection solutions are right for you.
