AN OVERVIEW ON ‘TEXTILE INDUSTRY '4.0'

AN OVERVIEW ON ‘TEXTILE INDUSTRY 4.0

ABSTRACT:

Industry 4.0 is the major concept of automation and dada exchange in manufacturing process and technology which include many systems and technology such as cyber physical system (CPS), the internet of things (IOT), artificial intelligence, cloud computing, cognitive computing and industrial internet of things (IIOT). The term ‘industry 4.0’ originated in 2011 from the project in high tech strategy of German government, which provides provision for computerizing or modernization of manufacturing and process. Major concepts included in ‘industry 4.0’ are smart manufacturing and smart factories. ‘Industry 4.0’ is neither new technology nor a business idea but in reality, it is a new advancement for achieving results that weren’t possible with old technology. This paper will provide illustrative examples, importance as well as future scope of 'Industry 4.0' in the textile sector.

INTRODUCTION:

‘Industry 4.0’ is one complete approach to manufacturing techniques. it will push global manufacturing to the new level of optimization and productivity. It will help the customer to meet with a new level of customized product. ‘Industry 4.0’ will have a bright future in the upcoming generation when it comes to revenue, investment and technological advantages. ‘Industry 4.0’ will lead to modernization of the production process and supply chain for achieving flexibility of production based on CPS and IOT together with ERP and other software systems. CPS can monitor the production process and provide real time communication between machines and humans. With the use of CPS and IOT information can be shared across the entire collaborative network. In this system from raw material to final product, digital tracking devices are connected to each other with this by using standard protocol, data analysis and error forecasting can be done more easily. Implementation of modern technology in spinning, weaving, processing and garmenting are essential to upgrade the textile industry. Efficient and timely maintenance systems are needed for achieving high productivity along with superior quality. Hence the MES system is one software system which comes under the ‘industry 4.0’, which stores and displays the device information, equipment depreciation maintenance schedule. With this system transmission of information to the machine manufacturer provide 3D models and repair guides for remote maintenance. Textile industry must be aware of the new technology and respond with judicious action in order to reduce the production cost and improve manufacturing productivity which ultimately promote industrial growth and profitability of the entire mill.

FUNDAMENTAL PART OF 'INDUSTRY 4.0':

There are four basic principles in the ‘industry 4.0’, which basically promote many industries to identify and implement the ‘industry 4.0’.

• Interconnection between machine, sensor, technology and people.

• Collection of huge amounts of data or information for innovation and improvement.

• Assessment of data or information for making appropriate decisions and solving problems.

• Performance of the task, on the basis of decision,

WORTHWHILE EXAMPLES OF ‘INDUSTRY 4.0’ IN TEXTILE SEGMENT.

DIGITAL CONTROL CENTER

Electronics and computer control systems in the textile industry include machine panels, the system for regulating and recording. In today’s scenario data acquisition, automatic monitoring and display of weak points are the key points for improvement in quality of product and improvement in productivity. This will allow us to identify and eliminate the weak points in the production process. It has following advantages

● High production rate

● Consistency in quality

● Reduced maintenance

● Reduced man power

● Flexibility

Digital control system has some great application in textile sector which mainly include

➔ Electronic let off and take up.

➔ Automatic pick finding

➔ Electronic yarn tension control

➔ Automatic start mark prevention.

INTELLIGENT TRANSMISSION OF FABRIC

Intelligent transmission of fabric from one place to another, comes under the fully automated system which includes automatic transmission of fabric when the system receives the signal. This system includes an elevator as a device which automatically transmit the fabric to the designated work floor.

‘WMS’ OPERATE WITH ERM SYSTEM IN FABRIC STORAGE AREA.

A warehouse management system (WMS) is software that allows the organization to control and administer warehouse operation from the time goods enter a warehouse until they move out. Operations in the warehouse include inventory management, picking process and auditing. Implementation of WMS can help an organization to reduce labor cost, improve inventory accuracy, improve flexibility, decrease the errors in picking and shipping goods and improve customer service.

Main features of warehouse management system as follows

● Customized workflowwith optimized warehouse design.

● Easy finding of goods with inventory management.

● Practicable picking and packing of goods (fabric rolls)

● Advance shipment notifications

● Key performance indicator (KPIs) for labor management in warehouse.

● Reporting.

INTELLIGENT FABRIC CUTTING SHOP FOR GARMENT INDUSTRY.

An intellocut process involve

⮚ Upload order details

⮚ Get artificial intelligence based cutplan

⮚ Fabric lay information is sent to intellocut tablet application

⮚ Enter all fabric lay information on the tablet application itself.

⮚ Track and get the reports of cutting performance.

Special features which are mainly concerned with intelligent fabric cutting systems are as follows:

❖ Automatic cut planning.

❖ Automatic execution of planning.

❖ Feedback from cutting floor with warning signals

❖ Reduced human errors with tablet-based recording of cutting data.

❖ Real-time visibility

INTELLIGENT SEWING SYSTEM IN GARMENT SECTOR.

The intelligent sewing system is software which analyses sewing data measured by the IT series. And the data is loaded on the personal computer and various kinds of information are displayed in the form of lists and charts. Thereby it provides better detection of problems.

Visualization of the production line include

● Progress information monitor

● Machine operation monitor

● Production line analysis

● Line balance simulation

● Sewing recorder

● Basic data on wages.

Production data on sewing sites can be directly measured by connecting an intelligent sewing system to the sewing machine, which displays production target and actual number of pieces produced. In this system data is automatically transmitted to a personal computer by connecting the system to a network, that enables real-time analysis of production data.

FUTURE SCOPE OF 'INDUSTRY 4.0' IN TEXTILE SECTOR:

Implementation of 'industry 4.0' in the textile sector will have an excellent future in terms of productivity, efficiency and profitability of the entire mill. It also creates a major impact in service and retail marketing. Adoption of 'industry 4.0' related to modern technology such as robotic process, Artificial intelligence, machine learning, Internet of things and modern automation provides new perspective and opportunities’ for the future reference. Implementation of new technologies in the spinning sector for example chute feed system, auto can change system result in better productivity and efficiency of machine. Textile industry 4.0 provides ‘smart factory’ into existence in which smart digital services are networked and they communicate with raw material, finished product, machines, tools etc. industry 4.0 is characterized by flexibility, efficient use of resources and integration of customer and business partner in business process. In textile industry 4.0 industrial internet of things has utilized for intelligent and integrated manufacturing which also includes smart service.

CONCLUSION:

The cyber physical system comprises a smart machine, storage system and production facilities, which are capable of autonomously changing information, altering actions and controlling each other independently. That ultimately enables improvement in the production process or manufacturing process. Cyber-physical system, Internet of things, smart factory and internet of service are the most common terms cited in academic research publications related to industry. Industry 4.0 takes technology to the next evolution by blurring the lines between digital and physical world. Textile industry 4.0 is an interpretation and application of industry revolution 4.0 in textile technology and textile manufacturing sector across the supply chain in spinning, weaving, finishing and garmenting. Textile industries have to move towards industrial revolution characterized by artificial intelligence, internet of things, 3D printing, wearable, robotics, nanotechnology, advanced material, biotechnology and others. ‘industry 4.0’ is the future of manufacturing technology and it will have a greater trend for automation and data exchange. Improved technology, digital system and automatic process will make the manufacturing process or production process optimum for the production of quality products. If textile manufacturing companies engage with the new trend of ‘industry 4.0’, then it will create greater impact in textile value chain in terms of productivity, quality and efficiency.

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