Garments automation is needed for the global demand of clothing has increased manifolds because of increased population, change of consumer’s attitude toward fast fashion, and increase in the average income per head in many countries. This increased demand for clothing is fulfilled by the developing countries, which are now becoming the manufacturing hub for several international fashion brands. Apparel manufacturing is still a labor-intensive process in these developing countries, although there has been automation available commercially. Availability of cheap labor and the high initial investment are the causes for which the garment industries are not adopting the technology. However, the global demand for high-quality clothing and stiff competition is now mandating many manufacturers to adopt automation technology.
Garments Automation in production of yarns, woven, and knitted fabrics
The production of yarns and sewing threads is highly automated. A long tradition in the automation of the spinning process is mainly based on the experience of a few machine manufacturers. Improvements in automation in garment manufacturing are mainly focused on fabric production. Three knitting processes are compared regarding automation, productivity, and flexibility. Also, the quality inspection of knitted structures is evolving to a camera-based automated monitoring system that needs to cover the complexity and variety of knitted structures. An approach in self-optimization is described for weaving machines to autonomously find an operating point, which improves all objective functions, compared with conventional (reference) machine settings. With the development of an on-loom imaging solution, the online monitoring of the weaving quality becomes possible and reduces waste at an early stage of production.
Garments Automation With PROTRACKER
Real-time production tracking system PROTRACKER is the first Bangladeshi software for ready-made garments industries. A professional & skilled team of Skylark Soft Limited developed this. PROTRACKER is a fully customizable system for the apparel industry. That manages the entire production process from getting order details to production. From shipping to invoicing can be integrated with the management software.
- Fully automated and real-time.
- Fully responsive and mobile optimized.
- Cloud-based & remotely accessible.
- Quick Decision Making.
- Less WIP & Zero Waiting Time.
- High Efficiency & Productivity
- Saves time, manpower, and cost.
- Auto-generated reports.
- Automated challan/gate pass.
- Fake production tracking.
- Email/SMS Notification.
- Automatic Rejection Counting System.
- Lifetime Data backup
- It tracks dishonest supervisors.
- It tracks real-time floor, line efficiency.
- It tracks NPT reports.
- Good appreciation from the buyer.
- Fast and easy to use.
- It tracks excess shipment.
- It tracks extra cutting and many more.
- Real-time Hourly Production Data
- Line target and manpower.
- Challan closing report.
- Lost bundle card checking.
- Operation Bulletin.
In the garments automation process from cutting, an operator only inserts order information like a buyer, order, color, size, etc. After receiving a lay chart from the cutting table, he generates barcode enabled bundle card. After printing the bundle card, he binds this bundle card to the fabric bundle. All kinds of the report will auto-generate. No manual works are needed. After that, QC Inspectors check that and send it to cut inventory/sewing input.
An operator scan bundles to send print/embroidery factory through automated challan/gate pass. After finishing the process in the print/embroidery factory, he receives it through the scan. He put rejection quantity if he gets any rejection from the print factory. Finally, all rejection report will generate as usual. The operator can send solid or printed garments to the individual line through the scan and automated challans. Loader/Helper/Input man will receive input details like challan/bundle details.
The middle of the sewing floor operator will sit with a pc. He scans the bundle card after receiving the completed and checked body from QC. Real-time reports like hourly production, efficiency will display on the floor display device.
PROTRACKER successfully automates all levels of garments from cutting to finishing with software for real-time production tracking. In a word, it is a real-time production tracking system for a garments automation process.