The textile sector is undergoing a significant transformation driven by shifts in consumer behaviour, and supply chain dynamics, as well as increasing economic uncertainty. With power shifting towards buyers, the consumers are the major drivers of market demand. That’s the reason that IoT in textile industry is creating a buzz as it can enhance the value of offerings for this industry.
When it comes to Industry 4.0, IoT is a crucial technology that facilitates the digital transformation of production processes and the integration of cyber-physical systems. By leveraging data analytics, IoT enables remote updates and real-time monitoring of textile machinery, eliminating the need for labour-intensive, time-consuming manual interventions. Furthermore, businesses can enhance their operational efficiencies and enable machines to perform tasks that were previously unachievable in earlier industrial eras through the analysis of sensor-generated data.
Major Benefits of IoT in Textile Industry
Inventory Management
Most textile manufacturers face significant challenges with inventory accuracy, as it is difficult to maintain ideal inventory levels without clear insight into the demand for specific products. However, IoT sensors in textile manufacturing can help solve this issue which offers real-time and accurate information about inventory levels. The real-time information on stocks can enable manufacturers to enhance their inventory optimisation strategies. IoT allows textile manufacturers to automate the restocking of stocks as per actual customer demand instead of just relying on retail orders.
Process Efficiency
The utilization of IoT can improve the process efficiency for textile manufacturers. Workers can collect relevant and real-time information from connected devices which allows for transparency into the duration of work orders and timely completion. The real-time data of all enables shop floor managers to access and analyze data instantly. When wearable technology is also incorporated, managers can gain a comprehensive view of operations, including the ability to track work progress. This gained information can be used to optimize processes, which enhances process efficiency.
Asset Monitoring
oT is highly beneficial in monitoring the various equipment and machinery involved in the textile manufacturing process. IoT textile production allows asset monitoring and tracking which enable manufacturers to keep a check on the location, quality, performance, anomalies, bottlenecks, and other parameters related to the overall process. Technologies such as RFID, Wi-Fi, and Bluetooth can all the moving parts which allow manufacturers can gain visibility into their assets, detect fluctuations in operations, and take timely action to ensure optimal performance.
Process Automation
IoT can drive automation on the shop floor of any manufacturing setup which further reduces the time-to-market, even for time-consuming tasks. IoT-powered automation is useful for all stages of production, including warehousing, to minimise labour intensity, regulate processing time and errors, and enhance worker conditions. For instance, if the manufacturing plant uses robotic arms for the precise guiding of clothing pieces through a sewing machine, IoT automation can further reduce costs and expedite the process. Moreover, technological geniuses like self-driving vehicles which sort and pick devices can transport items to their designated shelves, thus significantly diminishing manual effort and accelerating production speed.
Supply Chain Management
Reducing lead times is crucial to ensure prompt delivery of products and stay competitive in the textile sector. IoT enables manufacturers to integrate and implement the end-to-end process “in-house,” resulting in enhanced speed and supply chain efficiency. By performing tasks such as material sourcing, creative and technical design, samples, production, and shipping physically or virtually under the same roof, IoT facilitates seamless operations. The continuous flow of information across departments in real time assures that everyone has access to the same data which leads to much-needed consistency for the manufacturing plant.
Real-time Feedback
Textile-based businesses can leverage the network of connected textile machines on the manufacturing shop floor to receive instant notifications and feedback on defects or damaged goods. Such prompt feedback results in cost savings and waste reduction. Detecting errors early leads to faster rectification with minimal impact on the rest of the delivery process. Real-time monitoring and data collection of the production process can facilitate quicker, more proactive, and clearer communication. IoT provides insights that keep everyone in the manufacturing unit constantly updated and informed of any changes as they happen. This helps optimise business planning and stock replenishment.
Change Management
IoT allows textile manufacturers to design and produce customised apparel quickly with the growing demand. Real-time data on customer preferences can be incorporated into the production process to allow for changes in designs, instant review of modifications, and quality enhancement. With minimising unnecessary waste and errors during the sample phase but also enables real-time adjustments as needed. With IoT, textile manufacturers can respond quickly to customer needs and provide tailored products while reducing waste and errors.
IoT in Textile Industry: Expanding Businesses Opportunity
Innovation in the materials used for IoT devices has stagnated recently, and with ongoing supply chain issues-textile industry has also been affected. Currently, wearable technology is dependent on hard chips to measure the movements of the human body, but by incorporating smart textiles, clothing has also become the main tool for capturing data and gaining valuable insights. It makes it easier for users to work in a manufacturing plant as it keeps them safe in heavy-duty work as they get to know any irregularities within the machine beforehand. IoT-based smart textile manufacturing also increases consumer satisfaction as manufacturers can gather more behavioural data through fabric-based sensors created with the help of sewing technology.
Fabric As The Data Capture Tool for IoT in Textile Industry
IoT-based sewing technology has the potential to transform any sewable material into a smart product through a careful combination of materials and patterns. Driving innovation requires the utilisation of existing infrastructure, machinery, labour, and sewing processes. The smart approach is to sew flexible electronics directly into fabrics, as it only requires a needle and thread that are widely available across multiple industries. Fabric-based sensors can also be integrated without the need for specialised machinery, as long as the user can work with a sewing machine. Moreover, sewing technology and fabric-based sensors can be implemented widely across the textile industry which makes it possible for enterprises to leverage the data to achieve a profitable business.
The sewing technology in the textile industry can transform consumer interaction. From smart surfaces and tech-enabled uniforms to connected car seats and even smart furniture, manufacturers can leverage these tools to capture more data and offer greater value to their end users. In the current business landscape, it’s increasingly clear that every company is competing to become a data capture company, as this provides access to valuable information and potential profits.
Conclusion: A Connected Future
IoT in textile industry adds value to the textiles ecosystem and reshapes the usage of connected devices. The textile industry in combination with IoT can tremendously advance the state of manufacturing and open new opportunities for insightful feedback.
Rejig Digital is a renowned entity providing comprehensive IoT solutions that empower businesses to innovate and transform their operations with advanced analytics and automation for driving growth and competitive advantage.
