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advances in apparel production technology

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advances in apparel production technology

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  1. THE ROLE OF TECHNOLOGICAL ADVANCEMENT IN FASHION MANUFACTURING BAHIRDAR UNIVERSITY BAHIRDAR UNIVERSITY Ethiopian institute of textile and fashion Ethiopian institute of textile and fashion technology technology Advances in apparel production technology Title the role of technological advancement in fashion manufacturing NAME: - ZINABU GIRMA ID; - BDU1207615 Program: - MSc In Fashion Technology Submitted by; - zinabu girma Submitted to; - Dr shalemu S. Submission date; - 28/5/2012 E.C 7/2/2020 G.C i

  2. THE ROLE OF TECHNOLOGICAL ADVANCEMENT IN FASHION MANUFACTURING Table of Contents page 1. Introduction ........................................................................................................................ 1 2. Role of technological advancement in marketing, merchandising, human resource and supply chain management: ......................................................................................................... 2 2.1. Role of technological advancement in marketing and merchandising ................... 2 2.2. Role of technology in human resource and management ........................................ 3 2.3. management .......................................................................................................................... 4 Role of technological advancement in finance, procurement and supply chain 3. Role of technological advancement in product development, pattern making and designing .................................................................................................................................... 5 4. The role of technological advancement in marker making spreading and cutting; ............ 6 5. Role of technological advancement in sewing; .................................................................. 7 6. The role of technological advancement in finishing, packaging and dispatching ............ 10 7. Conclusion ........................................................................................................................ 11 8. References ........................................................................................................................ 12 ii

  3. THE ROLE OF TECHNOLOGICAL ADVANCEMENT IN FASHION MANUFACTURING Abstract In recent competitive and globalized market scenario it’s better to cotro0l cost and other constraints in the manufacturing industries to execute operations and processes fluently with rousted approach to meet target market demands and to fulfil customer requirements due to this perspective in rolling with technological advancement is obvious and plays its significant role to meet planned objectives and helps manufacturing firms to compete and be selected one abroad. This paper addresses the vital role of technological advancement in every aspect of fashion manufacturing industries. iii

  4. 1.Introduction Manual works are being replaced by automated and semi-automated machines. In today’s globalized economy and market level, modern technology is undoubtedly developing rapidly for the further modification of way of fashion implementation in different aspects throughout the world. It can be seen that technology is a substitution of all characteristics of life to drive the way of performing our activities with the ordinary on toward extraordinary to reduce human inconsistency and intervention in the manufacturing process and phenomena.Advanced technology established this parallel world, ‘cyberspace’. Much more in the manufacturing industries the role of technology was obviously significant and enables manufacturing firms to boost productivity and increment of substantial lucrative and short period of returning the investment to that intended technology. Technology increasingly affects all aspects of social life. In order to survive the garment industry in the turbulent environment, it is necessary to meet customer requirements with respect to quality, price and delivery term. These criteria can be fulfilled only with the restructuring of existing production– business systems (PBS) by introducing modern technologies, changing forms of organization and participation of motivated workers. That not only changes the way goods are produced, but it also changes the manner in which the goods are distributed and promoted. Changes in technology create new markets, new products and new ways to create competitive advantage.(colovic, 2014) Undoubtedly technology advancement also has vital role in fashion manufacturing, marketing and advertising industries. Starting from receiving customers in marketing section up to delivering or dispatching finished products to the intended customers, meaning that the impartment of advancement in this firm helps to reduce wastes related to manufacturing and data handling and also helps to reduce delivery days for the intended design of product rather than the conventional and ordinary type of production system and methodology. Consequently, advancement of technology in the fashion manufacturing industry also imparts vital role to reduce paper-based works and in other ward to improve digital thinking to meet and hit customer requirements and also additionally to deliver qualified products with short period of time to the intended customers. CAD/CAM has been used in textile productions like order processing, management information systems, and the applications to all other areas of manufacturing processes. This has altered the perspective of textile and garment producers in developing countries towards technology-based production systems because of the pressures of globalization of business. (Islam, 2012). It follows that the introduction of modern designed and automatized machineries and their functionality and feasibility with the fashion industries was adequately driving the way of fashion movement toward meeting of customer interests and requirements.And also, fashion industry is undergoing large scale changes as a direct result of the rise of technology and its impact on consumer behaviour. 1

  5. THE ROLE OF TECHNOLOGICAL ADVANCEMENT IN FASHION MANUFACTURING 2.Role of technological advancement in marketing, merchandising, human resource and supply chain management: 2.1.Role of technological advancement in marketing and merchandising Marketing is communicating the value of a product, service or brand to customers, for the purpose of promoting or selling that product, service, or brand. (Jain, 2013)Technology can be defined as an environmental force that refers to inventions or innovations from applied science or engineering research. The influence of technology on advertising and marketing allows advertisers to personalize their messages to consumers. Technology can differentiate a firm from its competitors and gives the firm a niche advantage in the industry. By using technology, marketers are catching consumers’ attention by gravitating to their personal interests. (essay, n.d.) Ultimately further introduction of technological advancement leads fashion manufacturers to communicate comprehensively and efficiently, meaning that the introduction of CRM,PDM, ERP and other kinds of soft wares enables to maximize the surplus of the supply chain that can meets both suppliers, customers, manufacturers to impart its advantages for niches in this specific department to communicate and handle customer related data, to manipulate and shorten planning and scheduling periods for specifically intended design of product to optimize information flow in the manufacturing floor and abroad outside connections for further improvements of the organization in the recent globalized market scenario. The detail introduction of virtual try-on, augmented reality, virtual product display methods and the development of market related soft wares can paves way to reduce monotonous work flow in this department and integration of solid advancements or hard ware advancements with software advancements can enable to address customers and suppliers efficiently and effectively in short period of time and helps to boost productivity by reducing paper based works and drives them toward digital thinking to synchronize the manufacturing process with whole departments inside the industry. Using customer buying data along with artificial intelligence and machine learning, companies are able to better predict fashions that will sell. In doing so, they can also leverage low-cost final inventory purchases to keep pricing so low that customers will buy on impulse and buy more often. This consequently helps manufacturing industries to understand and aware with Marketing techniques to choosing target markets through market analysis and market segmentation, as well as understanding consumer behavior and advertising a product's value to the customer and additionally to select trust worthy suppliers in ever aspects to receive qualified raw materials also leads to substantial improvement on productivity. 2

  6. THE ROLE OF TECHNOLOGICAL ADVANCEMENT IN FASHION MANUFACTURING 2.2.Role of technology in human resource and management Human resource management mean managing the human power provided in the organization within specified technique that leads them for further courage related with the manufacturing scenario in the manufacturing industry to handle and execute intended activity within the system The use of technology within human resource management has grown considerably over the last decade with the majority of organizations now using some form of HR information system (HRIS). (Watson-Wyatt, 2002)The study called Effects of HRM practices on IT usage” (Lee, 2009) shows that organizations use technologies for HR field such as employee participation, clearly defined jobs and extensive formal training. On the other hand, according to survey, companies which are using external IT capability, only internal career opportunities used IT tools. The basic concept of HRM is to attract and retain the right person at right place in right time with right remuneration. In textile HRM should appoint the skilful employee at the right ,appropriate ,correct place where he/she express their capabilities ,because if we place sensitive people at spinning production then he will face so many problems. For textile, it is compulsory to that the company treat the employee as an asset of the company. A simple human transform as asset by selection of right person for right place & train him and provide adequate career development opportunity. (Srivastava:, 2002) To glean better advantages and to get ready for responsibility related with the organization and under the organizational structure of a manufacturing firm technology and digital thinking can helps to drive the traditional working mechanism and method of data handling and scheduling of employee assignment. By the detail collaboration of human courage and computerized world with feasible soft wares for intended kind of manufacturing organization the working environment becomes sustainable and feasible and imparts its niches. Hinging on this era the way that substantial data related with employees, related with workforce management and training issues to create skill full employees for specific operation or to make the managers knowledge and objective based impartment of technology plays vital role to meet ultimate goals of the organization. Garment and fashion manufacturing industries were passed through tough phases of development to reach toward this level of automation for this substantial change, technology was playing vital role meaning that there is no automation which is eliminated 100% of human intervention due to this perspective to handle and do well with the emerging technologies the introduction of this advanced technologies in this department(HRM) helps to create right operators, at the right place for the specified operation will be assigned and the betterment of the advancement comes later on this 3

  7. THE ROLE OF TECHNOLOGICAL ADVANCEMENT IN FASHION MANUFACTURING 2.3.Role of technological advancement in finance, procurement and supply chain management In age of paper-based transaction and communication, the information flow in supply chain networks was time consuming and error prone. Due to globalisation, organisations had started changing the way of communication, implementation of technology, growing diversity of business transactions and process improvement for sharpening the business performance through IT applications in their Supply Chain Networks. Supply chain management (SCM) is an integrated and complex network concept that refers to the sum of all the processes starting from the procurement of the raw material from the manufacturer/ producer and ending with delivery of the end-product to the consumer. (Silver, 1998) IT in SCM provides a reduction in cycle time, a reduction of inventories, a minimisation of the Bullwhip effect, and improvement in the effectiveness of distribution channels, (Levary, 2000) applications of Radio Frequency Identification (RFID) in supply chain (Gould, 2000) advanced information and manufacturing technologies for better managing their supply chains (Talluri, 2000) providing information availability and visibility and allowing decisions based on total supply chain information (Simchi-Levi, 2003) The In depth introduction of information technology and the cyber physical system as a building block for the recently emerging technologies in the manufacturing industries enables manufacturers to walk with the speed that is comparable to the movement of technological advancement. additional to this the introduction of JIT philosophy, ERM (electronic record management), bar code tracking, RFID (radio frequency identification) and others tends the manufacturers way of leading their organizations to the tip of the pyramidal hierarchy of market share from the recent globalized and competitive market scenario and helps them to pass cumbersome challenges related with handling large amount of data and orders and in further leaning on this technologies manufacturers can track and cop level of inventory in their stock and ware house, the substantial reduction of inventory and related wastes enhances feature production and facilitates the manufacturing process from staggered manufacturing methodology toward the feasible one and finally enables to get loyal customers and builds good image of the organization this then increases acceptability in the competitive and globalized market scenario abroad. 4

  8. THE ROLE OF TECHNOLOGICAL ADVANCEMENT IN FASHION MANUFACTURING 3.Role of technological advancement in product development, pattern making and designing With the change in production technology, regulatory measures, economic issues, and demographic factors textile and garment manufacturing processes have been changing. Technological change (e.g., CAD, CAM, and CIM) is the most powerful change driver in this sector that includes new and advanced machines, computer-aided production, design, and control. The CAD/CAM for grading, pattern making, marking, and sewing is most important among the technological developments in this sector. For exporting with greater design content and high value-added products, technological change is crucial for the garment company. This is the main balancing factors between suppliers and customers for satisfying their demands. (Islam, 2012) The introduction of virtual sampling, digital simulation, virtual try-on and CAD/CAM in fashion manufacturing sector helps to meet customer demands by mitigating product design related problems at the design stage before the freeze point of the product approaches this implies that there is massive reduction on costs related with design related defect and if the product is designed with better attention and care in further it enables to reduce defects and scarp in the next processes that are held in the manufacturing cycle of a certain intended design of product. In relation to pattern design, the ability to move from 2D to 3D is perhaps the area of most interest. The creation of 2D pattern shapes that can be wrapped around a virtual mannequin fits nicely within the 2D CAD pattern development application used within the industry. The ability to move on from this point of development seems likely to be the most acceptable way forward for the designer and pattern technologist. (colovic, advances in apparel production), 2005) Undoubtedly the advancement on the above mentioned technologies and their feasibility with the manufacturing scenario of fashion sector enables to glean substantial advantages by reducing lead time for specific products , by making the designing process concurrent and information based rather than the sequential way of product developing methodology.in fact this technologies require huge amount of investment to install in the manufacturing sector but the ROI( return on investment) period was short and leads to boost productivity and profitability in the recent competitive and globalized market scenario and also supports the manufacturer to develop market related ,demand led , and customer fitted products in further this lengthens the existence of the manufacturer in business arena and becomes the selected and best one by customers abroad. 5

  9. THE ROLE OF TECHNOLOGICAL ADVANCEMENT IN FASHION MANUFACTURING 4.The role of technological advancement in marker making spreading and cutting; As the time passes there are different types of cutting marker making and spreading methods were developed which helps to enhance the quality of the product as well as time required for cutting and related processes in the cutting shop floor like fusing, sorting, bundling &ticketing process is reduced. These mechanisms can able to play their vital role for the improved production capacity of cutting section in fashion manufacturing sectors. Likely the step by step development of cutting process from hand shears that can cut little lays of fabric toward the modified semi-automatic technologies like straight knife round knife, band knife and toward automated machineries computer programming and computer numeric control system that can perform various operations at a time like the designed marker can be fed into the machine by USB slots and the machine itself can perform auto spreading of the fabric auto inspection and cutting collaborately with the help of mechatronics. In detail introduction of advanced technologies like Gerber accumar, Lectra, Rich peace, Optitex for pattern making, marker making and grading leads to abolish huge amount of time wastage on the way of product development cycle, sample designing and marker efficiency that can leads for further utilization of fabric was exceeded in contrary with the conventional way of tracing the silhouette of garment panels on the specified and intended marker papers. Additional to this automatic pattern cutting machines were emerged to help designers in niches and the further introduction of pin tables eliminated problems related with stripes and checked fabrics and others. Rewardingly also the application of continuous fusing machines, 3D heating, RFID and real time data tracking in the production floor can enables the manufacturers to control and monitor their sector with the help of IOT (internet of things) that can integrates and communicates every aspects and end terminals in the manufacturing industries. Due to the introduction of recently emerging technologies like this and application of JIT, KANBAN and QR (quick response) philosophies the production capacity was substantially improved and the prosperity of garment manufacturers become increased and the communication with sewing floor to optimize and balance the manufacturing process becomes manipulated. by this consequence unwanted production was reduced and also production losses due to missed communication within the manufacturing departments, (NPT) non-productive time , (NVAT) non-value adding time, production delays , product wastages and others also reduced. this implies that the further reduction of the above mentioned problem in the production floor lead to produce qualified products that can delight customers in various aspects like products that can meet short delivery dates ,better and improved quality, optimal and affordable prices this consequently drives the fashion manufacturing sector to compete in the recent globalized market scenario and helps to improve and boost productivity And also gleans competitive advantages from those advanced and technologies. 6

  10. THE ROLE OF TECHNOLOGICAL ADVANCEMENT IN FASHION MANUFACTURING 5.Role of technological advancement in sewing; In olden days when sewing machines were not introduced Sewing were carried out by wrapping animal hides and leaf of plants for clothing and for shelter, for example, they used sinew from caribou for thread and needles made of bones. The democratization of fashion began with the invention of the sewing machine, which turned a handicraft into an industry. The sewing machine made the mass production of clothing possible. (Khandalkar, 2006) Automation on sewing machines due to the invention of motor engine that capable to motorize mechanism of sewing machine and automation in the movement of sewing machine parts by the help of internal and external wise integration of mechatronics (mechanical with electronics) to synchronize operational accuracy and enhance conventional working mechanism of sewing machines to produce qualified and defect free products with maximum productivity and production capacity. In fashion manufacturing and apparel sectors sewing machines play vital role to change the 2D fabrics into 3D with the internal and external integration of sewing machines parts. These machines fell under the categories of basic or mechanical sewing machines which are driven by power exerted from the operator’s leg or electronic or motorized machines which are mostly used and available with affordable prices with different kinds of functionalities and brands for desired kind of operations. In contrary the advancement on the mechanization and automation of sewing machines in a way of garmenting or garment manufacturing was emerging to drive the conventional way of sewing to ward extraordinary level to reduce and eliminate the draw backs of conventional methods of sewing. In the scenario of Industry 4.0, smart products come with details about the operations to be done on them. The sequence of operations to be performed on a product is already loaded onto the carrier of that product. This information is already passed on to the machine for automated operations, and shown with better visualisation interfaces for manual operations. Improved man-machine interfaces also present information in a more appealing manner, and avoid possibility of making mistakes in the production processes. (Schuh, Gartzen, & Rodenhauser, 2015).) Obviously technology have un doubtable role to change the ordinary way of garmenting in the manufacturing industries, to say that due to the introduction and emergence of newly advanced modern technologies like CNC(computer numeric controlled machines), PLC(programmable logic controllable machines that can rectify machine languages into specific and understandable electrical signal to start the whole transmission of motion through the whole body of the machine and led to execute intended operations. this in further reduces inconsistency of human being and robust the way of sewing to produce quality products With Industry 4.0-technologies, plug and play and distributed systems are equipped with self - optimizing and machine learning behaviour, which enable firms to adapt machines according to products and produce small batch sizes. The operations to be performed on a 7

  11. THE ROLE OF TECHNOLOGICAL ADVANCEMENT IN FASHION MANUFACTURING part are initially loaded into the part through RFID tags (Sanders, Elangeswaran, & Wulfsberg, march,2016) The awareness of technology in sewing department have creating an immense change on the way of performing and monitoring operations. Implies that the emergence and introduction of technologies like modern fixtures and work aids lead to reduce takt and lead time for specific operations in the sequential process of garmenting due to this phenomenon the schematic flow of operations becomes short and it tends to satisfy employees by reducing fatigue and monotonicity of the operation by this cause the overwhelming challenges become reduce. It is well defined fact that technology can drives underlie cultural and conventional way of thinking and working procedure toward the peaks of digital thinking and objective based working and decsion making in the manufacturing industries mean that due to the advancement technology manufacturing industries becoming enriched with prosperity by implementing modern and advanced technologies in their entire organization. The introduction of information and communication systems into industrial network also leads to a steep rise in the degree of automation. Intelligent and self-optimising machines in the production line synchronise themselves with the entire value chain, right from order or materials from suppliers to delivery of goods to customers. (Spath, Ganschar, Gerlach, Hämmerle, & Krause, 2013) Technology in the fashion manufacturing sectors notably helps to improve the way of order tracking and being ready toward market led demands. unambiguously the introduction of RFID, bar coding and other related fixtures help to track and manipulate way of manufacturing by giving related data by the help of artificial intelligence, data analytics and optical sensing. Real time data tracking mechanism with the entire corporation of these mechanisms helps to boost production capacity of sewing shop floor with short cycles. with unanimously newly invented technologies for the mechanization of sewing like digital feed system that can be driven by its own individual servo motor can able to eliminate defects like birds’ nest, seam puckering and staggered stitches due to the conventional design of feed system on the sew able products also rewardingly Vision sew technologies, automatic bobbin changing and winding systems have tremendous effect on increasing sewing room productivity and reduce production costs. In the recent era of technology implementation of advanced technologies like circular knitting helps to fully eliminate costs and time for cut and sew processes due to the elevated performance of the machine to design and finish single garment at a time. also the introduction of alternate sewing methods like thread less seaming by ultrasonic seaming, seam bonding, laser light sewing by the help of laser light and optimal heating mechanisms by melting thermoplastic substrates inserted to sustain seam performance during performing this special kind of operation can reduces penetrance of needle to the intended design and helps to reduce bulkiness of seams and gives better performance and better look for the products due to this fact customers become more satisfied and the depth satisfaction of 8

  12. THE ROLE OF TECHNOLOGICAL ADVANCEMENT IN FASHION MANUFACTURING customers led the manufacturing industries to develop promptly by updating and imparting continual improvement within their industries. All in all, the role of technology in sewing department of fashion manufacturing industries is uncountable and leads to -High and improved over all productivity -Better forecasting and risk mitigation -Better tracking of inventory and production monitoring and control -Improved work method -Reduced production cost and short ROI (return on investment) -Better communication and work flow -Short delivery dates -Sort cycles of production -Wastage reduction -Customer satisfaction -Efficient utilization of resources and etc … 9

  13. THE ROLE OF TECHNOLOGICAL ADVANCEMENT IN FASHION MANUFACTURING 6.The role of technological advancement in finishing, packaging and dispatching Long periods ago before technology is introduced this much peoples can utilize ironing machines that can perform by the help of ember created by charcoal that helps to create heat and the heavy weighted iron plates were utilized to straighten Wrinkles and impar pleasant look to their garments. and to send messages and other information can utilize conventional courier method, In recent period and era of technology finishing, packaging and technology was reaching at its maximum due to invention of modified and functional electrical fuses and mechanical parts. by the integration of mechatronics, machine learning and artificial intelligence. Now a time technology has imparting its part to ward the way and method of finishing, packaging and dispatching of goods in the manufacturing and service industries. Due to the introduction of continuous finishing machines like tunnel finishers for suit producing companies, continuous shirt body and dolly press machines for shirt manufacturing industries and continuous t-shirt press machines for knit t-shirt manufacturing industries lead to improve performance, quality and out look of products with short cycle time this helps to maximize over all productivity of the manufacturing industries and to glean increased lucrative. One of the most significant factors for the dissatisfaction of employees were monotony and routine performances of operations this leads to create defects and products with poor quality this causes to dis satisfaction of customers in ward but due to the advancement of technologies and mechanisms in the recent fashion manufacturing industries problems like this has been mitigated and reduced In comprehensive view introduction of information technology in garment sectors communication flow between floor to floor was fluent and enables to create concurrent approach to the intended design of product development process hence finishing is one base process in the Sequence of product development hinging on better information related with the product helps to finalize the product with acceptable quality level to meet customer requirement. Due to the substantial advancement of technology and introduction of auto folding machines, enhanced packaging and inventory tracking System by the help of RFID and bar code reading technology emerging cumbersome challenges from the conventional way of finishing, packaging and dispatching operations were reduced immensely. In further due to the introduction of e-commerce, e-selling and dispatching soft wares fashion manufacturers Prompt their level of market through dispatching based on these technologies the world abroad this in fact can able to reach customers around the world. It follows that when we compare with the conventional way of finishing the advanced one is efficient and robust regarding this fashion manufacturing industries can able to compete in the recent Competitive market by producing and dispatching market led products. In contrary the conventional way of finishing, packing and dispatching method leads to excess inventory level and increased fatigue and loss of productivity. 10

  14. THE ROLE OF TECHNOLOGICAL ADVANCEMENT IN FASHION MANUFACTURING 7.Conclusion As a mater of fact introducing technologies in fashion manufacturing sectors have significant role in every departments to synchronize integrate and manipulate the ordinary way of manufacturing entirely to ward extra ordinary in detail and further helps to make processes robust and productive due to this phenomenon the overall productivity of the companies become boosted and helps them to compete abroad. 11

  15. THE ROLE OF TECHNOLOGICAL ADVANCEMENT IN FASHION MANUFACTURING 8.References colovic, D. G. (2005). advances in apparel production). WOOD HEAD PUBLISHING. colovic, D. G. (2014). management of technology systems in garment industry. woodhead puplishing. essay, u. (n.d.). UK Essays. Retrieved from http;//www.ukesays.com Gould. (2000). The role of RFID in SCM. Islam, D. N. (2012). the Impact of Global Technological Change on Textile and Garment Workers of Bangladesh. ijert, 12. Jain, D. E. (2013). Role of technology in modern marketing. research gate, 4. Khandalkar, P. G. (2006). Developments of cutting & sewing technologies in garment industry . ijert. Lee. (2009). effect of human resource management practice practice on IT. research gates. Levary. (2000). role of technology in SCM. Sanders, A., Elangeswaran, C., & Wulfsberg, J. (march,2016). industry 4.0 implies lean manufacturing. journal of industrial enginerring and management. Schuh, Gartzen, & Rodenhauser, M. ( 2015).). Promoting Work-based Learning through INDUSTRY 4.0. Procedia CIRP, 32, 82-87. Silver. (1998). thr role of IT based technologies in manufacturing industries. journal of management studies. Simchi-Levi, S. (2003). THE role of information technology in IT. Spath, Ganschar, Gerlach, Hämmerle, & Krause, S. ( 2013). Industrie 4.0. Stuttgart. journal of industrial engineering and management. Srivastava:, (. (2002). Textile industry in need of trained technicians). research gates. Talluri. (2000). Watson-Wyatt. ( 2002). the role of human resourse management in manufacturing industries. international management articles, 3. 12

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