At the Jack Intelligent Digital Clothing Factory in Hangzhou, Zhejiang, rolls of fabric “obey” instructions and are sorted out from the three-dimensional shelves with QR codes, and enter the smart cutting room and smart sewing workshop.
The large and small pieces that are cut into pieces are kept “without touching the ground” throughout the process. Under the “escort” of the intelligent hanging system, they are rolled off the production line in the form of ready-made garments in a short time, and then automatically sorted. Style, color separation, coding, packaging and storage.
The entire process data is updated in real time. Not only can it be displayed in real time on a huge electronic display, but it is also clear at a glance which link is slow and which equipment has problems…
This intelligent digital clothing factory built by Jack Technology Co., Ltd. (hereinafter referred to as “Jack”) has a higher automation rate, stronger quality control requirements, and more advanced clothing technology.
From small pieces to large production systems, the innovations, as well as the infinite reveries and expectations brought by technology to the clothing industry are no longer just “concepts” in PPT, but more and more. Entering into every link of the clothing industry chain, the clothing industry has realized an intelligent “butterfly transformation”.
Make the clothing production line smarter
At Jack, when clothing fabrics enter the production process, whether it is physical work such as material selection, handling, transmission, or cutting , sewing and other technical work, all the way to the finishing and packaging of finished garments, can be “handled” by the intelligent equipment in the modern production workshop.
According to Jack founder Ruan Jixiang, technology is not only a tool and guarantee for improving production efficiency and product quality, but also an inevitable choice for the garment industry to achieve high-quality development.
“For example, in the cutting process, Jack has launched a variety of hardware equipment equipped with software systems that can well solve the problem of defect detection and grabbing. It can not only achieve rapid inspection results, improve cutting quality, but also Reduce the cost of manual inspection.” Ruan Jixiang said, “With the help of Jack’s full-process software and hardware solutions, defects are identified through the AI intelligent cloth inspection machine, and the cloth loading machine can automatically load the inspected cloth onto the spreading machine; equipped with intelligent projection The spreading machine of the positioning system can automatically record defect information and locate the defect location through the marking machine, quickly finding defective pieces in the cutting process of the intelligent cutting bed. There is no need to manually inspect each piece, and qualified pieces can be Directly store them into the ‘cutting supermarket’ that specializes in storing cutouts for selection in subsequent processes.”
“Through the use of AI intelligent cloth inspection machines, possible quality problems can be solved in advance at the raw material end. .At the same time, through intelligent modules on devices such as the Internet of Things, the system can minimize the defective rate and rework rate of products.” said Tong Baoyu, head of Jack’s smart digital clothing factory.
Ruan Jixiang also introduced that compared with the traditional clothing production process, Jack’s smart digital clothing factory focuses its research and development on “complete systems” and “intelligent digitalization”.
Walking into Jack’s smart digital clothing factory, robots of all sizes are the busiest “workers” in the factory. They transport items from designated locations along set routes to processing points according to instructions.
In the sewing workshop, by integrating the intelligent hanging, sewing machine operation screen and management system, Jack has realized the “Internet of Things” and data interoperability of sewing equipment, which can not only fully grasp the equipment online rate, but also accurately calculate The working hours of picking, sewing, hanging and other processes can be used to evaluate lathe skills and improve the balance rate of the production line. It can also implement functions such as issuing process parameters, locking equipment parameters, and reporting for repairs with one click, which not only ensures product quality, but also improves production efficiency. . In the entire production process, the reliance on labor in traditional clothing assembly lines is greatly reduced.
According to Wen Lisheng, a professor at Donghua University and deputy leader of the expert group of the China Garment Intelligent Manufacturing Alliance, the most difficult thing about using robots in the clothing production process is the precise grabbing and conveying of various pieces. , collaboration of processing modules, folding and paving of industrial hands and other issues. Compared with traditional industrial robots, robots in clothing production lines not only have intelligent data analysis functions, but also have perception capabilities, decision-making capabilities, business capabilities, and human-computer interaction capabilities. They can realize “unmanned operation” in smart clothing manufacturing. ” or “few people” smart clothing manufacturing factory.
Digitalization opens up “information islands”
Long production cycles, high logistics costs, and inventory backlogs are common problems faced by clothing companies. At the same time, under the influence of the fast fashion trend, the delivery capabilities of large and medium-sized clothing companies have been put to the test. The transformation from large-scale production to small batch and customized production has become a general trend.
However, achieving this is not something that can be accomplished overnight. This requires clothing companies to improve operating efficiency on the basis of integrating the entire industry chain, so as to achieve rapid response.
“In the past, clothing production processes such as fabric inspection, loosening, cutting, sewing, sorting, packaging, etc., each production process was separate, and data and information could not be processed in real time. Sharing and information exchange still require a lot of manual work, and it is difficult to achieve “quick return of small orders” in the production process. Now, we are supported by the clothing equipment industrial Internet of Things platform and application software ecological platform, through a complete set of intelligent and…The two solutions of �Chain Cloud Link have opened up the “information islands” in seven major scenarios of clothing factories, including fabric auxiliary material warehouses and cutting, helping clothing companies improve production efficiency and help form a good ecological pattern up and down the industrial chain. “Tong Baoyu introduced.
Next to each sewing machine in Jack’s Zhilian digital clothing factory, there is a tablet computer. “The data is uploaded through this machine. “Tong Baoyu said, “Information such as order changes and style changes obtained when customers place orders will be transmitted to this terminal in real time in the form of instructions. Sewing machines no longer only sew clothes, but can also ‘produce numbers’ and can realize the trinity digital intelligent management model of people, machines and materials. ”
“Jack’s smart screen solution is based on the underlying data of sewing machines and hanging equipment, and is combined with software such as Jack’s MES (production information management system) to configure simple smart screen system operations to allow production data to be integrated Screen presentation realizes real-time interoperability of equipment layer, transmission layer, cloud platform and software, and effectively provides data collection and processing for clothing enterprise information systems. “Jin Luyan, General Manager of Jack’s Global Strategic Accounts Department in China, introduced.
In fact, Jack’s complete set of intelligent connectivity solutions has been gradually introduced into large and medium-sized clothing manufacturing enterprises since last year.
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Qingdao Ruihua Group is a “pioneer” in the digital transformation of garment enterprises. Through lean, automated, and information-based transformations, it has achieved data integration in the entire production process, increased overall production efficiency by 20%, and its flexible production The transformation of the model can reduce the minimum order quantity from the past 10,000 pieces to 1 piece, and reduce the product production cycle from 20 days to 7 days. Jack’s smart cutting room, smart hanging, Internet of Things template machine and automated sewing unit , automated logistics and other software and hardware systems have played an important role in it.
In-depth integration to create smart factories
Intelligent manufacturing is the wave of the times , is also the development direction of the clothing industry. Against this background, the transformation of my country’s clothing industry from “Made in China” to “Intelligent Manufacturing in China” is an inevitable trend.
“Leading” at the forefront of the industry, through complete sets of intelligent connectivity With a comprehensive display of the application scenarios of the solution, Jack has painted a multi-scenario interconnected smart clothing manufacturing blueprint for the clothing industry.
However, in Wen Lisheng’s view, the development of the clothing manufacturing industry In the pre-sewing, sewing section, finishing and ironing, and warehousing, logistics and distribution, the automatic cutting and warehousing, logistics and distribution links are better able to achieve digitization, networking and partial intelligent automation. The degree of modernization and automation is still relatively low.
At the 2022 China Clothing Technology Conference held in Hangzhou not long ago, Zong Ruilong, deputy director of the Textile Division of the Department of Consumer Goods Industry of the Ministry of Industry and Information Technology, also pointed out This point. He emphasized: “Clothing intelligent manufacturing technology should focus on sewing links and mass customization, as well as clothing functional technology to promote collaborative innovation in the upstream and downstream of the industrial chain, and increase the application of new materials and new processes in clothing. ”
As early as 2016, the Ministry of Industry and Information Technology gave the following definition of intelligent manufacturing: Intelligent manufacturing is based on the deep integration of new generation information and communication technology and advanced manufacturing technology, and runs through design, production, All aspects of manufacturing activities such as management and service are new production methods with self-perception, self-learning, self-decision-making, self-execution, self-adaptation and other functions.
In this regard, Wen Lisheng believes that for manufacturing enterprises For example, in order to transform smart manufacturing factories, we must first deeply integrate the new generation of information and communication technology with advanced manufacturing technology, which means that smart manufacturing factories need to be based on the digitalization of all production workshops; secondly, all businesses must be intelligent, and only by realizing Only by integrating intelligent design, intelligent production, intelligent management, intelligent services and other businesses can it be possible to build an intelligent manufacturing factory with self-perception, self-learning, self-decision-making, self-execution and self-adaptation.
“Clothing Intelligent Manufacturing The complexity of the system comes not only from the development of related technologies, but also from changes in the clothing products themselves, customer needs, and supply chains. Wen Lisheng said that the complexity of manufacturing can no longer be solved by traditional information technology. As the complexity of manufacturing systems continues to increase, the response capabilities of information technology must also continue to improve. The complexity of intelligent manufacturing requires intelligent cloud architecture. information system to solve the problem.
“In the process of digital transformation, all sewing equipment must first complete digital twins and lay a solid foundation for intelligent manufacturing; all sewing equipment must become the carrier of AI, making sewing The equipment has the functions of machine perception, machine learning, machine thinking, and machine behavior; the manufacturing model of clothing products is transformed into modular manufacturing, which is conducive to the realization of intelligence; a modular processing station is constructed with ‘human + intelligent sewing + intelligent robot’ and fixed modular sewing processing lines; based on the practice of fixed modular sewing processing lines, gradually practice self-learning, self-decision-making, adaptive, self-executing, and dynamic modular sewing processing lines to achieve a true sense of of smart factories and smart production. “Wen Lisheng said, “This is the step to truly realize an intelligent clothing sewing factory. ”
Keywords:
Digital clothing factory fabric production
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Digital clothing factory fabric production
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