Apparel Quality Management-II

END TERM ASSIGMENT

National Institute of Fashion Technology

Department of Fashion Technology

TOPIC- Research on the role of quality in the future trends

of technology adoption in garment manufacturing

SUBMITTED TO: SUBMITTED BY:

Prof. Vimal Singh

P. Ravi Kumar (BFT/20/196)
ASSISTANT PROFESSOR Ritika Garg (BFT/20/197)
NIFT GANDHINAGAR Srishti Sinha (BFT/20/442)
Tejesh Shami (BFT/20/1206)

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 TABLE OF CONTENTS

S. No. Content Page No.

1. Introduction 1

2. Background 2
(8 Dimensions of quality, Quality 4.0, Tools)

3. Research Questions 5

4. Research Objectives 6

5. Literature Review discussing some Major 7

Technologies used in Garment Manufacturing

6. Role of these latest technologies in Quality 13

Improvement

7. Survey Analysis 16

8. References 20

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Introduction
The fourth industrial revolution, sometimes known as "Industry 4.0," is currently underway.
Not simply innovation, but also paradigm shifts in manufacturing and service delivery are
being driven by data, analytics, collaboration, scalability, and connectivity.

A new industrial reality presents businesses with both an opportunity and a requirement to
adapt. These factors include artificial intelligence and machine learning, big data, cloud
computing, augmented and virtual reality, new materials, 3D printing, and the Internet of
Things. Perhaps more importantly, however, is how these factors interact.

A cultural shift is taking place as businesses progress towards Quality 4.0, and it will have an
effect on the workforce, the leadership, as well as issues like product innovation, production
efficiency, supply chain performance, compliance, and, of course, quality.

Thanks to Fourth Industrial Revolution technology, the divisions between the physical, digital,
and biological sectors of global industrial systems are evaporating. The speed at which
technology is developing now has a big impact on how people live and work.

These technologies drive businesses and governments to rethink and retool everything they do
internally, and governments are compelled to rethink and retool their national competitive
advantages and development strategies.

Fashion is no different; in fact, some of the most intriguing discoveries have come from the
production and manufacture of fashion, which has altered how the entire sector currently
functions.

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Background

The eight dimensions of quality, often referred to as the "Eight Dimensions of Quality
Management," are a framework that helps organizations understand and measure various
aspects of product or service quality. These dimensions provide a comprehensive view of
quality and serve as a guideline for quality improvement efforts.

8 Dimensions of Quality

1. Performance: brands can usually be ranked objectively on individual aspects of

performance.
2. Features: Features are additional characteristics that enhance the appeal of the product
or service to the user.
3. Reliability: This is a key element for users who need the product to work without fail.
4. Conformance: Is the product made exactly at the designer intended customer usually
think high quality product as which exactly needs the requirements placed on it.
5. Durability: Durability measures the length of a product’s life. When the product can
be repaired, estimating durability is more complicated. The item will be used until it is
no longer economical to operate it. This happens when the repair rate and the associated
costs increase significantly.
6. Serviceability: Serviceability is the speed with which the product can be put into
service when it breaks down, as well as the competence and the behaviour of the service
person.
7. Aesthetics: This is the usual appeal of the product, often taking into account factors
such as style, colour,packing alternative and other sensory features. i.e.Those that have
features the basic performance of the competition.
8. Perceived Quality: Perceived Quality is the quality attributed to a good or service
based on indirect measures.

Quality 4.0
"In the context of Industry 4.0, the term "Quality 4.0" refers to the future of organisational
excellence and quality. Leading their organisations to apply tried-and-true quality disciplines
to cutting-edge, digital technologies can be a crucial responsibility for quality experts. At the
same time that quality has become more important on the business agenda, new technologies
have evolved to meet the issues of quality management.

The list of prominent events involving subpar items is growing. Such occurrences, which in
some circumstances end in fatalities or major injuries, may have disastrous effects on
businesses, including bankruptcy.

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Governments have increased regulatory scrutiny to safeguard public safety, which has
increased expenses for businesses as they attempt to abide by rules and regulations and lower
risk exposure.

The emergence of the "factory of the future," in which digitally improved plant structures and
processes promote efficiency and flexibility in the factory and throughout the supply chain, is
being fueled in part by numerous innovations, including Quality 4.0. Numerous options exist
for digital technologies to assist increase quality. For instance, businesses can use analytics to
monitor processes, gather data in real-time, and foresee quality concerns and maintenance
requirements. Digital tools also help people complete their tasks more quickly, more
effectively, and more cheaply.

Quality 4.0 Tools

In addition to the timeless and well-known quality tools and principles, the Quality 4.0 tools
below should be leveraged to alleviate these challenges when implementing and deploying
systems to support digital transformation.

● Artificial intelligence: computer vision, language processing, chatbots, personal

assistants, navigation, robotics, making complex decisions.
● Big data: infrastructure (such as MapReduce, Hadoop, Hive, and NoSQL databases),
easier access to data sources, tools for managing and analyzing large data sets without
having to use supercomputers.
● Blockchain: increasing transparency and auditability of transactions (for assets and
information), monitoring conditions so transactions don’t occur unless quality
objectives are met.
● Deep learning: image classification, complex pattern recognition, time series
forecasting, text generation, creating sound and art, creating fictitious video from real
video, adjusting images based on heuristics (make a frowning person in a photo appear
to smile, for example).
● Enabling technologies: affordable sensors and actuators, cloud computing, open-
source software, augmented reality (AR), mixed reality, virtual reality (VR), data
streaming (such as Kafka and Storm), 5G networks, IPv6, IoT.
● Machine learning: text analysis, recommendation systems, email spam filters, fraud
detection, classifying objects into groups, forecasting.
● Data science: the practice of bringing together heterogeneous data sets for making
predictions, performing classifications, finding patterns in large data sets, reducing
large sets of observations to most significant predictors, applying sound traditional
techniques (such as visualization, inference and simulation) to generate viable models
and solutions.

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Challenges concerning Quality 4.0
Organisations can be expected to face some challenges in their quest to achieve excellence
through Quality 4.0.

● Lack of innovation and creativity: While being open to innovation, an organisation

should also consider principles of quality to ensure stable operations. Quality plays a
critical role in enabling and fostering innovation and creativity. If quality standards are
not embraced alongside innovation, the transformation process of the organisation may
slow down
● Inability to understand customer expectations: Quality assurance is regarded as an
internal discipline that manages the way products and services are developed and
delivered. However, it is imperative to understand the customer expectations, and pain
points of a value-added delivery process. Organisations endeavouring for customer
experience may have to look beyond the inward-focussed approach of quality assurance
● Sluggish approach to delivery’s pain points: A quality organisation should consider
a proactive approach to understand the pain points of delivery and recommend 6
effective solutions. Hands-on exposure to delivery processes can help in generating
practical solutions. It is vital to seamlessly integrate quality with the delivery process.
● Outdated solutions: Solutions that worked on a theory formulated several years ago
might not work today due to changes in technology, lifecycle models and even people
characteristics. So, the theory of quality needs to be redefined to meet today’s
expectations.

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Research Questions

After reading many research papers and theory about the quality aspects and quality 4.0, we
came out with our basic research questions that came into our mind which are as follows:

1. How does the integration of advanced technologies, such as Internet of Things (IoT),
artificial intelligence (AI), and robotics, impact the quality of garment manufacturing
processes?
2. What are the key quality challenges and considerations associated with the adoption of
emerging technologies in garment manufacturing, such as 3D printing, automation, and
virtual reality?
3. How can quality management practices be adapted to ensure optimal performance and
reliability of smart textiles and wearable technologies in garment manufacturing?
4. What are the potential benefits and drawbacks of using quality control systems and real-
time monitoring technologies in garment manufacturing, and how do they contribute to
overall product quality improvement?
5. How does the implementation of digital quality assurance systems, such as blockchain
and traceability technologies, impact the transparency and accountability of supply
chains in garment manufacturing?
6. What are the critical success factors and barriers for garment manufacturers in adopting
advanced quality management systems and technologies, and how do these factors
influence their competitiveness in the market?
7. How can quality standards and certifications be adapted to accommodate the evolving
technological landscape in garment manufacturing, ensuring that products meet
customer expectations and comply with regulatory requirements?
8. What are the customer perceptions and expectations regarding quality in relation to the
adoption of new technologies in garment manufacturing, and how can manufacturers
align their quality strategies accordingly?

These research questions can serve as a starting point for investigating the role of quality in the
future trends of technology adoption in garment manufacturing. They address various aspects
of quality management, technological advancements, and their implications for the industry.

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 Research Objectives

➔ Investigate the impact of advanced technologies (such as IoT, AI, and robotics) on the quality
of garment manufacturing processes, assessing their benefits, drawbacks, and overall
effectiveness.
➔ Analyze the challenges and considerations associated with the adoption of emerging
technologies (e.g., 3D printing, automation, virtual reality) in garment manufacturing,
focusing on their effects on quality control, supply chain management, and product reliability.
➔ Examine the performance and reliability of smart textiles and wearable technologies in
garment manufacturing, identifying effective quality management practices for their
integration and utilization, and assessing their impact on customer satisfaction and market
competitiveness.
➔ Propose adaptations to existing quality standards and certifications in the garment
manufacturing industry to accommodate the evolving technological landscape, ensuring their
relevance, effectiveness, and alignment with customer expectations and regulatory
requirements.
➔ These research objectives provide a focused and concise overview of the key areas to be
investigated when studying the role of quality in the future trends of technology adoption in
garment manufacturing.

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Literature Review

Garment manufacturing has witnessed a significant transformation through the adoption of

major technologies. Cloud computing facilitates seamless data management and collaboration,
while 3D design and printing revolutionize the design process and enable customization. The
Internet of Things (IoT) ensures real-time monitoring and optimization of processes, while
artificial intelligence (AI) drives intelligent decision-making and predictive analytics. Robotics
automates tasks, enhancing precision and productivity. These technologies collectively
enhance efficiency, innovation, and product quality in the garment manufacturing industry,
paving the way for streamlined operations, personalized products, and improved customer
satisfaction.

Some Major Technologies used in Garment Manufacturing:

1. Cloud computing
2. 3D Design and printing
3. Internet of things
4. Artificial intelligence
5. Robotics
6.

1. Cloud computing
Cloud computing is Internet based computing, by which the shared resources, software and
various information are provided to computers and other devices on-demand, like electricity.

On-demand self-service internet infrastructure where you have to pay as you go and use only
what you need, which is all managed by a browser, application or API. Cloud computing is
broken up into multiple elements including: Cloud Infrastructure, Cloud Platforms and Cloud
Applications.

Benefits of cloud computing:

● The advancement of cloud computing has led people to believe that companies,
including textile firms and apparel industry, will no longer need to invest in maintaining
assets like servers, internal software, and storage systems. Instead, they can rent these
resources on-demand, reducing IT investment costs and saving valuable business time.

● This system provides real-time notifications to a brand about any delays that occur in
various stages of the production process, such as procurement of raw materials,
production, or transportation. By leveraging cloud technology, the brand is promptly
informed of these delays, providing them with enough time to make the right decisions
to ensure timely delivery of the order.

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 ● Despite the prevalence of traditional communication methods and procedures in the
apparel industry, cloud computing is an ideal solution for companies looking to
modernise their operations. As many brands and retailers worldwide are already
leveraging cloud technology, it presents an excellent opportunity for managing global
supply chains in the apparel industry.

2. 3d Design And Printing

Brands are also looking into how 3D printing may help them produce things on demand and
open up new customization options. This has become more important as competitiveness has
shifted to offering items that are personalised to the customer's likes and demands in a fast and
efficient manner.

● New 3D rendering technologies, such as CLO, enable brands to alter designs in real
time and instantaneously assess modifications. This can help to enhance design quality
by verifying silhouette and fit earlier in the development phase, reducing waste and
mistakes in the sample before finalization.

● Another is EFI Optitex, which significantly reduces the costly and time-consuming
process of finding an appropriate fit by transforming essential design elements such as
flat sketches and technical patterns into simulated 3D renderings that allow users to cut,
loosen the fit, and make all necessary adjustments in real-time.

● In addition, 3D printing has been extremely useful for on-demand production. From
Adidas' 3D printed shoes to Ministry of Supply's in-store 3D printer, which generates
personalised knitwear on the spot, 3D printing is becoming increasingly popular.
Printing clothing on demand minimises fabric waste by around 35%.

● Digital knitting is also transforming the apparel sector, and it is making significant
progress. It not only demonstrates remarkable developments in the field of 3D printing,
but it also provides an entirely new level of customization. Shima Seiki, an Australian
fashion label, can turn cones of yarn into a whole, seamless garment in under an hour,
while Ze-Nit creates digitally knitted urban apparel that allows functionality and
benefits to be placed where the body needs them most.

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3. Internet Of Things
With only 41% of organisations having a well-developed IoT testing plan in place and 30%
planning to include IoT capabilities into their products, organisations are currently behind the
curve.

Departments In Which Iot Can Be Implemented And Its Role:

1. Production and Manufacturing: IoT devices can be integrated into production lines
and machinery to monitor and control manufacturing processes. Sensors can track
parameters like temperature, humidity, and machine performance, ensuring consistent
quality and identifying any deviations or issues in real-time. IoT also facilitates
automated data collection, analysis, and optimization of production workflows.

2. Supply Chain and Inventory Management: IoT enables improved visibility and
traceability throughout the supply chain. RFID tags, sensors, and beacons can be used
to track the movement of garments, raw materials, and components. This ensures
accurate inventory management, reduces losses, prevents counterfeiting, and enables
efficient order fulfillment.

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 3. Quality Control and Assurance: IoT devices play a crucial role in quality control by
monitoring various aspects of the manufacturing process. Sensors can detect defects,
measure fabric strength, identify color variations, and ensure compliance with quality
standards. Real-time data analytics help manufacturers identify and rectify issues
promptly, improving overall product quality.

4. Maintenance and Asset Management: IoT facilitates predictive maintenance of

machinery and equipment used in garment manufacturing. Sensors monitor equipment
conditions and performance, providing insights into maintenance needs and potential
failures. This proactive approach reduces unplanned downtime, optimizes maintenance
schedules, and extends the lifespan of critical assets.

5. Research and Development: IoT devices enable the collection of real-world data on
garment usage, performance, and customer preferences. This data can be analyzed to
gain insights into market trends, customer behavior, and product performance.
Manufacturers can leverage this information to drive innovation, develop new product
lines, and enhance existing products based on customer feedback.

6. Customer Engagement and Personalization: IoT-enabled garments can provide

interactive and personalized experiences to customers. Smart garments embedded with
sensors can monitor vital signs, track activity, or provide real-time feedback on
performance. This data can be used to offer personalized recommendations, tailor
marketing campaigns, and create unique customer experiences.

7. Compliance and Sustainability: IoT devices can help monitor and ensure compliance
with environmental and sustainability standards in garment manufacturing. Sensors can
measure energy consumption, water usage, and emissions, facilitating efficient resource
management and reducing environmental impact.

These are just a few examples of the departments where IoT can be applied in the garment
manufacturing and apparel industry. The interconnectedness and data-driven capabilities of
IoT offer extensive opportunities for optimization, automation, and innovation across the entire
value chain.

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4. Artificial Intelligence
It is expected that the use of artificial intelligence (AI) will continue to grow in just about every
facet of innovative technology, due to the growing number of applications we use in our
connected world.
New investment in AI is expected to be $6-7 billion in North America alone. By 2025, global
investment in AI is forecasted to reach nearly $200 billion. This is the result of the constantly
evolving amounts of data utilized in software applications, which require ever-increasing test
coverage.

● Apparel CAD Systems -the use of AI-based CAD systems in the apparel industry.
While commercially available systems focus on pattern design, grading, and
production, researchers are working to create
systems that can automatically generate effective
apparel designs. These systems use iterative GA
processes, human preference and emotion, 3D
modeling, and intelligent drape prediction to aid
apparel designers in creating innovative and high-
quality garments. The main challenge in
developing 3D garment CAD systems is modeling
garment drape accurately. Overall, AI-based CAD
systems have the potential to significantly
improve productivity, quality, and innovation in the apparel industry.

● Forecasting Sales - The use of AI in apparel sales forecasting is explored through

various studies, with researchers proposing multivariate fuzzy forecasting models and
NN-based systems to predict sales of clothing items. However, it is difficult to put some
of these systems into practice due to the multiple soft computing techniques employed.
Wong and Guo's recent work investigates medium-term sales forecasting in fashion
retailing using the real forecasting process and shows that intelligent approaches can
outperform traditional mathematical methods. Additionally, these proposed models can
be extended to solve other forecasting problems with similar time series patterns.

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5. Robotics
The growth of robotics in garment manufacturing is driven by various factors, including the
need for automation to fill labour gaps, the demand for flexibility in manufacturing operations
to adapt to changing trends, and increased investment in new technologies. Fashion robots are
increasingly being used to reduce production time and maintain high-quality products. Robots
are employed in garment manufacturing processes to improve efficiency and increase
production speed.
Robots have long been ideal for doing laborious, repetitive jobs on factory assembly lines.
However, recent technological advances have given robots memory and dexterity, allowing
them to be extremely programmable and collaborative. It's not about getting rid of jobs; it's
about making people smarter and keeping humans safe by replacing them in dangerous
situations when robots can help. SoftWear Automation, for example, has developed "Sewbots"
with robotic arms and vacuum grippers that can precisely guide a piece of cloth through a
sewing machine, lowering costs and speeding up the process. Sewbo, a robotics company
founded just two years ago, released a robot capable of stitching a t-shirt without the need for
human interaction, utilising water-soluble stiffening treatments to transform cloth into
cardboard-like material. For its part, Nike has been producing shoes under the Grabit brand
since 2013, a robotics firm that uses electroadhesion to assist machines in manipulating objects.

Application of Robotics in Garment Manufacturing:

There is a widespread use of automation and robotics in the production:
● Fabric Inspection
● CAD
● Pattern Making
● Fabric Spreading & Grading
● Cutting
● Sewing
● Pressing
● Material Handling
● Radio Frequency Identification (RFID)

Factors responsible for the growth of robotics in garment manufacturing:

Robotic technology is being introduced in the garment industry to improve the accuracy of
fabric testing and enhance the efficiency and quality of the printing process. Robots equipped
with sensors can track fabric movement and adjust parameters for greater accuracy. Textile
printing robots can create custom patterns on clothes, potentially improving production
processes and reducing manufacturing costs in the long run. Keeping up with advancements in
this field is essential for businesses.

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Fig- Automated Embroidery Fig- Automation in Ironing

Robotic technology is transforming the garment industry by improving printing efficiency and
quality through the use of textile printing robots that can create customised patterns. This
technology has the potential to reduce manufacturing costs and enhance production.

Role Of These Latest Technology In Quality Improvement

CLOUD COMPUTING -

● Collaborative design and development: Cloud-based design tools allow teams from
different locations to collaborate in real-time, reducing errors, and improving the
quality of the design process.

● Increased automation: Cloud computing enables automated processes in the fashion

and textile industry, reducing human error and increasing consistency in quality.

● Better data management: Cloud-based systems allow companies to manage large

amounts of data in a centralized location, making it easier to analyze data and identify
patterns that can improve quality.

● Faster decision-making: Cloud-based systems enable companies to make faster

decisions by accessing real-time data and analytics, which helps improve the quality of
products and services.

● Improved supply chain management: Cloud-based systems enable companies to

manage their supply chain more efficiently, ensuring that materials and products are
delivered on time and to the right specifications, which helps improve quality.

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3D DESIGN AND PRINTING -

● Prototyping: 3D printing allows designers to create physical prototypes of garments

and accessories quickly and cost-effectively. This can help them identify design flaws
and make necessary adjustments before mass production, improving the quality of the
final product.

● Customization: 3D printing enables companies to offer custom-fit clothing and

accessories, improving the overall fit and comfort of the products and increasing
customer satisfaction.

● Sustainability: 3D printing reduces material waste by creating only what is needed,

reducing the environmental impact of manufacturing and improving the sustainability
of the products.

● Reduced lead times: 3D printing can accelerate the design and production process,
reducing lead times and enabling companies to respond more quickly to customer
demand, which can improve the quality of the products.

● Improved precision: 3D design allows for more precise and accurate design details,
ensuring that products are produced to the desired specifications and improving the
quality of the final product.

ARTIFICIAL INTELLIGENCE -

● Quality control: AI-powered systems can perform automated quality control checks
on textiles and clothing, identifying defects and anomalies that would be difficult for
humans to spot. This can help companies catch quality issues before products are
shipped to customers, reducing waste and improving customer satisfaction.

● Predictive maintenance: AI can also help companies identify when equipment needs
maintenance before it breaks down, reducing downtime and improving the quality of
the manufacturing process.

● Personalized recommendations: AI-powered recommendation systems can help

customers find products that match their individual preferences and needs, improving
their overall satisfaction with the products they purchase.

● Sustainable manufacturing: AI can help companies optimize their manufacturing

processes to reduce waste and improve sustainability, which can improve the quality of
the products they produce.

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 ● Design optimization: AI-powered design tools can help companies optimize their
designs to reduce material waste and improve the durability and functionality of their
products, which can improve overall quality.

INTERNET OF THINGS (IOT) -

● Quality Control and Defect Detection: IoT devices can be used to monitor product
quality during various stages of garment manufacturing. Sensors and cameras can
detect defects, such as stitching errors or fabric flaws, and trigger alerts or automated
actions for timely intervention. This helps in reducing rework, enhancing product
quality, and ensuring consistency.
Stage of the supply chain, from raw materials to finished products, ensuring that quality
is maintained throughout the process.

● Real-time monitoring: IoT sensors can also be used to monitor production processes
in real-time, detecting quality issues and enabling quick corrective action to be taken.

● Energy Efficiency and sustainable manufacturing practices: IoT-enabled energy

management systems can monitor energy consumption in garment manufacturing
facilities. Smart meters and sensors can provide real-time data on energy usage, identify
energy-intensive processes, and enable optimization strategies for reducing energy
waste and achieving sustainability goals.

● Data Analytics and Process Optimization: IoT-generated data from various stages of
garment manufacturing can be collected and analyzed to identify patterns,
inefficiencies, and areas of improvement. Advanced analytics and machine learning
techniques can uncover insights for optimizing production processes, reducing waste,
and enhancing overall operational performance.

● Predictive maintenance: IoT can help companies identify when machinery needs
maintenance before it breaks down, reducing downtime and improving the quality of
the manufacturing process.

● Improved customer experience: IoT-enabled smart devices can provide customers

with real-time information about products, such as materials, sustainability, and
production processes, which can improve their overall satisfaction with the products
they purchase.

● Wearable technology: IoT-enabled wearable technology can be used to monitor

clothing usage and provide data on wear and tear, helping companies improve product
design and quality.

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ROBOTICS-

● Precision Cutting and Sewing: With the use of 3D scanning and modelling, robots
can cut fabrics more accurately, which minimises wastage and ensures the perfect fit.

● Quality Inspection: Robots can be equipped with advanced sensors and cameras to
detect defects in fabrics. This helps in identifying quality issues early on in the
production process, preventing defective products from being shipped to customers.

● Automation:It helps in folding, packing, and labelling. This reduces human error,
and improves the consistency and accuracy of these tasks.

● Increased Production Efficiency: Robots can work continuously and tirelessly,

which results in increased production efficiency and faster turnaround times. This
means that companies can produce high-quality products at a faster rate, which can
translate into increased profits.

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Survey Analysis

We created a google form of questionnaire to conduct the survey. We circulated this form
among the people working in the production unit.

Size of sample: 20

➔ INFERENCE: Most of the employees of the firm are aware about the latest technology
trends.

➔ INFERENCE: We found out that 80% of the employees are provided with proper
training and workshop as per requirement.

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➔ INFERENCE: ERP and BlockChain are the most popular technologies amongst the
other ones.

➔ INFERENCE: If we exclude the worker, Every other employee of the firm is aware
about the latest technology trends in the fashion industry as the above graph suggests.

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➔ INFERENCE: Majority of the firms spend 1-3 lakh on their R and D department which
shows that they are keen to adopt something more innovative if it suits their budget and
increase their profit.

➔ INFERENCE: With leading percentage of 61.9%, most of the firm have between 50
to 70 days as their lead time

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INFERENCE: 85.7% of employees said that the implementation of these latest trends has
increased their productivity, efficiency and overall growth in the market and they have
statistical data to back up their words. Also, hose employees who come under that 14.3% are
mainly operators so they must not have much idea about the same.

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