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The Impact of AI on Textile Manufacturing

Published: January 15, 2025
Author: TANVI_MUNJAL

Opportunities and Challenges

By B.Basu 

Former scientist: Bombay Textile Research Association. Mumbai -86 

Former Dy Manager CTS, Orkay Gr.of Industries, Mumbai.

Former Manager CTS & Process Control: Beekaylon Ind ltd. Silvassa. 

Former G.M. Reliance Ind. Ltd. 

Former Faculty, T&P Officer, ISO – MR, Anuradha Engg. College, Chikhli, Buldana. 

Former Head of Sasmira power loom service Centre, Bhiwandi. 

Former Faculty and T&P Coordinator, SGGS, Nanded. 

Former Adjunct Faculty, VJTI, Mumbai.

Visiting Faculty NIFT & ATDC. 

Published 93 papers at the National & International Levels. 

Abstract: Today in the world of Science & Technology, AI is wrapped in every sphere of our life. Since its introduction into Textile Industries, there are the results found with Growth. It was developed by John McCarthy ( 1927-2011) an American Scientist and since then the world has a growing spree in almost all Technological aspects. Although, it has got some disadvantages over employment and towards installation Charges, but we predict that this technology will generate more employment like the Computer Science and Technology is grown. 

           In the Textile Industries, those who are still in the era of traditional technology are on the losing side. But those who have adopted this modern technology are the gainers in every respect i.e.in higher productivity, quality improvements, cost reduction, and achieved the target of Zero defects and waste. Today the C-Status people( CEO, COO, CTS etc) can control the Plant sitting at Home which has saved a lot to Organizations.  The Logistic and Supply chain System, Storage and Procurement systems, are just at the tip of the Managerial staff where there is no waste of time towards tracing the goods and loading on the shipment procedures. The industries are benefited and let them go forwards. 

What It Is?  

It is the computerised way of Human Intelligence. It is one sort of Robotic Technology that is controlled by the human sitting even from a remote place! It has numerous benefits such as faster and more accurate work, saving time and is very much helpful to eliminate any Human error. It is a zero-risk operation for all industries. It has got erroneous benefits in the Textile Industries whose growth is very rapid in India and that of in the world market. 

       Yes, there are disadvantages like making the employees lazier at their workplaces, people forgetting to act on their own and of course, there are chances of growing unemployment. However, as computers have created several new job potentialities, AI will be expected to open new job opportunities in sophisticated ways. 

In the Textile Industries right from the Start of the Blow Room to the Ring Frame, weaving preparatory to Loom shed, grey fabric to Finishing, AI has captured at every stage for the quality, production and Cost Control Processes. 

In the spinning Lines, start with the Blow Room, the manual works are eliminated. Unlike earlier days, today the mixing is done with as high as 200+ bales improving the consistency of the cotton quality and thereafter the final yarn properties. Thanks to the Intelligence for the improved Technology!  There is a direct feedback system from the Blow room to the Carding system. (pic -1)  With the introduction of the “auto leveller”, (pic -2).

Pic – 1: Automatic feeding system in carding direct from Blow Room

Where the yarn`s Uster value improves, eliminating all the short-term/long-term variations. It is used in carding and draw frame machines to correct variations in the linear density of the sliver. By adjusting the draft with an automatic censoring system, it controls any variation in Sliver and minimises the CV%. This system improves production, and quality, minimises end breakages and controls waste generation.

Pic – 2: Auto Leveller

Unlike the earlier, the  Uster % used to be as high as 18-20% in carding and 15% in combed yarn, today it has come down to 7.5 – 8% for both. With the introduction of Compact yarn (another modern technology), yarn quality like hairiness, thick & thin yarn, and weak yarn are eliminated.

The auto doffing system in the Ring Frame is so formulated that the ring bobbins directly go to the winding Machines, get the yarn cleaned and the automatic Splicing is done. The winding packages are doffed automatically and go to the next process thus eliminating huge manpower, wastage, power consumption, ‘0’ down gradation, faster movements and higher productivity with 100% efficiency. 

In Sizing machines, the automatic stress control system (preferably towards negative stress) is also done by the higher Technological intelligence and no manual operation is found. It has drastically improved the performance of the High-Speed Looms. 

  In the loom shed the fabric defects are instantly focused on a computer screen and it is rectified then and there. No need to wait for the Checking table report and corrections. 

Sitting at the office, the supervisory staff can have observations about the efficiency and running status of each & every loom. For any stoppage, the causes are detected whether it is due to any fault of material, machine or man. 

  From the microprocessing system, one can find the meterage produced in any loom with the percentage of the efficiency. Even the Managers can see and control every aspect of the working place right from the Blow Room to Ring Frame, Weaving Preparatory to Cloth Production, efficiency and performances, cause wise failure of any performances even sitting at Home. 

In the Machine Maintenance area, it helps the maintenance manager in knowing the Predictive maintenance, and any lacuna in machine performances. 

In the Dyeing and Finishing areas, it has been introduced as highly helpful in Computerised colour matching, recipe formulation, optimisation of the Process control with temperature regulations, preventing water wastage, environmental control, hall temperature maintenance, avoiding any fabric damage and proper utilisation of manpower. 

In the Garments Sectors, it is used for pattern making and selections, waste and defects control. 

In the area of logistics and supply chain with the help of AI, the storage system, trackability, easy findings of the locations of the raw materials and finished products, and then ready to dispatch avoiding any wastage of time. 

In the area of Inventory Management, it is helping by analysing all data, forecasting of demand and supply, stock control the prediction of the demand, and no excess stock thus saving money and time. 

Pic – 3: The cost savings areas

The picture – 3 shows the cost reduction areas with the Intelligence Level which have been discussed in this chapter. The pic 3 describes in a nutshell about the facts. 

Conclusion, today, it is the most advanced Technology for the most accurate work, time-saving management, no wastage in any area, saving manpower and money. It is getting welcome by the modern Industries. There are various disadvantages to this system high Installation costs, increase in unemployability, minimising human intelligence as everything is automatic, and there is no way to make any decision. But it is welcome in this modern era for the accuracy in running the operations.

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