According to a study by the Waste and Resources Action Programme, production flaws including snags and needle lines result in up to 15% of fabric being wasted. Manufacturers may suffer large financial losses as a result, and the environment may suffer as well.
Even worse for producers is when the consumer receives the flawed fabric, which can result in quality complaints that could jeopardise future sales. It’s far too simple for a human to overlook a minor flaw in a large roll of fabric, causing the fabric to be delivered to the wrong customer.
That is why Pailung has been putting a lot of effort into creating more sophisticated methods of detecting fabric flaws. Their most recent invention makes use of cameras that are housed inside of their knitting equipment and outfitted with using computer vision to find flaws in the production process.
For textile producers, real-time defect monitoring is a game changer. The knitting machine may be shut down instantly when a defect is found, stopping production until the issue is fixed and minimising the manufacturer’s waste fabric losses.
But that’s only one of the advantages that Pailung’s new, three-tier software suite will provide textile businesses. According to James C.C. Wang, Chairman and CEO of Pailung, “We developed this software to aid textile manufacturers in their digital transformation and enable them to enjoy the benefits of textile industry 4.0.”A collection of knitting detail resources is archived by the Knitting Fabric Management System (KFMS). This database can be used by any technician to manufacture all of the fabrics that a Pailung knitting machine produces. without first understanding how those fabrics are created.
Previously, just one technician might have had the expertise to create a specific fabric, but today, any technician can create that fabric. By doing this, the technician’s knowledge of all aspects of fabric manufacturing is effectively transferred to the factory as a whole.
For each cloth, specific settings can be kept. Knitting specifications, such as the type of machine, the yarn, its specifications, its length, and weight, etc. Additionally, there are adjustment factors, such as timing, timing angle, tension, and knitting needle.
Manage all of your knitting machines from a single dashboard.
One computer can be used by the technician to manage several knitting machines using the Pailung Online Management System (POMS). With the help of this centralised system, all workflows—from production to order scheduling and machine monitoring—can be carried out remotely. Through the POMS, you may access every fabric that has been saved in the KFMS along with the parameters that go with it. The technician can then use the dashboard on their computer to choose a fabric, plan production and check the status of each knitting machine.The Manufacturing Execution System (MES) can be further connected with the KFMS and POMS. The ERP system of the plant can use the data sent by these three systems collectively to account for the resources of the knitting machines.
They can be used to explain things like the discrepancy between production and planned delivery volumes, the ratio of running time to downtime on knitting machines, the kind and frequency of knitting machine defects, etc.
Automated Knitting Machine Configuration and Upkeep
statistics from the KFMS and POMS updates the MES, which automatically configures each knitting machine using the fabric parameters. This eliminates the need for a professional to physically put them up one at a time.
Each knitting machine can be swiftly reset in accordance with the fabric slated for production, instantly swapping all parameters. This can save a significant amount of time and labour by replacing a lot of manual adjustments and repair order scheduling.
Using the MES has the added benefit of predictive maintenance. It continuously checks the functioning of each knitting machine and notifies the POMS of any anomalies. As more performance data from the knitting machines is captured, big data can be used to optimise this function.
increased precision and effectiveness in Quality Assurance
When used in conjunction with the Fabric Defect Detection (FDD) system, the MES can offer even additional advantages. The FDD system, which is installed near the top of the cylinder, employs computer vision to scan the fabric for flaws and is able to identify any flaw right away.
When a fabric problem is found, knitting machines can be instantly stopped. This lessens the amount of defective fabric that is wasted, the manufacturer’s losses, and the negative effects of textile production on the environment.When so much fabric is being produced by numerous knitting machines, it can be quite challenging to detect fabric flaws with the naked eye. As a result, human quality control typically takes a lot of time and resources. Not only could AI fabric inspection save everyone This saves time and resources and even ensures greater accuracy. For instance, there is a 0.5% FS discrepancy between the yarn length setting value in the MES and the actual measurement.
The fact that the FDD system may be applied to both tubular and open-width devices increases the flexibility with which industrial space can be used.
Improve the calibre of knit fabrics
What feature of Pailung’s software suite is the most advantageous? It involves more than just finding flaws and getting rid of subpar fabric; it involves raising the standard of knitted materials. The information gathered during the current production can be used to enhance subsequent productions, and so on.
Manufacturers of textiles who have recently Failure to adapt to industry 4.0 will result in failure. Those who have made the necessary adjustments will profit and outperform their rivals. Manufacturers of textiles should embrace digital change now and look towards the future.
