Implementation of Smart Quality Management System in Garment Industry

Textile and garment industries are one of the essential parts of human existence as they are the source to provide the basic requirement of humans, called clothes. In order to improve the quality standards and to increase the productivity level, these industries started to implement the quality mana

Project Title

Implementation of Smart Quality Management System in Garment Industry

Project Area of Specialization

Electrical/Electronic Engineering

Project Summary

Textile and garment industries are one of the essential parts of human existence as they are the source to provide the basic requirement of humans, called clothes. In order to improve the quality standards and to increase the productivity level, these industries started to implement the quality management system (QMS) but industries are still facing multiple issues regarding manual data entry, high execution time, unstrict quality inspection, untrained workers etc.

The Smart Quality Management System (SQMS) is an IoT based quality management system which will be responsible for strict quality checking of the produced garments. The industries use 7.0 audit system for quality inspection in which the quality checker (QC) checks 7 pieces from produced garments and manually fills the data on sheets. The workers have to stop the machines manually when more defected pieces are produced. We will design a system based on IoT which will automatically turn off the machine when required. The RGB lights on the machine will show the status of the machine. We will also design a user-friendly application so that QC can enter the data directly into the application which will be stored in ERP system of the industry. The system will be helpful in improving the quality of the products as well as lessening the loss time of the industry.

Project Objectives

This project aims:

• To automatically turn off the machine when 3 or more defects are found.
• To make a user-friendly application for system.
• To visually represent the performance of the operations.

Project Implementation Method

In QMS, the quality checking was done manually, both at inline and endline. Because of this manual data entry, there was the delay in quality inspection and the defected items were generated, effecting the quality of the production.

The Smart Quality Management System is an automated system which decides whether to turn on or off the machine according to the recorded number of defected items from the machine. The quality checker (QC) of the line inputs the status of the produced garments in an application that uploads the data in ERP system of the company and that data is also displayed at the screen in production department and end-line screen. The data is also sent to the microcontroller for further process.

The working tables has RGB lights which shows the status of the machine. The 7.0 audit system is used in industry for quality inspection. The quality checker (QC) checks the 7 random pieces of garments. The microcontroller gives the output according to the number of defects that are entered by quality checker. There can be following four cases:

• If the QC finds no defects in those seven pieces, he will turn on the green light by pressing green light option in application.
• If QC finds one defect, he will light up yellow light with application and give warning to the operator of that machine.
• If he finds more than one defect, he will light up red light with the application and the application will give command to microcontroller to cut down the power of that machine. The operator will be given training to avoid further defects.
• If the checker finds the machine faulty, he will light up blue light followed by stopping the machine and the technician will be called.

Benefits of the Project

• The quality of the products will be improved.
• There will be real time data entry of the defects.
• The idle time will be reduced.
• Production will be increased.
• The industry will be able to meet customer’s requirements by providing quality products.
• There will be low chances of human error.

Technical Details of Final Deliverable

This project aims to implement a fully functional prototype of smart quality management system. The deliverable product would include user-friendly application, a web dashboard and a prototype of IoT based RGB light and operation machine controller. This project is an integration of techniques and robust framework to provide an hardware /software integrated system to management team of a garment industry with valuable information about the operation performance and defects data of their system. Some of them are:

• Skipped Stitch
• Wavy Stitch
• Loose or Tight Stitching
• Bubbling
• Broken Stitches
• Uneven Gauges
• Uneven Margins
• Drop Stitch
• Exposed Stitch
• Uneven Stich
• Puckering
• Needle Chew
• Needle Holes
• Open Seams
• Raw Edges
• Pleats
• Wrong Construction
• Join Stitches
• Uneven Seam
• Uncut Thread
• Missed Parts
• Missing Operation
• Wrong Label
• Incorrect Trim
• Di Color
• Improper Fusing
• Exposed Markings
• Damage

and many other important parameters.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Others

Other Industries

Medical , Petroleum , Agriculture , Food , Manufacturing

Core Technology

Internet of Things (IoT)

Other Technologies

Robotics, Others

Sustainable Development Goals

Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and Production

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com