Automatic roll grading has arrived to significantly disrupt the knitting industry!
The introduction of Smartex CORE represents a monumental breakthrough, introducing cutting-edge hardware infused with the power of artificial intelligence (AI) & machine learning (ML). This advanced technology not only swiftly identifies defects but also has the capability to halt machines, revolutionizing the production process. But the innovation doesn't stop there. With the implementation of Smartex FACT, the automatic classification of roll quality empowers our customers to achieve a remarkable milestone — 100% automatically graded production.
Traditional manual inspection processes are time-consuming, prone to human error, costly, & labor-intensive & expensive. Now with Smartex, digitalized quality grading systems enable real-time monitoring of the production process. Any deviations from quality standards can be detected & addressed promptly, preventing the production of substandard materials.
This simple process begins with customers establishing their Quality Standards, specifying points for each type of defect, & devising a grading system that outlines the point distribution for each grade with the help of our dedicated Customer Success Team.
Upon completion of a roll from a client, its grade is promptly displayed on the Smartex FACT platform, accessible through the My Rolls page. Instantly, problematic rolls will stand out for digital inspection & proactive follow-up decision making.
Why is this disruptive?
This breakthrough is groundbreaking because, for the first time, our clients can access automated quality data regarding greige production without any manual inputs. Traditionally, such insights were only available for finished fabrics during the final inspection.
Now, with Smartex FACT, inspection solely requires a quick consultation of the My Rolls page to identify problematic rolls, drastically reducing the effort of manual inspection. Users are armed with reliable, shareable data about the quality of every roll produced.
This new capability is immensely advantageous for our customers as it opens up two operational enhancement workflows:
1. FACT Workflow: Production managers can regularly consult Smartex FACT to identify problematic rolls (with Grades D or C). With immediate digital access to the issues associated with these rolls, decisions regarding waste or defect trimming can be swiftly executed & communicated to the customer. In the case of A Graded rolls, users can opt to bypass manual inspection entirely, with digital twins of each fabric roll providing them insurance & quality verification they can pass to their customers.
2. FACT + LOOP Workflow: Rolls labeled as Grade A quality receive the Fast Track mark, enabling them to proceed directly to shipment. Conversely, rolls classified as grades B, C, or D lack the Fast Track designation & require inspection. This inspection can be accomplished digitally on Smartex FACT within seconds, or through manual inspection on the designated inspection machine. You can see the flow below:
How this Works for Impetus
We successfully implemented this approach with IMPETUS, yielding promising results during a four-week pilot.
The goals of this project included reducing the quantity of rolls with the need for inspection, as well as decreasing fabric waste while improving quality & traceability.
Instead of randomly selecting rolls for final inspection, Impetus used Automatic Roll Grading to select only rolls with C & D grades. With access to quality data through Smartex FACT & Smartex LOOP, Impetus was able to gather operational insights about production & how to improve it.
The ability to understand the root cause of the quality losses allowed Impetus to adjust its production & reduce the number of rolls requiring inspection by 50%. This achievement was made possible through the identification of machines responsible for manufacturing a particularly challenging article— Modal with Elastane, & being able to reduce the number of thick yarn defects that were being produced. Operators had previously overlooked some occasions when the Smartex CORE system stopped the machine, contributing to the issue. Knowing which machines to target facilitated enhanced collaboration between the Production & Quality teams, enabling them to work together more effectively. As a result, Impetus successfully elevated the overall quality of production while simultaneously optimizing the efficiency of the inspection process for the number of rolls involved.
As a result of this four week study, Impetus was able to reach each of the goals discussed at the beginning of the project using Smartex FACT & LOOP. By reducing problematic rolls from 33% to 16%, workers were able to spend more time on other tasks & reduce manual inspection time.
"Through seamless integration of Smartex LOOP & FACT, we precisely target & address problem areas, leading to an impressive 50% reduction in inspected rolls."
- Joana Cunha, Impetus Quality Director
The fusion of Smartex FACT with these strategic workflows not only optimizes the way our clients manage & ensure the quality of their production but also enhances the overall efficiency of their operations.
Would you like to become a Modern Textile Factory, armed with Smartex’s suite of solutions?