Garment Enterprise Production Management and Auxiliary Decision-making System

China is one of the world’s major textiles and garments producers. Traditional production and management approaches have many problems, e.g. lack of efficient and scientific management, excessive dependency on experiences for work planning, inconsistent worker performance and output planning which results in incorrect judgment, different worker efficiencies which might cause uneven divisions of work among groups and local insufficient employment of workforce, incorrect definitions of standard work hours which might lead to partiality, inefficient and inaccurate manual data collection, etc. At the same time, due to increasing labor costs and inability to track order production status in a real-time, untimely information collection, slow production process improvement, etc., garment producers suffer from low production efficiency and are difficult to reach expected levels of economic benefits.

 

With technology development, IoT and RFID technologies are introduced in garment production management to help garment producers achieve transparent monitoring of production lines, transfer production information in a real-time manner, enable managers to have real-time control of production processes, reasonably schedule production activities, improve production efficiency, minimize waste, and provide customers with better services.

The system replaces existing paper and cloth films (work tickets) with RFID labels to count production work pieces and uses controllers, exchanges, etc. to build an enterprise network to upload real-time production information to the server for analysis and statistics and to display such information on the LED screen in a real-time manner for managers to view.

 

After the enterprise receives an order from customer, they first of all need to customize the production plan in the software, set the workshop groups, process steps and prices, and write such information on the order card and authorization card. The manager may initialize labels according to order size, one label for one garment. After the warehouse prepares materials, the CAD engineer finishes the drawing and then a cut bed is used for cutting the cloth. After cutting, the whole set of cloth for a single garment is tied together. A label representing this garment is clipped to a key component. When classifying components, separate tied cloth by different locations and follow the original piecing process step. The workshop head follows the work plan in allocating divided components to corresponding workers for processing and uses the authorization card to activate the card reader on the work position. When a worker begins work, he/she shall scan his/her badge on the card reader to login. Read the badge one time for each finished work piece. You may count work pieces by reading the card (for components with labels, directly scan the label instead of reading the badge) to provide statistical information on order. The worker shall scan his badge again to logout after finishing the current work process.