To grow and thrive, technology isn’t just an advantage—it’s a necessity. Gokaldas Exports Ltd., is embracing this reality, using cutting-edge tools like IoT, AI and RFID. These innovations are making operations smoother, cutting costs and boosting efficiency. This feature explores how digital transformation is reshaping the company, the key technologies driving it and their impact on business.
The apparel and textile industry is known for being labour-intensive and driven by years of experience. However, digital transformation can add complexity, especially on the shopfloor or within the order process across the entire manufacturing value chain. Successful transformation begins with strong commitment from leaders, who invest in new capabilities, align resources and foster collaboration. With strong leadership, a clear vision, efficient execution and effective teamwork, digital transformation can serve as a powerful catalyst for growth and innovation. It has attained great success at Gokaldas Exports. Here’s how:
- Integration and visibility between the functional departments from product development to shipping the goods to the customer.
- The use of QR Labels, RFID and AI technologies has enabled end-to-end traceability of orders within the manufacturing cycle, helping in the development of SMART factories and efficient production lines. These innovations allow Gokaldas Exports to manufacture all products in-house, ensuring continuous improvement and cost-effective product availability.
- Optimisation and utilisation of materials and machinery.
- Lead time reduction in the manufacturing cycle by maintaining transparency and accountability across all stages—from fabric storage to shipping—and managing work-in-progress (WIP) at each stage; thus, the overall manufacturing cycle has been shortened.
- Productivity increase on production floor and order processing. For instance, tracking line output while monitoring quality defect occurrences at the needlepoint, combined with real-time line balancing, provides immediate insights to optimise line management effectively.
- Business insights derived from digital tools have helped the company make better decisions and continually improve the manufacturing process.
- Finally, Gokaldas Exports has framed a clear strategic approach for digital transformation and built a dedicated digital team to support these initiatives.
To successfully start digital transformation and identify key areas for technology integration, this diagram shows the important components needed. Embrace technology by digitising the integration of People, Machines, Material and Processes into a unified platform, enabling data insights for effective decision making.
| Some of the used cases in business process are:
Material 1. Barcoding the incoming material (fabric roll and trims/accessories) to facilitate traceability. 2. Warehouse management – centralised width checking by Digital Tape, Shade identification by QR Label and Shrinkage identification by Camera Vision using Artificial Intelligence technology. 3. Cut Plan – fabric optimisation plan and usage of end bits to reduce wastage. Online traceability of spreading and cutting to track and monitor the cutting room efficiency. 4. Centralised CADD system – optimal way of using the technology of automated marker making with nesting engine incorporating the cut plan. Machine 1. Asset tagging and inventory tracking by location. These technologies have been instrumental in monitoring the health of each machine, ensuring location traceability and assessing machine availability to enhance and optimise production planning. Additionally, breakdown monitoring helps measure machine OEE (Overall Equipment Effectiveness) and MTBF (Mean Time Between Failures). Scanning machines at each location during the audit process ensures that assets are correctly placed and accounted for in their designated locations. 2. Downtime capturing 3. Preventive maintenance and scheduling 4. Automation-Hanger system in the line 5. Spare parts management by issuing and receiving tagging to the machine People 1. The operator skill evaluation technique focuses not on specific operations, but rather on proficiency in stitching methods and the handling of stitching movements. 2. Intelligent operator allocation based on the skill requirement of an operator. Process 1. Cut to Pack order traceability with QR label technology. 2. Time and action calendar and scheduling the task from order entry to shipment. 3. Sample traceability and digital storage of samples for better visibility of critical information. 4. Implementing a Quality Management System involves tracing defects throughout to the final packing stage to guarantee the shipment of high-quality garments to customers. An audit toolkit ensures the integrity of system adherence and process implementation throughout the manufacturing cycle on the shopfloor. 5. Line design and product line balancing optimisation use the TAKT time concept, with real-time SMV evaluation and critical path analysis (such as garment throughput time) to optimise line balancing techniques. |
Future Project: SMART line manufacturing
Installing an IoT gadget at each workstation along a production line enables real-time tracking of operator activity, including machine start times. By scanning the bundle ticket, the system identifies which parts are entering the line, enabling analysis of the critical path and estimation of throughput time. Productivity measurement at day’s end includes assessing performance against standards and distinguishing between off-standard and on-standard operations. Monitoring cycle times aids in efficient line management, ensuring optimal productivity and control.
Utilising camera vision and AI technology for operator motion analysis helps assess needle versus non-needle time, allowing for the reduction of Standard Minute Value (SMV) and improving operational efficiency. By measuring cycle times and identifying unnecessary movements, we can eliminate waste and optimise performance. This data, combined with IoT devices, also enables intelligent insights for comparison with previous performance, guiding decisions and corrective actions.
What makes this project unique is that it integrates all business processes into a single platform for end-to-end tracking, connects and automates the workflow, provides a personalised dashboard via a mobile app and enables customer connectivity through a QR code, ensuring sustainability and traceability.
