Upgrading of textile manufacturing based on Industry 4.0

Zhen Chen &Mingjie Xing
College of Textile, Qingdao University, Qingdao, Shandong 266071, China

Keywords: textile industrial upgrading; Industry 4.0; intelligent manufacturing; CPS; IoT.

Abstract. China textile competitive edge fades as the increase of production factors cost. “Industry4.0″ solution would boost industrial upgrading to realize intelligent and flexible manufacturing for masscustomization. Cyber-physic system (CPS) and Internet of things (IoT) are essential for the futuremanufacturing. This paper provides illustrative examples and presents the principle of the textilecollaboration network. It discusses the obstacle of industrial upgrading and offers proposals onimplementation policies.

Introduction

Due to the rising cost, high-end consumer, and the complex value chain, competitiveness of China’smanufacturing industry weakens. Besides, re-industrialization sweeps the world, which makes itimminent to upgrade [1]. Based on the manufacturing PMI index, RCA competition index and textilecost analysis, this work shows the current situation of China’s textile manufacturing industry andprovides a reference for enterprises.

China textile production slows down and export growth picks up. PMI (Revealed ComparativeAdvantage) index (Fig. 1) indicates a depression of China’s manufacturing. BCG (Boston ConsultingGroup) releases a report [2] presenting that China cost advantage is considerably diminished.

According to a RCA (Revealed Comparative Advantage) index and export share (Fig. 2) based on WTO data [3], China export performs a high occupancy, but India has a higher RCA index.International Textile Manufacturers Federation released 2014 International Production Cost Comparison Report [4], as is shown in Fig. 3 that illustrates a poor total cost advantage in China.

Textile Intelligent Manufacturing

Intelligent Manufacturing

In 1991, Mark Weiser proposed the concept of pervasive computing [5] that computing andcommunications devices will be embedded anywhere and implement information exchange. GeorgeStylios [6] assumed that the key to change textile production fundamentally was intelligent computingand engineering environment, production process integration and manufacturing flexibility.
Intelligent Manufacturing is an application of network information technology throughout the manufacturing supply chain and characterized by consumer demand-led and collaborative development. Smart factory provides a flexible, adaptive solution for intelligent manufacturing [7].

Industry 4.0.

2011 Hanover Messe put forward the “Industry 4.0″ concept for the first time and “Industry 4.0″roadmap was released in 2013. It is characterized [8]:Horizontal integration across value networks,end-to-end digital integration across the entire value chain and vertical integration and networked production systems. Industry 4.0 will lead to virtualization and modularization of production processand supply chain, achieving flexibility and personalization of production [9] based on CPS and Io Ttogether with ERP, MES, PLM, SCM and other software system.

CPS can monitor the production process and realize decentralized decision-making andself-optimize. Real-time communication between machine and machine (M2M) or human could beimplemented through IoT and CPS [10]. Information is shared across the entire collaborative network.

From raw materials to product sales, digital tracking device is connected to each other according tostandard protocols for data analysis, errors forecast and self-configuring.

Textile 4.0

Key technologies of automation in spinning, weaving and other aspects are essential to upgrade the textile industry. Textile 4.0 would be a process chain of independent production [11] (Fig. 4).Information carrier can be textile material container, bobbin, warp beam, and fabric. Radio frequency identification technology (RFID) [12] and sensors are basic to collect and store information, such as equipment operation status, and maintenance information. The plant will self-configure and self-optimize [13] (Fig. 5) quickly and flexibly to meet custom manufacturing orders. Meanwhile, all information will be fed back to the MES and ERP systems for future management decisions.

Opportunities and Challenges
The next stage of development is an era of integration of traditional manufacturing industries and smarttechnology. It is imperative to promote the development of key technologies of intelligentmanufacturing and strengthen skilled personnel training. Establishing pilot and spreading experience isa promising way, as well as homogenization competition alliance (HCA), especially for small andmedium-sized enterprise.

Since Industry 4.0 is in its initial phase, it is unadvisable to pursue it blindly and exaggerate itssignificance for the manufacturing industry. Most textile manufacturing, lacking innovation, is atmid-low end of the value chain. It is feasible to consider synthetically both the new upgrading and thebasic construction. Several issues must be resolved, such as setting and implementation of the industrystandard, device protocol and information sharing scheme.

Conclusions
The boom of global “re-industrialization” would make manufacturing more intensely competitive andthe traditional model is substituted for emerging model, which could be called integration of industrialchain better than an industrial revolution, and all participants in the production process collaborateproduction in a new way. Textile industry must be aware of the new challenges and respond with ajudicious action in order to reduce production cost, improve manufacturing productivity, promoteindustrial growth, change the labor force structure and ultimately change the competitiveness of thecompany and the region. Technological innovation and personnel are basic drive of industrytransformation. Meanwhile, it should be cautious to upgrade textiles 4.0 and it is imminent to figure outthe industry standard and itsimplementation.

References
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