In the apparel manufacturing industry, is it even possible to use digital twins?

Many people would think that garment manufacturing is too complicated for digital twins, given the diverse production processes, varied fabric properties, etc. However, this technology has the potential to enable manufacturers to create a digital rendition of their garment products from design and production till the end of the product life cycle. Manufacturers can make more informed decisions with real-time insights into what is happening in their current production line and predict what might happen in the future.

According to Fortune Business Insights, the global digital twin market size is projected to growfrom 6.75 billion USD in 2021 to 96.49 billion USD in 2029, at a CAGR of 40.6% during the forecast period.

So, it’s not too hard to envisage a near future where digital twins revolutionize apparel manufacturing. As digital twin applications are rapidly shifting from concept to reality, this article will help you explore and learn more about them. However, before diving into the applications, let’s first understand what a digital twin is.



What is a Digital Twin?


A digital twin represents a digital replica of a physical object, process, or service. Digital twins rely on real-time data collection from various sensors, devices, and sources attached to the physical object or system. These replicas use real-world data to create simulations.

NASA introduced the concept of using a digital twin to study physical objects in the 1960s. Now, digital
twins are widely used in different industries. According to Statista, many industries, including
manufacturing, automotive, aviation, energy, utilities, healthcare, logistics, and retail, have adopted
digital twins as a means to boost productivity and efficiency. Moreover, the manufacturing industry is forecast to reach a market size worth over six billion U.S. dollars by 2025.


What is a Digital Twin in Manufacturing?

In apparel manufacturing, digital twins can be a virtual representation of a product, asset, specific production line, or any other real-world scenario within a production process. Digital twins enable manufacturers to understand past and present conditions and mitigate future challenges. These virtual reflections are a great way to identify production inefficiencies and develop solutions to improve their physical counterparts.

The digital twin integrates artificial intelligence, machine learning, the Industrial Internet of Things (IIoT), and software analytics to drive innovation and improve performance. It enables apparel manufacturers to gain insights and deeper visibility into production.


Different Types of Digital Twins

Using digital twins, manufacturers can replicate individual components as well as entire systems. Every digital twin models a real-world object or system; however, their scope, purpose, and complexity can differ significantly. The following are the four main types of digital twins.

Component Twins - They simulate an individual part of a system or product in the manufacturing process.

Asset Twins - Also called product twins, they represent a physical product rather than an individual part. An asset twin can consist of multiple component twins, enabling manufacturers to see how various parts work together in a single real-world product. For example, an asset twin can be individual equipment in a production line.

System Twin - System twins or unit twins represent systems of products that work together. The asset twin represents products formed from many parts, while the system twin represents these products as components of a larger whole. For example, a system twin can be an entire production line.

Process Twin - They simulate systems working together. For example, a process twin could model the entire factory, including the factory floor employees operating the machines.


How are Digital Twins Used in Garment Manufacturing?

The following are some of the noteworthy applications of digital twins in apparel manufacturing:

1. Shop Floor Efficiency Improvement

In a production unit, digital twins can be set up by deploying IIoT-enabled sensors throughout the manufacturing floor. For example, in a production line, we can set up sensors and digital devices to collect real-time production information. These IIoT-enabled sensors communicate with the cloud-based infrastructure. This technology uses real-time reporting to build a model and perform continuous monitoring of the production line.

By setting up digital twins for assets on the shop floor, you can efficiently manage and control the production processes. Irrespective of the size and complexity of the manufacturing floor, you can control the entire factory down to the granular level with digital twins. If there is any error, you can easily detect the bottleneck and recommend the right solution.

You can collect data on equipment, machines, systems, and employees in real-time to improve and optimize efficiencies of production lines without interrupting current production.


2. Process Optimization

Digital twin processes in a production line can help monitor and analyze key performance indicators (KPIs). If anything goes wrong, you can make adjustments to the digital twin and identify new ways to optimize production, perform root-cause analysis, and work on a corrective action plan.


3. Preventive Maintenance

In a garment factory, failure of any equipment or machinery can lead to the unplanned cost of replacing that equipment as well as forced downtime. Digital twins help manufacturers to practice preventive maintenance, allowing them to identify the lifetime of each component and undertake scheduled maintenance before the actual failure occurs.


4. Quality Management

You can maintain product quality and reduce rework by keeping track of sensor data. Digital twins can simulate different parts of the production process to help you identify discrepancies and determine if better materials or processes can be leveraged.


5. Design Customization

Using digital twins, manufacturers can design and test clothing twins with varying designs to offer a personalized and unique experience to customers. In the design stage, the apparel can be modeled with digital twin technology, and then it can be tested, optimized, and improved before it even exists in the real world. It can help dramatically shorten the design cycle, avoid design flaws, and save the design cost.


6. Sustainable Production

Digital twins can be leveraged to test the practicability of garments before production and make manufacturing more sustainable. Using digital twins, manufacturers can develop accurate 3D models of garments, avoiding the waste of resources associated with building prototypes. Product simulations can be used to detect potential garment defects or shortcomings, mitigating waste that would have been produced during production.


7. Data Analytics and Insights

The data collected from digital twins in the apparel industry can be analyzed to gain valuable insights. This data can help in trend analysis, demand forecasting, identifying customer preferences, and optimizing product offerings.


8. Enhanced Buyer Experience

Digital twins enable a more personalized and immersive buyer experience. By integrating digital twins with augmented reality (AR) or virtual reality (VR) technologies, buyers can virtually test & try on products, visualize different styling options, and provide tailored recommendations, enhancing their overall experience with the manufacturers.


Benefits of Digital Twins in Manufacturing of Apparel

The advantages of digital twins in garment manufacturing are numerous. Here’s a list of some of the notable ones:


• Model and test new plant processes or equipment
  
• Increased productivity
  
• Increased reliability of equipment and production lines
  
• Reduced downtime
  
• Improved product quality
  
• Quicker production times
  
• Lower maintenance costs
  
• Improved customer service
  
• More efficient supply chain
  
• Enhanced profitability
  
• Remote production control
  

The Way Ahead


While the apparel manufacturing sector has struggled to keep pace with the new technologies, digital twins can change the dynamics by providing garment manufacturers with innovative ways to improve their processes. The garment industry could benefit from using digital twins for data collection, analysis, and forecast during the design and production phase. Manufacturers can reap significant value in various aspects, such as increased efficiencies, reduced errors, lowered costs, and improved speed to market with a new product.

If you are on a never-ending quest to remain competitive in apparel manufacturing, start leveraging digital twins to simulate the future to avoid errors and gain significant value. Solvei8 modules also work as a digital twin with real-time data capturing and built-in IIOT capabilities where we can integrate with systems, processes, components, and assets. Reach out to us to know how Solvei8’s unique expertise and modules designed for apparel manufacturing can help you reach your digital transformation goals. Send your queries to hello@solvei8.com!

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