The development of the clothing industry today is under the strong influence of new technologies. Moreover, in the harsh conditions of a market economy, only those players who offer not only high-quality products, but also products that are original in aesthetic and design terms, can maintain demand for their products. There are niches in which typical methods for the production of textile products, more often used in domestic needs, are involved. Regardless of the direction of the factory, the clothing industry requires regular updates to the production infrastructure from participants in this market segment. Today it is not just a matter of switching to automatic lines, but the task of comprehensive modernization of the technical infrastructure.
Garment Technology
Technological processes of sewing production can be divided into three categories: cutting, manufacturing and control. The first includes technologies for creating a nesting map, material calculation, preparation of raw materials and flooring, drawing up patterns for the layout of patterns, etc. Depending on what tasks the clothing industry solves for a particular enterprise, employees use certain methods. For example, directly cutting material is realized manually or mechanically, by cutting or cutting.
Garment manufacturing techniques also represent an extensive group of techniques. Among them, it is possible to single out directly sewing, thread connection, sewing, stitching, stitching and quilting. Each operation is also implemented in several ways, the choice of which depends on the conditions of the factory.
As for the technologies for ensuring control of products, in factories, a kind of audit of materials is usually performed according to qualitative and quantitative characteristics, after which a sorting is carried out and a product passport is drawn up. The modern sewing industry is actively introducing control stages using automated equipment or special measuring tools to accurately assess product characteristics.
Equipment for the manufacture of clothing
A significant breakthrough in technical modernization in the field of clothing industry occurred 20 years ago, when engineers and technologists were able to achieve a sharp increase in the speed of machines. At the moment, existing sewing rate indicators are considered optimal. Work in several modes is realized today by units with thyristor control and AC drives. In this case, the technological process can be performed in a separate order or as one of a group of tasks that a universal installation solves.
For example, there are special units for laying finishing lines along the edges of wrapping materials. These blanks include cuffs, valves, collars, shirts, etc.
It is important to emphasize that the technology of the clothing industry in the form of the same stitching or cutting is implemented with different parameters. That is, even if the machine is focused on the performance of one function, the operator can set the characteristics of the operation in different formats.
For example, the mentioned thyristor control implies the possibility of changing the length of the stitch and the direction of the ruler going along the edge. The most advanced mechanisms also provide for the ability of machines to carry out automatic corrections of the working process, depending on the performance of the sensors. Of course, the sewing industry is not complete without auxiliary equipment. This group can include aggregates of support, fixation and transportation, which realize an indirect additional function in the production process. Usually these are semi-automatic machines controlled by the operators themselves.
The concept of bundled equipment kits
Practice shows that effective optimization of production is possible only if the operation is not fragmented, but combined into one complex of equipment. Developers of sewing machines have long been working in this direction, offering multifunctional installations. Such models perform several operations simultaneously, providing the product with a certain degree of readiness at the output. This is not to say that the complex method allows you to cover a complete list of technological actions and also it cannot be said that the units are combined into one machine. Nevertheless, this concept is conditional and only demonstrates the principle of the approach in which close coupling of technical equipment is achieved, which optimizes the manufacturing technique to the maximum.
In particular, the modern sewing industry operates machines that allow lysing armholes on the back and on the shelf, picking up tubular sleeves, stitching sleeves and other related operations in a single complex of several machines.
But it is important to consider another aspect. Although complex production lines, of course, provide high efficiency with minimal labor costs, they can not always compete with the traditional disparate approach to perform technical sewing operations in qualitative parameters.
Process management
Traditional methods of control and management are reduced primarily to methods of technical organization of individual sections of the production workshop. Physically, operations can be controlled in three ways: manual, semi-automatic, and automatic. Some equipment models provide for three modes at once, but this is rare - two formats are more common, one of which is automatic.
Using the user interface, the operator sets the program according to which this or that operation with certain parameters is implemented. In particular, a modern sewing factory can automatically arrange patterns in accordance with the scheme that was embedded in the computer. Schemes and commands themselves are usually set using the menu. Mechanized control methods also do not finally leave the industry, as in some cases they are more efficient and economical. This applies to small enterprises and individual lines in which the use of automated production is economically unjustified.
Computer technology as a means of control
Controllers and microprocessors are actively introduced in the clothing industry. These are small devices that are responsible for controlling various technological processes. For example, one microprocessor can control dozens of operations simultaneously.
Of course, physically the actions are carried out by means of mechanized hydraulic and electromechanical units and assemblies, to which commands from the controller are given. The initial link for the generation of certain solutions are sensors and detectors. This may be, for example, a device for monitoring the remaining length of the thread. As it is finished, the corresponding signal arrives at the processor, after which the controller gives a command to automatically lay a new coil. A striking illustration of such approaches is the thread trimming mechanism. With this equipment, a garment factory without operator intervention can automatically reduce the length of the cut ends of the threads so that they match the thickness of the eye of the needle. Most often, edged movable mechanisms are used in zigzag stitch machines.
The complexity of the operation of computerized production lies in the fact that the operator or group of maintenance personnel must work out the programs and operating modes of the controller in detail, otherwise the slightest error in the parameters to be laid will lead to rejection on a large scale when it comes to mass production.
Raw materials used in production
Sewing production requires the use of a wide range of materials, including accessories. The raw material base is formed mainly by textile materials. These include polyester, woolen, half-woolen, cotton and viscose fabrics. Some clothing models also require a group of duplicate materials, which includes doublerin, non-woven and various linings in the form of twill, polyester and viscose. Fur of natural and artificial origin is also in demand. We can say that this is a premium raw material for the clothing industry, which ultimately affects the price tags of products.
As for the furnishing and finishing materials, these include sewing cotton-laced threads, reinforcing fibers, buttons, rivets and various hardware. It is important to note that the fittings differ in many characteristics, even if functionally the same elements correspond to each other. Through the shape, color and texture, manufacturers convey the design shades of a particular part.
Manufactured products
The assortment of clothes is huge, but do not forget that sewing factories are not only engaged in the production of such things, but also produce technical products using the same textiles. One way or another, the basis of the assortment of any garment factory is clothing, which is presented in different groups and subgroups. In particular, it can be coats, hats, pants, sundresses, swimwear, etc.
To streamline and classify products, various attributes are used. In particular, products are distinguished by material, shape, seasonality, purpose and other parameters. Appropriately, it is possible to classify and branches of the clothing industry that specialize in the production of certain products.
Recently, highly specialized factories are spreading, which cover a specific segment and strive to occupy a leader position in it. These include enterprises engaged in the manufacture of extreme clothing, uniforms, items for anglers and travelers, etc.
The main consumers of garment products
Most of the manufactured products account for the domestic needs segment. The participants in this market are guided by the demands of the ordinary consumer, offering not only clothes, but also carpet materials, home textiles, and consumer goods. Again, specialized enterprises of the clothing industry often collaborate with law enforcement agencies, medical institutions and representatives of the construction sector. They offer these consumer groups products in the form of geotextiles, membrane insulators, substrates and other specific materials.
Separate areas in which sewing factories also present their products include furniture manufacturing, sports, tourism, as well as mechanical engineering. In these areas, sewing production of light industry is presented only indirectly, but some products of this segment are produced only with the use of textiles. For example, for tourists, manufacturers offer backpacks, sun loungers and tents made of high-strength materials. Large factories are developing unique technologies for the production of raw materials, which are subjected to multi-stage processing to obtain the necessary protective properties.
The development of the clothing industry in Russia
The future of the industry is largely dependent on technological innovations, but not only they determine the direction of further development. Small and large enterprises are paying increasing attention to logistics optimization. Transportation, storage of raw materials, turnover within production lines - these and other stages require maintaining high efficiency, otherwise their organization costs unreasonably high cost. Of course, the clothing industry in Russia in recent years has advanced in technological support. But, unlike foreign manufacturers, the same automated and robotic lines are more often used on the conveyors of large enterprises manufacturing standard products.
The original products, produced in small-scale formats, are still produced in conditions of traditional mechanized equipment. Computerization, in turn, leaves its mark not only on controls.
Thanks to special programs, the clothing industry in Russia has the opportunity to effectively develop new design solutions within individual production units.
Conclusion
The success of sewing factories depends on a wide range of different factors. Among them are the level of technical equipment, and the quality of the raw materials used, as well as labor productivity. At the same time, the modern clothing industry cannot but focus on the needs of the target audience. Some manufacturers initially choose a specific narrow niche, while other factories cover a wide audience of consumers, adjusting the direction of production depending on the trend. Also, the chosen development approach to a large extent determines the methods of enterprise planning.