SOUTHEAST UNIVERSITY

DEPARTMENT OF TEXTILE ENGINEERING

ASSIGNMENT
TOPIC: Application of Computer in Garments Industry
Course code: TCSE 4011
Course Tittle: Application of computer in textile
Submitted To:
Md. Shamim Alam
Assistant Professor

Submitted By:
Name ID
1.Manos Chandra Ray 2016000400091
2.Afsana Alamgir Mila 2017000400013
3.Md. Yeasin Arafat Omi 2017000400014
4.Khorshed Alam Sharkar 2017000400023
5.Mahfuzur Rahman Himel 2017000400085
6.Ashique Mahmud 2017000400091
7.Md. Mojahidul Islam 2017000400092
8.Md. Shakurul Islam 2017000400120
9.Md. Mohi Uddin 2017000400122
 Application of Computer in Garments Industry
Modern textile engineering is a multi-discipline subject and textile engineers
should have sufficient background in science and mathematics. They should also
know application of computer in textile engineering. On the one hand computers
are used for design and development of new textile materials, computerized
laboratory equipment and computer controlled manufacturing process and
equipment. On the other hand, there are complex computational problems in
production, quality control and management of textiles. Textile products are basic
need of human beings but also people are increasingly demanding high quality
products at reasonable price and textile market is competitive but lucrative. Use
of computer saves time, increase productivity and reduce cost. Application of
computer is now very widespread in every aspect of textile engineering.

For example, modern textile and garment machineries are computer controlled.
Production process is also controlled by computers such as in computer aided
spinning, woven and garment design, computer aided color measurement, color
matching of textiles, dye recipe formulation, mixing ratio formulation and
optimization and merchandising.
Therefore, students and professionals of textile engineering should know how to
use computer effectively. This may range from writing computer program and
solving problems related to manufacturing and production of textile products as
well as for inventory control, costing, retailing, decision support, forecasting etc.
Students should also know some basics of computer hardware and computer
interfacing environment as most machines and test equipment are computer
controlled and production process from input to output is computerized.

Computer application in different sectors of textile

technology:
Computer application in textile is very widespread and integrated in all phases of
textile engineering. Major applications of computer in textile are point out below:

1. Research and development of materials and textile process.

2. Computer aided textile production and process control.

3. Production planning.

4. Process control.

5. Quality control.

6. Inventory control.

7. Analysis of engineering data.

8. Solution of engineering problems.

9. Management decision process.

10. Development of teaching tools like lab software.

11. Textile machine manufacturing.

12. Automation of textile machines, equipments and processes.

 Purposes of application of computer in textile (ACT):

In the light of the above discussion, the aims and objectives of ACT can be
summarized as follows:

 Know the areas of computer application in textile industry and understand how to
work with computer systems in textile processing and new product development.
 Learn computer fundamentals and programming languages and necessary tools.
 Learn how to apply computer knowledge such as programming in textile
processes.
 Learn visual programming languages tools to develop user friendly programs and
software.
 Learn Microsoft office spreadsheet tool such as Excel for consumption,
calculations and presentation of results as graphs, charts etc.
 Learn basic of Database Management System such as Mysql, Oracle including MS
Access and learn how to connect databases from applications.
 Use of commercial and open source software for fiber technology, spinning,
weaving, knitting, coloration technology and textile testing.
 Use of different statistical methods to analyze engineering data.
 Use of different mathematical techniques to solve engineering problems and use
of mathematical packages like MATLAB.
 Use of computer in textile materials and inspection techniques to get some idea
on hardware such as computer interfacing systems and micro-controllers used in
textile machineries.

If we consider the application of computer in wet processing

the application can mainly be categorized as bellow:
 Applications of computer in testing equipment for wet processing.
 Applications of computer in process machineries for wet processing.
 Applications of computer in process management for wet processing.
 Applications of computer in overall process management for wet
processing.
Computer aided testing equipment in wet processing:
It is the engineering application of computers for the inspection of quality of the
products. While designing a textile product, the requirements must be defined
followed by development process and acceptance testing. CAQA includes
measuring equipment management, goods inward inspection, vendor rating,
attribute chart, statistical process control and documentation. These practices
provide a set of processes and procedures that address the quality assurance
requirements throughout the hardware or software production cycle from
requirements specification through design, implementation and testing, to
acceptance and deployment. The Computer Aided Quality Assurance should
ensure tests and procedures are properly carried out and evaluated and if any
modifications in the product are investigated when necessary, should generate
technical and management system reports, produce statistical reports through
relevant data, measures to improve the quality of fabrics by reducing cost and
bringing about better utilization of raw materials. Specifications should be
developed and standard practices must be used for evaluating materials, product
characteristics, performance and quality. Sensors are used by continuous
production machines to control the quality of the product. This ensures
production of identical, high quality products, such as plain, plied and fancy yarns
and standard or specialized fabrics. Few computer aided equipments are as
bellow;

There are some testing equipments that are used in wet processing laboratory
they are:
 Spectrophotometer
 Data color
 Buffer Calculator
 Different kinds of computer aided fastness tester.

Spectrophotometer:
Spectrophotometer usually used in textile to measure the efficiency of dyeing
and k/s value ect.it is used in the quantitative measurement of the reflection or
transmission properties of a material as a function of wavelength. It is more
specific than the general term electromagnetic spectroscopy in that
spectrophotometry deals with visible light, near-ultraviolet, and near-infrared, but
does not cover time-resolved spectroscopic techniques.
 Spectrophotometer

Spectrophotometry involves the use of a spectrophotometer. A

spectrophotometer is a photometer that can measure intensity as a function of
the light source wavelength. Important features of spectrophotometers are
spectral bandwidth and linear range of absorption or reflectance measurement.

Datacolor:
In testing laboratory it can be used to match color recipe before going to bulk
production. With increasing pressure for smaller production lots, shorter time to
market and intricate blends, the only way to optimize time, recipe development
and production is to have a broad knowledge base taken directly from dyers
themselves. Datacolor process is a unique software solution that uses the
knowledge of the experts in your company to help you manage dyeing recipes
and entire processes. It automatically creates or specifies the best production
recipe for any color, dyed on a specific fabric and for a particular customer.

Buffer calculator:
It is used to calculate the amount of acids/alkali required to maintain a proper
buffer solutions for the use.

Different kinds of computer aided fastness tester:

Fastness properties of fabrics should be tested accurately for the production. For
that computer assistance are taken for better results. few testers are as bellow,
AATCC Rotary Crockmeter , automated pilling (automated pilling Ici Pilling
Testing Machine (TSE-A010)) and abrasion tester, automated percpirometer etc.

Many more applications are there in the testing lab of wet processing as an
example to test the fabric quality there are few more computer aided
machines.the application of computer is day by day increasing in various places
with the improvement of technologies and almost everywhere computer
assistance can be used for correct results.

Computer aided process machineries:

In textile wet processing there are many pretreatments processes are carried out
before sending the fabric to the dyeing and printing sections.as an examples
singeing where optimum temperature required, scouring, bleaching,
mercerization where ample amount of tension required which can be maintained
by applying automation or computer assistance. After than that fabrics sent to
dyeing and printing section.

For dyeing sections:

For dyeing procedure the accuracy of process is required for a proper dyeing
process there are some machineries which comes with computer assistance in the
machine for a better performance. There are some dyeing machines which has
softwares that work independently after the command that is made by the
operator. Digital monitor with information of m:l ratio, chemical ratio, machine
speed, temperature, pressure etc. criteria can be maintained for better dyeing
effect.

Computer match prediction for fluorescent dyes by neural networks:

Fluorescent dyes present difficulties for match prediction due to their variable
excitation and emission characteristics, which depend on a variety of factors. An
empirical approach is therefore favored, such as that used in the artificial neural
network method. In this paper, the production of a database with four acid dyes
(two fluorescent and two non-fluorescent) is described, along with the large
number of mixture dyeing’s that were carried out. The data were used to
construct a network connecting reflectance values with concentrations in
formulations. The results show that, although time consuming, this approach is
viable and accurate.
Datacolor :
During the bulk production accurate formulation of recipes datacolor also used.

Highly efficient ultraviolet photodetectors based on TiO2 nanocrystal–

polymer:
Solution-processed inorganic/organic hybrid films based on anatine TiO2 Nano
crystals and poly (9,9-dihexylfluorene) (PFH) are fabricated via a simple spin-
coating method and characterized by atomic force microscopy, UV–vis absorption
and photoluminescence spectra. The photodetector devices are made from
hybrid TiO2/PFH bulk heterojunction films sandwiched between poly(3,4-
ethylenedioxythiophene)–poly(styrenesulfonate) pre-coated ITO and Al
electrodes. The device characteristics, including current–voltage (I–V) curves
under UV illumination, spectral response, response time and bias dependence,
are studied. The photovoltaic effect is observed and the photocurrent shows an
increase with increasing TiO2content from 2.5 to 11 wt%. The high UV photo-to-
dark current ratio of 103, fast response time less than 200 ms and a responsivity
of 54.6 mA W − 1 are obtained for the hybrid photodetector. The fast
photoresponse is attributed to the enhanced interfacial dissociation of excitons.
The overlap of the spectral response with the UV–A range (320–400 nm) and the
low-cost wet fabrication method show their potential for environmental and
biological uses.

Ultrasonic-assisted wet processing:

Ultrasound reduces processing time and energy consumption, maintains or
improves product quality, and reduces the use of auxiliary chemicals. In essence,
the use of ultrasound for dyeing will use electricity to replace expensive thermal
energy and chemicals, which have to be treated in waste water.

Bubbling phenomenon, Ultrasound energy is sound waves with frequencies above

20,000 oscillations per second, which is above the upper limit of human hearing.
In liquid, these high-frequency waves cause the formation of microscopic bubbles,
or cavitations. They also cause insignificant heating of the liquid. Ultrasound
causes cavitational bubbles to form in liquid. When the bubbles collapse, they
generate tiny but powerful shock waves. We needed to agitate the border layer of
liquid to get the liquor through the barrier more quickly, and these shock waves
seemed like the perfect stirring mechanism.
Ultrasonic wave also can be used to increase the amorphous reasons in fabric to
better the dye uptake.

For printing section:

This process can be divided into two parts one preparation part and two is to
applying the print paste on the fabric.

Preparation:
Designing: It is done by as followings;
Photoshop: Before the application of printing on fabrics there is a necessity of an
appropriate designing which was used to be done manually now a days can be
done accurately with necessary information like repeat size, number of color etc.
with the help of Photoshop.

Computer Aided Design (CAD):

CAD is an electronic system which is used for designing new products or part of a
product or altering the existing products or replacing the entire product done
manually. CAD is used by the designer to design different geometric shapes with
the help of graphics software. The CAD system has been built up from the
Graphical User Interface with NURBS geometry and boundary representation data
via a geometric modeling kernel. The graphics system provided by the CAD allows
designers to create electronic images that can be portrayed into two or three
dimensional solid component which can be rotated or scaled or transformed as it
is viewed.

Screen preparation: In the past the screen preparation was a quite a difficult task
and was time consuming as well and accuracy was not achieved. Now a days glass
fiber used as screen, and galvano, laqour screen etc made by computer
assistance.
 Galvano screen

Printing process:
Digital textile printing, often referred to as direct to garment printing, DTG
printing, and digital garment printing is a process of printing on textiles and
garments using specialized or modified inkjet technology. Inkjet printing on fabric
is also possible with an inkjet printer by using fabric sheets with a removable
paper backing. Today major inkjet technology manufacturers can offer specialized
products designed for direct printing on textiles, not only for sampling but also for
bulk production. Burnout effect can be brought or plasma technology, laser
technology can be also used for printing.

Process management in wet processing:

Computer Integrated manufacturing (CIM) uses computers to control the entire
production process that involves engineering, production, marketing and all the
support functions of a manufacturing enterprise. In the traditional business
paradigm, the company is assumed as an island, i.e., an independent and self-
operating entity. As a company is a part of a broader matrix of business systems
composed of customers, suppliers, products and global information, it leads to
integration along different axes, namely geographical and functional. Its main
objective is streamlining the process of manufacturing and integrating it with all
the other business functions such as financing, marketing and accounting. To
eliminate the wastage, basic manufacturing functions as well as materials
handling and inventory control can be simulated by computers. Nowadays there
are many simulation softwares available. The elements of CIM system include
manufacturing planning and control, manufacturing engineering, manufacturing
processes and indirect elements such as sales order processing and finance and
accounting. Manufacturing planning and control includes shop floor control,
inventory control etc. Manufacturing engineering includes CAD/CAM, CAPP etc.
Manufacturing process includes robots, material handling systems etc.

Computer Aided Manufacturing:

This is the component of the CIM that directly deals with manufacturing
operations. The computer systems are used by the manufacturers because they
are accurate and also easily adaptable. They also provide easy access to data
storage and cost effective, high quality production. CAM makes use of the
computer based software tools to assist the engineers for manufacturing or
prototyping the product components.

 Computer helps to compute how long a machine will work and what would
be the amount of production that the machine will give by that time.
 During the manufacturing there are automatic system which can identify
the fault in process and can guide to solve the problems.

Computer Aided Process Planning:

As process planning involves determining sequence of individual manufacturing
operations needed to produce a given part or product, CAPP must be capable of
understanding and analyzing the characteristics of the part of a product,
possessing multiple knowledge about the tools and their characteristics, possess
the capability of analyzing the inter dependencies between the part, the process
involved, quality of the product and cost of the product.

Overall Process Monitoring & Managing:

Process monitoring is one of the most important part of synchronization of the
process. In the textile industry, some of the complex activities such as process
monitoring, management and planning makes used of knowledge based expert
system, where human experts are scarce.

Enterprise Resource Planning (ERP):

ERP is the latest high-end solution provided by information technology for
business application. Globalization has led to increase in competition and quality
awareness and therefore it has become very important for the textile industry of
Bangladesh to integrate itself with information technology to survive. To sustain
competitive advantage, companies must re-examine and fine-tune their business
processes to deliver high quality goods at very low costs. ERP is an integrated
system that allows information to enter at a single point in process & updates a
single shared database for all functions that directly or indirectly depend on this
information. ERP solutions came into existence in corporate world due to various
problems faced in Management Information System (MIS), Integrated
Information System (IIS), Executive Information System (EIS), Corporate
Information System (CIS), Enterprise Wide System (EWS), and Material
Requirement Planning (MRP), Manufacturing Resource Planning (MRP II). This
paper deals with the functions of ERP, Necessity and benefits of ERP system.
Challenges of aligning ERP with textile processes, taxonomy of textile ERP system,
Development of ERP system, Existing ERP systems, ERP system providers, ERP
system Implementation, simply to understand - ERP system organizes all of the
companies information into one centralized system, which is always available.

ERP Plan

Through ERP in Wet Process We can make a synchronized relations between the
production floor for monitoring and inventories, fabrics, dyes that are consumed
and wasted and also the market conditions.
The technology trends that will drive textile designing include:
1. Computer aided design (CAD) or Computer aided manufacturing (CAM)
2. Shape-memory applications in textile design
3. 3D printing in textile design

1. Computer-aided design (CAD) in textile design:

Computer-aided design (CAD) has brought a revolution in the textile designing.
Textile designer become benefited from CAD to visualize and see their
imaginative design in final form without producing any sample swatch. Customers
can also give ideas for designing according to their particular requirement.
With the increasing convergence of technologies, CAD/CAM will continue to
evolve into an integrated environment that drives the entire company. No longer
serving just design or production functions within the company, CAD/CAM will
become an integral part of the company ‘intranet’, – feeding sourcing,
merchandising and marketing processes that support the entire enterprise.

Fig: Uses of CAD in Textile Designing

Other applications of CAD/CAM in textile designing includes:

(a) Modularization:
Proprietary software packages will give way to modular plug-ins-software
solutions that are narrow in focus and designed to easily integrate with existing
custom or off-the-shelf software.

(b) 3D body scanning:

3D laser scanning interpreted into accurate 2D flat patterns will become a viable
entity in the industry. This technology will enable a proper fit of a garment and
will fuel the end of mass production and excessive retail inventories. In their
second generation, body scanners will be combined with video display and will
enable the customer to ‘tryon’ sized-to-fit virtual garments.

(c) Mass customization:

As we enter the technology age of mass customization, CAD/CAM technology will
become a driving force in the sales and marketing of apparel.

2. Shape-memory applications in textile design:

Shape memory materials (SMM) are smart materials that can remember and
recover substantial programmed deformation upon activation and exposing to an
external stimulus. The concept of shape memory fabric in textile designing is new.
Shape-memory materials can be used for clothing, textile as yarn, fabric or fiber.
Shape-memory fibers can be implemented to develop smart textiles that respond
to thermal stimulus. Although It has some applications such as in brassieres and
flame retardant laminates. But it also has better potential for textile and clothing
and related products. These products are shoes, various breathable fabrics,
thermal insulating fabrics and crease, shrink-resistant finishes for apparel fabrics,
etc. These products can be made with finishing, coating, laminating, blending, and
other innovative structures.

3.3D printing in textile design:

3D printing has its roots in the production of simple plastic prototypes. 3D
printing builds up three-dimensional objects, one layer at a time, following digital
designs loaded into their memories. 3D printing has revolutionary changed in
textile design. As the technology continues to grow, its limitations and costs will
gradually diminish. The idea of mass-customized design can become a reality with
the application of 3D printing, which can reduce the problem of size and fit.

Conclusion:
Latest technologies in textile designing that offer maximum flexibility and
guarantee the quality and consistency of the processes are needed for the
industry today. Some tools allow users to recreate an environment identical to
their traditional one. Some can produce markers only one to two percent less
efficiently than those of an experienced marker person. The key to the future is
compatibility. To maintain continuity and reduce problems, new systems should
be created that accommodate the old.