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Implementation of an Automated Manufacturing Process for Smart Clothing: the Case Study of a Smart Sports Bra

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Implementation of an Automated Manufacturing Process for Smart Clothing: the Case Study of a Smart Sports Bra processes Article Implementation of an Automated Manufacturing Process for Smart Clothing: The Case Study of a Smart Sports Bra Suhyun Lee 1, Soo Hyeon Rho 1, Sojung Lee 1 , Jiwoong Lee 2, Sang Won Lee 2, Daeyoung Lim 1 and Wonyoung Jeong 1,* 1 Human Convergence Technology R&D Department, Korea Institute of Industrial Technology, Ansan 15588, Korea; [email protected] (S.L.); [email protected] (S.H.R.); [email protected] (S.L.); [email protected] (D.L.) 2 Department of Mechanical Engineering, School of Mechanical Engineering, Sungkyunkwan University, Suwon 16419, Korea; [email protected] (J.L.); [email protected] (S.W.L.) * Correspondence: [email protected]; Tel.: +82-31-8040-6233 Abstract: The garment manufacturing industry is a labor-intensive industry, with one of the slowest transitions to automation. Hence, it is essential to build a smart factory based on automated systems to improve productivity and allow responsive production in the market. In this study, the manufacturing processes for a smart sports bra were established and optimized using various automated machines. For this system, computer-based 3D virtual design software, a technical embroidery machine, an automatic cutting machine, an industrial robot arm with gripper, and an industrial pattern sewing machine were used. The design and materials of the sports bra were selected considering embroidery, cutting, robot gripping, and sewing processes. In addition, conductive thread and light-emitting diode (LED) sequences were used to implement smart functions to the sports bra. Transport of intermediate materials, work orders, and process conditions were optimized to improve the flexible connection of each process and the quality of the final product. This study suggests the concept of the Citation: Lee, S.; Rho, S.H.; Lee, S.; automated manufacturing system that minimizes human intervention by connecting the processes Lee, J.; Lee, S.W.; Lim, D.; Jeong, W. needed to produce a smart sports bra using various automation equipment and programs already Implementation of an Automated used in the industry. Manufacturing Process for Smart Clothing: The Case Study of a Smart Keywords: automation; garment manufacturing processes; smart factory; smart clothing; micro Sports Bra. Processes 2021, 9, 289. factory; automated processes https://doi.org/10.3390/pr9020289 Academic Editor: José Barbosa Received: 30 December 2020 1. Introduction Accepted: 29 January 2021 Published: 2 February 2021 With the fourth industrial revolution and manufacturing innovations that started in Germany, the fashion industry is changing. The concepts of smart factories and automation Publisher’s Note: MDPI stays neutral are mixed complexly and used in the fashion industry. On the other hand, there are consid- with regard to jurisdictional claims in erable differences between factory automation and smart factories. Factory automation published maps and institutional affil- refers to a system that automates the entire unmanned factory and manufacturing process iations. using automatic equipment, such as computers and robots. In contrast, smart factories give each function to various objects related to manufacturing. Each of these objects is a factory that communicates to each other through internet of things (IoT) devices and can autonomously connect, collect, and analyze data [1]. Smart factory and automation systems can enable the development of a fashion system based on the product quantities Copyright: © 2021 by the authors. Licensee MDPI, Basel, Switzerland. that are better balanced with market demand, more consistent with the customers’ needs, This article is an open access article highly customized, and transparent for their entire lifecycle [2]. distributed under the terms and Garments are essential items for humans. As the population increases and lifestyles conditions of the Creative Commons change, customers’ needs for various new clothing styles are also increasing. The process Attribution (CC BY) license (https:// of manufacturing garments is a labor-intensive and mass-produced industry. Serious creativecommons.org/licenses/by/ environmental problems and social costs have occurred due to excessive mass production 4.0/). to supply new products to the market quickly. In addition, producers continue to move Processes 2021, 9, 289. https://doi.org/10.3390/pr9020289 https://www.mdpi.com/journal/processes Processes 2021, 9, x FOR PEER REVIEW 2 of 17 Processes 2021, 9, 289 2 of 16 to supply new products to the market quickly. In addition, producers continue to move their production bases to developing countries with lower wages to lower production their production bases to developing countries with lower wages to lower production costs. Focusing on the 4.0 smart factory, the garment manufacturing industry needs to be costs. Focusing on the 4.0 smart factory, the garment manufacturing industry needs to be transformed into an automated manufacturing process through several technologies such transformed into an automated manufacturing process through several technologies such asas computer computer systems systems and and digital digital facilities facilities because because of theof the limitations limitations of the of relocationthe relocation of the of productionthe production base base and theand needs the needs of customers. of customers. TheThe automation automation of garmentof garment manufacturing manufacturin hasg been has suggestedbeen suggested as one of as the one measures of the formeasures rapid military for rapid production military production because soldiers because can soldiers be mobilized can be to mobilized the army to quickly the army to improvequickly militaryto improve power. military On thepower. other On hand, the other automation hand, automation of the garment of the industry garment has indus- not beentry has implemented not been implemented to any large extent to any because large ex clothingtent because products clothing do not products undergo do the not same un- formdergo or the production same form process, or production such as process, devices su orch automobiles. as devices or The automobiles. styles are The diverse styles and are changediverse very and often,change and very there often, is a sizeand issue.there is Even a size with issue. the sameEven design,with the the same pattern design, varies the dependingpattern varies on thedepending size, and on the the process size, and may the be process different. may The be different. initial investment The initial cost invest- to buildment an cost automated to build facilityan automated in the production facility in the site production is high. In addition, site is high. automation In addition, is not auto- so urgentlymation is needed not so becauseurgently it needed still has because an inexpensive it still has workforce an inexpensive available. workforce available. TheThe complete complete automation automation of of garment garment manufacturing manufacturing is is impossible impossible because because a a human human forceforce is is still still needed needed to to control control the the direction direction and and position position of of the the sewn sewn fabric fabric during during the the sewingsewing process. process. Regardless Regardless of of how how much much technology technology develops, develops, more more than than 95% 95% automation automa- appearstion appears impossible impossible because because garment garment styles styles change change very very quickly, quickly, and and its its forms forms are are so so numerous.numerous. Nevertheless, partial partial automation automation is is being being realized realized gradually. gradually. Research Research on onau- automationtomation is isaimed aimed atat automatically automatically and and easily easily manufacturing manufacturing garments garments and and textiles textiles for forsale sale rather rather than than prototypes prototypes [3]. [3 Therefore,]. Therefore, a future a future garmen garmentt manufacturing manufacturing system system is ex- is expectedpected to to be be a asmart smart factory. factory. This This is is becaus becausee the the production production costs are increasing gradually,gradually, andand reactive reactive and and local local production production according according to to customization customization needs needs is is required. required. As As shown shown inin Figure Figure1, 1, in in the the near near future, future, the the fashion fashion industry industry is is expected expected to to transform transform into into the the means means ofof instant instant production production and and delivery delivery of of clothing clothing designed designed and and ordered ordered by by customers customers [4 [4].]. FigureFigure 1. 1.Scheme Scheme of of the the impact impact of of technology technology on on fashion fashion industry industry [ 4[4].]. Research has been actively conducted in the field of automation of garment manufac- turing for many years, particularly in robot gripping and automatic sewing systems [3,5–8]. Processes 2021, 9, x FOR PEER REVIEW 3 of 17 Processes 2021, 9, 289 3 of 16 Research has been actively conducted in the field of automation of garment manu- facturing for many years, particularly in robot gripping and automatic sewing systems [3,5–8]. A robot-based sewing system named SEWBO (Sewbo, Inc., Seattle, WA, USA) sewedA robot-based all the necessary sewing system seams named of a T-shirt SEWBO au (Sewbo,tomatically Inc., Seattle,using an WA, industrial USA) sewed robot
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