Factory automation does more than just lower costs—it increases productivity and reduces injury risks
The fast-paced fashion industry is always evolving. Customers now have wider access to fashion items than ever before, making them crave the next garment before wearing out the last. As social media increases public awareness of fashion trends, garment manufacturers need to find new ways to keep up. More and more garment manufacturers are looking to manufacturing automation to remain current. For most, the only way to meet demand while cutting costs is to use computerized systems designed to streamline production and handle bulk orders.
Are you thinking of making the leap towards automated garment machinery? Here are the top 10 benefits of factory automation.
1. Automation reduces factory costs
Cost reduction is one of the main reasons manufacturers consider automation. By replacing human workers with machines, manufacturers can use automation to significantly cut labor and training costs. Take Nike’s 2021 Flyknit sneaker range, for example. Nike got robots to make the upper part of the sneaker, significantly reducing production costs while enhancing productivity.
Savings from automation cause a ripple effect further down the production line, and the cost per item is reduced as a result. Despite high start-up costs, the long-term savings from automation make it a worthwhile investment for garment manufacturers.
2. Automation reduces labor requirements
Factory automation reduces the factory floor from hundreds of workers to just a few department managers. Machines and robots can take over unskilled tasks that originally required multiple staff. Furthermore, a reduced workforce means lower staff turnover and sick days, so that factories no longer have to worry about training newcomers.
3. Automation improves employee safety
An estimated 1.4 million worker injuries occur in garment factories per year, many of which are due to inadequate machinery training. Fatigue, misunderstandings, and incorrect use of machines can cause injury, disfigurement, or even death. Factory automation decreases workers’ contact with dangerous moving machines, in turn reducing the risk of workplace accidents. This is hugely beneficial for manufacturers, as they no longer risk lawsuits from injured parties or their families.
4. Automation reduces product defects
With automation comes predictability. Machines can be set to make products or clothing parts in a consistent way, leading to decreased wastage. Fabric cutting, for example, is more precise using a machine, as it avoids the risk of human error that comes with manual cutting. This reduces the risk of product recalls later down the line, helping manufacturers guarantee consistent quality to customers.
5. Heavy-duty automated machines increase productivity
Machines maintain high productivity levels without tiring the way humans do. Moreover, machines do not require toilet or lunch breaks, sick days, or time for staff handovers at the beginning of a new shift. Machines make products of the same quality even under challenging working conditions, which is impossible for manual workers to achieve. By increasing productivity, heavy-duty automated machines let manufacturers take on bulk orders and enhance overall turnover.
6. Better planning increases factory output
Automated machinery’s increased consistency and productivity also enable manufacturers to accurately plan demand and place advance orders for raw materials. Advanced planning means manufacturers only purchase what they need, reducing fabric wastage from over-ordering.
7. Reduced lead times help manufacturers hit targets
It’s a fact that machines work faster than people do. For example, instead of spending hours spreading layers of fabric manually, automatic spreading machines can handle up to 90 meters of fabric per minute. Lead times are reduced as a result, as manufacturers no longer need to wait for manual workers to produce orders.
8. Automation keeps everything in-house
Automated factories work smarter. Automation affords manufacturers greater control over the entire production process by keeping everything in-house. This enhances factory managers’ oversight of production while letting them cut loose from external suppliers that are susceptible to delays.
9. Integrated machines boost productivity
Linked together to collect and share data, integrated machines are guaranteed to boost factory productivity. By remotely reviewing and collating data such as quality control pass and fail rates, integrated machines help managers make decisions on the go. Managers get to view data for an entire fleet of garment machines at a glance instead of individually, letting them optimize production in a timely fashion.
10. Automation enhances manufacturer reputation
Together, these 10 benefits of factory automation have one crucial upshot: a stellar reputation. By leveraging automation to consistently hit order deadlines and avoid product defects, manufacturers can increase customer satisfaction, and in turn, their reputation. The greater the reputation, the more customers will flock to a manufacturer with bulk orders.
Conclusion
Garment manufacturers must evolve if they are to meet the global demand for high-quality clothing—and factory automation provides a way forward. Machines can perform monotonous, dangerous, or physically challenging tasks, removing the need for human intervention. Not only does this save manufacturers money and remove safety hazards, but it also enhances efficiency and reduces fabric wastage.
Automated machines provide products and components of consistent quality, ensuring that orders are fulfilled to the highest standard. Initial installation costs are soon offset by faster lead times and a reduced workforce, leaving machines to churn out thousands of items under otherwise challenging conditions. If you want to see these benefits for yourself, contact us today to learn about our garment manufacturing automation solutions.
