Client: Shahi Exports Pvt. Ltd.
Industry: Textile Manufacturing
Challenge
Inconsistent Roll Data, Missed Defects, and Quality Gaps
Manual inspection and measurement led to inefficiencies in fabric production and quality assurance:
- Unreliable roll length and yardage recording due to manual meters.
- Missed detection of weaving errors, color streaks, and tension lines.
- High labor dependency and slow throughput.
Solution
Automated Fabric Quantification & Quality Indexing System
Sunbio IT Solutions implemented an integrated AIML-based fabric inspection platform combining vision, AI, and real-time data analytics.
- High-Resolution Vision Cameras: Capture live fabric imagery at line speed.
- AI Quantification Engine: Calculates exact roll length, density, and yield with ±0.1% accuracy.
- Defect Intelligence Module: Detects and classifies surface defects instantly.
- Edge Processing Controller: Provides on-site inference and instant alerts.
- Quality Dashboard: Displays defect heatmaps, roll analytics, and real-time trends.
System Architecture
From Fabric to Data-Driven Quality Control
- Vision Cameras: Acquire high-speed visual data from live fabric lines.
- AI Engine: Performs quantification and defect localization.
- Edge Controller: Executes inference with low latency.
- Cloud Dashboard: Stores roll history and defect records for traceability.
Results
Precision, Productivity, and Predictive Quality
| Metric/Area |
Before Implementation |
After AIML Deployment |
Improvement |
| Fabric Measurement | Manual, ±2–3% error | AI quantification, ±0.1% accuracy | Consistent traceability |
| Defect Detection | Operator dependent | Real-time AI classification | 360° quality visibility |
| Productivity | Multi-operator inspection | Autonomous single-line workflow | +40% throughput gain |
| Data Utilization | Paper-based logs | Digital dashboards & analytics | Instant decision-making |
Business Impact
Smarter Textile Manufacturing Through AIML
- Standardized AI inspection across production lines reduced rejections.
- Enhanced operational efficiency and minimized manual dependency.
- Traceable digital quality records for every roll improved transparency.