Foundation Certifiacte in Higher Education Module Code – DOC314 – Digital Skills for Higher Education Module Leader – Ms. Dilki Weerakoon Assesment Type – Group Coursework Title - How Industry 4.0 affects the textile and garment sector in Sri Lanka Student ID Name 20230153 M.S.A.Mohommed 20230208 D.H.R.Ariyapala 20230214 M.G.K.Kulathilaka 20230209 M.D.T.R.Wijayawardena 20230184 H.D.S.M.Thathsara 20230225 J.N.K.Jagoda Abstract The Sri Lankan economy is heavily reliant on the textile and apparel sector. It is one of the primary export incomes generating sources of the country and has provided hundreds of thousands of jobs for Sri Lankans over the past few decades. The need for the research of how industry 4.0 is important in this industry arises as the industry within the country has faced a few difficulties and has not developed technologically to the same extent as the other nations. In order to secure the obtained successfulness in this competitive environment and address these challenges we need to adapt to the new technological developments. The purpose of this study is to identify these problems and the technological solutions that may be used to solve them. This report's facts and figures were analysed from online, peer-reviewed academic sources, and some information was corrected by professionals in the textile and garment industry. From this report we aim to provide a clear image of the position the textile and garment industry holds in Sri Lanka and how in comparison to other countries, it may be improved with the use of industry 4.0 technology. Acknowledgement Firstly, we would like to express our gratitude and appreciation to our lecturer of DOC 314 (Digital Skills for Higher Education), Ms. Dilki Weerakoon for providing us the opportunity to create this report. Secondly, we would like to acknowledge our tutorial lecturer, Ms. Savindi Weerakoon for guiding us through the process of creating this report. This report has given us the opportunity to gain knowledge about how Industry 4.0 has affected the textile and the garment sector. Furthermore, we would like to express our gratitude to our group members who participated actively in this report. We would like to acknowledge everyone who has helped us directly or indirectly and we appreciate your support. Table of Content List of Figures and Tables Figures Tables Abbreviations ✔ IoT – Internet of Things ✔ AI – Artificial Intelligence ✔ ML – Machine Learning ✔ RFID – Radio Frequency Identification ✔ 3D – 3 Dimensional ✔ BPO – Business Process Outsourcing ✔ R & D – Research and Development ✔ EDB – Export Development Board ✔ JAAF – Joint Apparel Association Forum 1.Introduction 1.1. What is Industry 4.0.? Earlier to 2011, the term “Industry 4.0" was virtually fictional; however, it was first officially introduced to the world by executive chairman of the world economic forum Mr. Klaus Schwab in 2015. Industry 4.0 is a new phase in the industrial revolution that introduces intelligent networking of industrial machines and processes with the help of information and communication technology. In other words, “It connects the physical world with the digital world”. Key technologies of Industry 4.0 are Internet of Things, Artificial Intelligence, Cloud computing, Big Data and analytics, Advanced robotics, Additive manufacturing and Cyber physical systems. Breakthroughs in artificial intelligence, data analytics, automation, additive manufacturing, and various other technologies are driving significant improvements in industrial procedures while lessening our reliance on human labour and judgement. (Eminify,2021) (SAP,2022) (IBM,2022) (MaKinsey,2022) 1.2. Textile and garment industry The textile garment industry encompasses various activities such as research, design, production, and distribution of textiles, fabrics, and clothing. It plays a significant role in the industrialization of developing countries. In Sri Lanka, this industry holds great importance for the economy, as it contributes to both job creation and export earnings. Sri Lanka's textile and garment sector has experienced remarkable growth in export revenues, primarily driven by key markets such as the United States, the European Union, and several Asian countries. Notably, in 2022, the industry generated $5.93 billion in export revenue, directly employed around 350,000 people, and accounted for 46.46% of the national export income. Sri Lankan apparel has evolved from traditional exports and tailoring designs to providing sophisticated solutions, creativity and experience in BPO services, Fashion, R&D and Innovation Centres, bridging the country’s gap between developing and developed. It is no surprise that Sri Lanka’s top three apparel companies are already amongst the world’s 50 most important suppliers. (Kiron,2014) 2. How the industry 4.0 affects the textile and garment sector in the global context. Figure -Textile and Garment industry https://www.industriall-union.org/textile-leather-garmentshoes-and-textile-services The textile and garment industry has become a global phenomenon. The main function of the industry 4.0 is digitalization and automation. In the textile industry it is implemented by having flexible and automated supply chain processes. Modern textile machines are highly advanced. They can design, research, model and distribute fabrics in a digital environment supported by virtual reality technologies. The quality control of the fabrics can also be done by modern machinery. Before the fourth industrial revolution the quality control of the garments has been done by the humans. This method is inefficient. Thus, the quality control systems were produced. Today the textile industry is developing in a steady speed. (Paldiya, 2021) 2.1. Examples for how the industry 4.0 affects the textile industry in a global context. There are plenty of examples of how the fourth industrial development affect the textile industry. Many inventions to ease the tasks in textile industry has been invented. 2.1.1. RFID Tags RFID or Radio Frequency Identification is a wireless technology which uses radio waves to communicate between the reader and a tag. This has revolutionized many industries including the textile industry. There are many benefits of RFID tags in the textile industry. Some of them are, 1.Inventory management – RFID technology provides real-time information about the location of the product. This minimizes overstocking of products. 2. Quality control – Quality is a crucial factor in the process of manufacturing products. Today, the textile industry is highly advanced and competitive. RFID technology ensures the quality of the products. It can monitor the quality of the product. 3.Supply chain visibility – RFID provides the user real-time information about the movements of the inventory. This helps for the improvement of the customer satisfaction. (Kohan Textile Journal, 2023) Figure -RFID tags https://textilelearner.net/rfid-technology-in-fashionand-textile/ 2.1.2Perks for sports With sportswear playing an important role in the garment industry, there’s great opportunities that sports brands can gain through various technological solutions. With there being a considerable disaster in sports like football, rugby data analytics, the Internet of Things (IoT) technologies offer highly beneficial information regarding the fitness of players, midway through the match. Thus, it enhances coaches with insight regarding the performance of their players and also help them in deciding if they need to be replaced or not. Polar Team Pro Shirt is a smart shirt that comes with smoothly integrated sensors to monitor heart rate and a pocket for player tracking sensor located on the upper back for optimal GPS reception. The second skin fit ensures constriction free movement on the field and also maintains a specific body moisture system that keeps players cool no matter what challenge the game throws at you. This type of smart shirt also blocks the damaging effects of ultraviolet rays so players can concentrate and play easily in the heat of the game. (Jain, 2021) Figure 3-Smart sportwear https://textilelearner.net/internet-of-things-iot-in-fashion-industry/ 2.1.3. Addictive manufacturing Additive manufacturing, commonly known as 3D printing, is a method that layers materials one by one based on a computer model to build a tangible (or 3D) item. Unlike subtractive manufacturing, which produces its end product by cutting away from a block of material, additive manufacturing produces its final product by adding pieces. Addictive manufacturing, (2023) • Customized Apparel: Additive manufacturing uses 3D scanning technology to create personalized clothing items, improving comfort and reducing waste. • Prototyping and Design: 3D printing enables textile designers to quickly create prototypes, evaluating textiles' appearance, feel, and functionality before large-scale production, streamlining the design process and reducing costs. • Customized Footwear: Additive manufacturing in the textile industry creates custom shoes and insoles by scanning feet, creating 3D models, improving comfort, reducing injury risk, and offering a unique user experience. (Lakmali, G.D.E., Vidanagamachchi, K. and Nanayakkara, L.D.J.F., 2020) 2.1.4. Automation in Fabric Cutting This process was also done manually earlier but now automatic fabric cutting machine is being used. As a result, it is possible to cut the fabric more accurately and smoothly than before. According to the design of the garment now the design of that pattern is saved directly in the computer memory without making marker paper and according to that instruction the cutting machine automatically cuts multiple layers of fabric together, in a short time and accurately. This cutting process is also done somewhere using laser. The use of automatic cutting machines has reduced both the number of workers and the time compared to manually or operator operated machines. (Kiron, 2021) Figure 4-Automatic fabric cutting machine https://www.onlineclothingstudy.com/2016/12/7-automatic-cnc-fabric-cuttingmachines.html Figure 5-Additive manufacturing https://www.karlmayer.com/en/additive-manufacturing-in-the-textile-industry/ 3.How can be improved the textile and garment sector in Sri Lanka with the features of industry 4.0 As mentioned in the report, textile industry has undergone a global expansion. The development of the textile and garment industry in Sri Lanka has been steadily rising. The fourth industrial revolution has a massive impact on it. Although, there is a development in the textile industry in Sri Lanka, it can still be improved. 3.1. Cloud computing Cloud computing as technology is becoming more prominent in many industries and has potential to revolutionize the Sri Lankan textile and garment industry in the context of Industry 4.0. Cloud computing empowers textile manufacturers to expand their operations, improve competitiveness, and enhance their overall performance. By adopting cloud-based solutions such as ERP and CRM systems, the industry can achieve significant improvements. Cloudbased ERP enables tighter control over production processes, reduces wastages and costs and improves product quality. Moreover, the scalability and accessibility of cloud-based ERP make it a cost-effective choice for businesses. Additionally, cloud-based CRM systems provide realtime insights into customer behaviour, leading to better customer retention and revenue generated. (Deeproom technology, 2022) (Delvadiya, 2023) Figure 6-Qualit control https://www.pmg-pm.co.uk/clever-blog/ 3.2. Internet of Things IoT enables clothing manufacturers to improve the interactivity, educational value, and client customization of their items. By integrating IoT solutions into textile manufacturing processes, manufacturers can achieve several key benefits, including cost reductions, real-time feedback, quality enhancement and real-time equipment performance monitoring. IoT solutions such as Intelligent systems embedded in machinery can enhance productivity by minimizing downtime and predicting maintenance needs. Moreover, IoT-powered sensors can monitor product quality throughout the production process, allowing for immediate adjustments and ensuring high standards. Thereby by harnessing the power of IoT technologies, Sri Lankan textile manufacturers can successfully compete in the global market and pave the way for growth and development. (PAYODA.com, 2020) (Rejig Digital.com, 2022) 3.3. Big data applications in textile industry Big data could be defined by the 5V concept ● Volume – the size of the data set ● Velocity - the speed with which data is gathered, processed, and made usable ● Variety - comprises of the variety of stored data, which can come from many sources and be in a variety of forms. ● Veracity - pertaining to the updating and accuracy of the retrieved data; ● Value - includes the advantages and knowledge obtained from the data processing Big data is mostly used for analysis and monitoring process of a business. Applications of big data turn data collected along the supply chain into knowledge that supports industries in their quest for methods to be more competitive and provide incentives for the development of new business models. Big Data is an essential tool in the extensive integration of factories because of its high data collecting, storage, and processing capacity, which enables factories to become more intelligent and agile. Big Data technology strengthens the relationship between textile businesses and their customers, especially in retail, where the industry may be better able to comprehend its customers through data gleaned from the internet, social media, and other sources. A company may utilize big data to make decisions that are supported by evidence in order to increase business value, optimize and manage the production process, improve maintenance procedures, etc. (Forno, 2021) 3.4. AI and robotic applications in textile industry Robotics and artificial intelligence play a crucial part in the environment visualized by Industry 4.0, functioning in a way to assist and collaborate with people as they carry out industrial activities, bringing them closer together as a result. The concerns of cost reduction and a lack of skilled personnel have been solved globally with the deployment of these technologies, yet to be implemented in Sri Lanka. Logistics processes - the usage of drones to transport clothing and the tracking technologiesequipped autonomous vehicle model for stock monitoring and control. Textile manufacturing - Robots can work with people to complete tasks including folding components, gathering parcels, assembling batches, and packing goods. With the AI technology during the sewing process devices were created that, when combined with ordinary machinery, reduced or eliminated manual interventions. Example: - a factory in China using robotic sewing machines has the capacity to produce 800,000 shirts in one day, at a rate of 22 s per shirt Quality control – Using Artificial intelligence and robotic vision system an autonomous inspection station can be built for receiving the examined product and positioning it in accordance with the signal received. (Forno, 2021) 4.Barriers for the industry 4.0 in the textile and garment sector in Sri Lanka. 4.1. Lack of new investment Sri Lankan textile industry is facing problem of Low productivity due to its obsolete textile machineries. To overcome this problem and to stand in competition, Sri Lanka Textile Industry will require high investments. There is a continuous trend of investing in spinning since many years. Sri Lanka is facing externally as well as internally problems which restrict the new investment The unpredictable internal condition of Sri Lanka causes a rapid decrease in foreign investment that affected all industries but especially textile industry. (Islam, Khan, 2013) 4.2. Different attitudes and decision making of people Employee working attitude is also an essential factor to consider to take the human resource management decision of a company. Employee working attitude changes organizational culture, develop employee commitment, trustworthiness, efficiency, and effectiveness of job tasks, etc. Poor employee attitude creates unresolvable problems in the human resource process of apparel companies in Sri Lanka. Different types, ages, social groups of employees are working in apparel companies since they have poor attitudes that have to tolerate and corrected when managing people in the apparel industry. (Welmilla, 2020) Figure 7- Technologies used in the textile industry https://apparelresources.com/technology-news/manufacturingtech/industry-4-0-technologies-apparel-manufacturing-challenges-ahead/ 4.3. Expensive installation of technology The textile and the garment industry have played a major part in the Sri Lankan economy. It has made a name for themselves in the global context. Even in the midst of the worst economic crisis Sri Lanka faced, the quality of the Sri Lankan textile and garment prevailed. The textile and the garment sector in Sri Lanka use labour. But with the developing technology, some ideas have been provided to use technology instead of labour. The Export Development Board (EDB) and the Joint Apparel Association Forum (JAAF) have made decisions to promote technologies in the areas of inventory management and the design management. EDB supports the use of machinery and new technologies in the textile industry. But this new opportunity comes with a cost. It is very expensive to install. new machinery. So, the initial cost of this project is high. Sri Lanka is facing the aftermath of an economic crisis. It is difficult to have access to such high-cost technologies in these times. (Export Development Board, 2015) 4.4. Increasing Cost of Production The cost of production of textile rises due to many reasons like increasing interest rate, double digit inflation and decreasing value of Sri Lankan Rupees. The above all reason increased the cost of production of textile industry which create problem for a textile industry to compete in international market. (Islam, M., Khan, M.A., 2013) Figure 8-new technologies in the apparel industry https://www.cgsinc.com/blog/what-industry-4.0-means-apparel-fashionand-footwear-manufacturers Figure 9-Industry 4.0 used in the apparel industry https://apparelresources.com/technology-news/manufacturingtech/industry-4-0-technologies-apparel-manufacturing-challenges-ahead/ Conclusion In conclusion, the industrial revolution 4.0 has created a great number of opportunities which the Sri Lankan garment textile sector can reap benefits from. The trend is mainly positive and with the integration of technologies like artificial intelligence, Internet of Things (IoT), and data analytics manufacturers can lead the way to economic growth and development. While there are many barriers such as lack of skilled workforce, lack of government support and policies and reluctance to change, by embracing such technologies clothing manufacturers can revolutionize their operations. Thereby by embracing this concept Sri Lanka can boost its growth, generate employment opportunities and face the global competition head on. sssReferences Deeproom Technology (2022) The Benefits of Cloud technology in the apparel industry [online]. Available from: https://blog.deeprom.ai/the-benefits-of-cloud-technology-in-theapparel-industry-c369f336e97c [Accessed: 26th of June, 2023] Delvadiya, D., (2023) cloud computing in the textile and apparel industry[online]. Available from: https://www.tutorialspoint.com/cloud-computing-in-textile-and-apparelindustry [Accessed: 24th of June, 2023] EDB, (2015) Emerging technologies in Sri Lankan apparel industry[online]. Available from: https://www.srilankabusiness.com/blog/sri-lankan-apparel-industry.html [Accessed: 25th of June, 2023] Islam, M., Khan, A.M., (2013) Textile Industries in Bangladesh and Challenges of Growth[online]. 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Available from: https://www.mckinsey.com/capabilities/operations/our-insights/capturingthe-true-value-of-industry-four-point-zero [Accessed: 26th of June, 2023] Appendices Workload Matrix Allocated Azmeth Hirushi Gagani Thamindu Sandaru Tasks Sajjad Ariyapala Kulathilaka Rehan Malshan Nadija Kaushika Title and the cover Done page Abstract Done Acknowledgement Done Table of contents Done and list of figures Abbreviations Done Introduction How industry 4.0 Done Done Done Done Done Done Done affects the textile industry in global context Ways to improve the textile sector in Sri Lanka Barriers for the Done Done development of textile industry in Sri Lanka Conclusion Done References Done Appendices Done -Workload Matrix -Meeting Agenda Table 1-Workload matrix Done Meeting Agenda 1st Coursework meeting Date: 18th of June, 2023 Time: 5.00 p.m.-6.00 p.m. Venue: Zoom meeting Attendees: 1) Azmeth Sajjad 2) Hirushi Ariayapala 3) Gagani Kulathilaka 4) Thamindu Rehan 5) Sandaru Malshan 6) Nadija Kaushika Time Discussion 5.00 p.m.-5.15 p.m. Getting familiar with the group members 5.15 p.m.-5.35 p.m. Discussing about the given topic 5.35 p.m.-6.00 p.m. Dividing the topics among the members Table 2-1st coursework meeting 2nd Coursework meeting Date:23rd of June, 2023 Time:10.30 a.m.-12.30 p.m. Venue: Lab 06 Attendees: 1) Azmeth Sajjad 2) Hirushi Ariyapala 3) Gagani Kulathilaka 4) Thamindu Rehan 5) Sandaru Thathsara 6) Nadija Kaushika Time Discussion 10.30 a.m.-11.00 p.m. Discussing about the information we gathered 11.00 a.m.-12.00 p.m. Creating a rough sketch of the report 12.00 p.m.- 12.30 p.m. Creating the title page and setting up a time for the next meeting Table 3-2nd coursework meeting 3rd Coursework meeting Date: 25th of June, 2023 Time:6.00 p.m. – 8.00 p.m. Venue: Zoom meeting Attendees: 1) Azmeth Sajjad 2) Hirushi Ariyapala 3) Gagani Kulathilaka 4) Thamindu Rehan 5) Sandaru Malshan 6) Nadija Kaushika Time Discussion 6.00p.m.-7.00p.m. Started the meeting by sharing a word document among the members to edit their information in it 7.00p.m.-7.30p.m. Referring to the content in the document and finding the errors 7.30p.m.-8.00p.m. Table 4-3rd coursework meeting Correcting the errors in the document 4th Coursework meeting Date:27th of June, 2023 Time: 10.30 a.m.- 12.30 p.m. Venue: Lab 06 Attendees: 1) Azmeth Sajjad 2) Hirushi Ariyapala 3) Gagani Kulathilaka 4) Thamindu Rehan 5) Sandaru Malshan 6) Nadija Kaushika Time Discussion 10.30 a.m.- 11.30 a.m. Completed the report’s main body, including all necessary sections. 11.30 a.m.-12.00 p.m. Conducted a comprehensive review of the entire report for accuracy and consistency. 12.00 p.m.-12.30 p.m. Made any necessary revisions or additions based on the review. Table 5-4th coursework meeting 5th Coursework meeting Date: 30th of June, 2023 Time:10.30 a.m.-12.30 p.m. Venue: Lab 06 Attendees: 1) Azmeth Sajjad 2) Hirushi Ariyapala 3) Gagani Kulathilaka 4) Thamindu Rehan 5) Sandaru Malshan 6) Nadija Kaushika Time Discussion 10.30 a.m.-11.00 a.m. Finalised the report’s conclusion and executive summary sections. 11.00 a.m.-11.30 a.m. Edited and proofread the entire report for grammar,spelling and formatting. 11.30 a.m.-12.30 p.m. Created a professional layout and design for the report, ensuring visual appeal. Table 6-5th coursework meeting 6th Coursework meeting Date:01st of July, 2023 Time:4.00 p.m.-6.00 p.m. Venue: Zoom meeting Attendees: 1) Azmeth Sajjad 2) Hirushi Ariyapala 3) Gagani Kulathilaka 4) Thamindu Rehan 5) Sandaru Malshan 6) Nadija Kaushika Time Discussion 4.00 p.m.- 4.30 p.m. Prepared the report presentation by selecting key points and visuals. 4.30 p.m.- 5.30 p.m. Conducted a practice ruof the report presentation to ensure a smooth delivery. 5.30 p.m.- 6.00 p.m. Finalized the report and accompanying presentation materials for distribution. Table 7-6th coursework meeting