At the recent International Conference on Automation and Robotics, organized by The Textile Association of India, Mumbai Chapter, Mr. Gilberto Loureiro, Founder and CEO of Smartex AI, captivated the audience with his vision for the future of textile production. Drawing from personal experiences and industry insights, he highlighted the persistent quality control challenges in textiles and introduced Smartex’s transformative AI-driven solutions. This article delves into Mr. Loureiro’s presentation, exploring how Smartex AI is reshaping fabric production with advanced technologies and real-world applications.
Addressing the Persistent Nightmares of Fabric Quality
Mr. Loureiro opened his presentation by reflecting on the familiar struggles of fabric production—defects, delays, mismatched colors, and quality inconsistencies. He acknowledged these issues as a shared challenge for textile producers, garment manufacturers, and fashion brands. “Defects, when left unchecked, propagate through every stage of production, from knitting and dyeing to cutting and stitching, causing delays, waste, and compromised relationships with buyers,” he emphasized.
The industry has long relied on tolerance systems like the four-point grading method, which often mask the underlying issues rather than addressing them. Mr. Loureiro’s personal journey as a textile quality inspector shaped his commitment to tackling this problem head-on.
Introducing AI-Driven Quality Tracking
Smartex AI’s innovative solutions are revolutionizing textile manufacturing. With more than 100 engineers and deployments in over 10 countries, the company has created a robust system combining AI-powered cameras and sensors to inspect fabrics in real time. “Imagine a system akin to the Uber app but for fabric production, where you can track your order, monitor production progress, and receive alerts about defects,” explained Mr. Loureiro.
The system allows for proactive defect detection at the earliest stages of production, drastically reducing waste and enabling precise quality control. For example, knitting machines equipped with Smartex cameras can identify issues such as needle marks, sinker defects, and yarn inconsistencies.
Bridging Digital Gaps in Textile Factories
Despite the promise of AI and automation, Mr. Loureiro stressed the importance of building a strong digital infrastructure in factories. “We need to install internet, hardware, and train teams. Without these, all talk of AI and blockchain remains meaningless,” he stated. The Smartex team spends much of its time installing high-resolution cameras, sensors, and data collection systems in factories worldwide.
This approach not only identifies defects but also creates a digital twin of the fabric roll, mapping defects by position and severity. This data integrates seamlessly with factory systems, allowing for detailed traceability and targeted interventions.
Real-World Impact and Empowering Workers
Smartex AI’s impact extends beyond technology to empowering workers. By digitizing inspection processes, operators can perform quality checks ten times faster, enhancing efficiency without replacing human labor. “This is a great example of AI empowering workers,” Mr. Loureiro noted, sharing a case study from Turkey where inspection operators inspect entire fabric rolls in 30 seconds using Smartex systems.
The system also improves relationships across the supply chain. By reducing defect rates early in production, manufacturers avoid costly rejections, safeguard their buyer relationships, and optimize cutting plans.
The Road Ahead for AI in Textiles
While Smartex AI has achieved remarkable milestones, Mr. Loureiro admitted the journey is far from over. “Textile complexity is immense, with diverse yarns, patterns, and production variables. While we’ve reached 90-95% defect detection accuracy, there’s still room to grow,” he stated. The company continues to invest heavily in R&D to refine its systems further, ensuring even the most nuanced defects are detected in real-time.
The solution has already been adopted by major players in Europe, Turkey, and Bangladesh, delivering measurable improvements in defect management and production efficiency.
Mr. Gilberto Loureiro’s presentation at the International Conference on Automation and Robotics provided an inspiring glimpse into the future of textile manufacturing. Smartex AI’s AI-driven solutions are not only addressing long-standing quality issues but also fostering a culture of transparency and accountability in the industry. By empowering workers and enabling real-time defect detection, Smartex is paving the way for smarter, more sustainable textile production.
As the textile industry embraces digitization, Smartex AI serves as a powerful example of how innovation and collaboration can transform challenges into opportunities for growth.
