Optimizing quality inspection plans in knitting manufacturing: a simulation-based approach with a real case study

This paper introduces a simulation-based approach to enhance quality defect detection in a prominent French textile company’s manufacturing process. The production workflow is initially simulated and analyzed to identify key parameters influencing defect creation and detection. After assessing the existing control process using performance metrics, a novel Inspection Quality Plan (IQP) is formulated. To validate the effectiveness of the proposed IQP, a simulation model is developed and calibrated to mirror real-world conditions. This model, initially validated against the current solution, acts as a benchmark for evaluating predefined scenarios and determining optimal configurations. The implemented scenario, tested in the workshop under authentic conditions, results in a remarkable 42% improvement in defect detection within the knitting process. The positive outcomes are meticulously examined and discussed. This study, employing a holistic approach that integrates simulation modeling, performance evaluation, and real-world deployment, establishes an optimized strategy for enhancing defect detection in the textile industry. It underscores the effectiveness of the proposed IQP, showcasing significant improvements observed in practical settings based on a simulation model.