AI-Driven Anomaly Detection in Textile Manufacturing Using IoT and Deep Learning
摘要
The textile industry faces significant challenges in quality control due to the complexity of detecting subtle defects in fabrics during high-speed and high-volume production. Traditional inspection methods rely heavily on human inspection, which is labor-intensive, error-prone, and unable to keep pace with modern manufacturing speeds. This paper presents an advanced Computer Vision and Deep Learning-based anomaly detection system for textile quality assurance that addresses these limitations. By leveraging ensemble Convolutional Neural Networks (CNNs), Autoencoders, and Vision Trans-formers, integrated with IoT-enabled sensors and edge computing devices, our model achieves superior defect detection accuracy across diverse fabric types (weft and warp defects, slubs, holes, oil stains, mispicks, color incon-sistencies, broken ends, and fabric wrinkles etc.) and environmental conditions. The system improves supply chain efficiency by 27%, reduces material waste by 32%, and ensures consistent quality with minimal human intervention. Experimental results demonstrate the effectiveness of CNN variants such as ResNet, EfficientNet-B3, and Vision Transformers, achieving an accuracy of over 97.13% with a false positive rate of less than 2.8%. The proposed framework is scalable, energy-efficient, and deployable in real-world textile manufacturing units with minimal disruption to existing workflows. Cost–benefit analysis indicates a return on investment within 8–12 months of implementation.