ProdIQ: The Future of Textile Quality Assurance
Digitizing the production floor for Pakistan’s largest denim exporter. Replacing manual checklists with an enterprise-grade, real-time Quality Management System (QMS) at Soorty Textile.
- Textile Manufacturing / Industrial IoT
- Enterprise SaaS Development
- Mobile App Development (Rugged Devices)
- Real-Time Data Analytics
- Production Workflow Automation
- QA/QC Digital Transformation
The Challenge
Soorty Textile is one of the top companies in the world for denim manufacturing and produces millions of fabric and garment pieces every month. Correlating the scale of their operations, the company has modernized their facilities. However, the Quality Assurance (QA) process was still relying on manual paper check-sheets. This was causing a Data Lag, and management was frequently alerted to a spike in defects (for example, shade variation and skewing) hours after the defects were made, resulting in rework and material waste. Soorty required a readily applicable, digital solution that allowed on the spot quality information from factory floors and made it available for management.
The Solution
TekScrum facilitated the launch of ProdIQ, the proprietary tablet-based Quality Management System designed specifically for the textile workflow.
- Tablet-Based Floor Inspection App: We geared up line inspectors with an intuitive Android application. Instead of paper logs, inspectors input defect facts (DHU – Defect Per Hundred Units) in actual-time the usage of a visible Fabric Map interface.
- The Traffic Light Alert System: In order to eliminate waste, we developed an automated logic engine. Once defect rates on a particular line exceed a particular threshold, for example >3%, a Red Alert is triggered on the floor dashboard and SMS and Email notifications are sent to the Production Manager so the line can be stopped.
- Centralized Quality Dashboard: For the HQ team, we built a comprehensive web-based analytics suite. Directors can view global performance across different units (Spinning, Weaving, Finishing, Garment) in a single pane of glass, tracking key metrics like First Time Right (FTR) and Cut-to-Ship ratios.
- ERP Integration: ProdIQ does not operate independently. Instead, we incorporate PredIQ with Soorty’s SAP/Oracle ERP systems to enable automatic synchronization of order numbers, styles, and batch quantities.
ProdIQ has greatly changed our factory floor. Instead of reactive decision-making, we now have proactive quality control. Seeing the Live DHU of any line in our factory, from any location in the world, is revolutionary for our operations.
Before & After - A Visual Journey
How We Supported (The Tech Stack)
- Native Android: Optimized for low-end tablets used on factory floors.
- Offline Mode: Ensures data is saved even if Wi-Fi drops in the warehouse.
- MERN Stack (MongoDB, Express, React, Node): MERN Stack (MongoDB, Express, React, Node): For a flexible, excessive-velocity database that handles unstructured illness data.
- Real-Time Sockets: Real-Time Sockets: For instant dashboard updates.
- Industrial IoT: Industrial IoT: Integration with digital counters and scales.
- Cloud Hosting: Auto-scaling servers to handle shift-change data spikes.
- Data Security: Role-based access ensuring buyers only see their specific order data.
Ongoing Support
TekScrum has Reliability Support 24/7.. We are in the process of deploying the AI-Visual Inspection functionalities, in which we are testing automatic defect recognition in fabrics streams to further automate the workflow.
