Automated Model Based on SMED, FMEA, and IoT Oriented Toward Industry 4.0 to Increase Compliant Products in a Textile Company

Abstract

Abstract— In the textile sector, production efficiency is a key element for the sustainability and competitiveness of companies. This study analyzes the case of the circular knitting company Corporación Textil Espain & Espinoza S.A.C. In 2024, this company had a non-conforming product rate of 0.51%, which exceeds the established contractual limit of 0.4%. This excess resulted in 0.51% non-conforming products, exceeding the established contractual limit of 0.4%. This excess resulted in an economic cost that exceeded USD 59,112.72 (4.85% of annual profits) due to downtime, machine failures, and reprocessing. Ring binding (14.37%) and excess broken needles (17.81%) were the main causes, both of which were related to a lack of equipment calibration and maintenance. An automated model based on IoT sensors, SMED, and FMEA methodologies is suggested to minimize these incidents. This model is aimed at Industry 4.0 and is intended to optimize changeover times, avoid frequent failures, and increase the number of compliant products in the circular knitting process.