Revolutionizing Garment Production Tracking for a Tirupur Factory with Counting Scales and Raspberry Pi Integration
Overview
In 2025, a leading garment factory in Tirupur faced challenges with its earlier RFID and QR code-based production tracking system. While these technologies were initially introduced to improve efficiency, they fell short in providing the desired accuracy and real-time insights. GAG Nexus Pvt Ltd implemented a new solution using counting scales integrated with Raspberry Pi, which drastically improved accuracy, streamlined data collection, and enhanced real-time tracking across production stages. Here’s how we transformed their garment production process.
The Challange
Previously, the factory relied on RFID and QR code-based tracking at each production stage—cutting, stitching, checking, ironing, and packing. However, the system introduced several challenges:
- Inaccurate Scanning: Workers faced difficulties scanning QR codes and RFID tags accurately, leading to delays and errors in the data collection process.
- Lack of Real-Time Tracking: Despite using technology, the system did not provide real-time visibility into the progress of production, causing inefficiencies.
- Cumbersome Manual Processes: The cut sheet, which contained vital details like lot number, style, color, and size, had to be manually attached to each fabric bundle, which slowed down the workflow.
Despite the initial success of QR code and RFID technologies, the factory needed a more reliable and efficient solution.
Our Innovative Solution
GAG Nexus introduced a comprehensive new approach using counting scales integrated with Raspberry Pi and label printers, offering a seamless, real-time tracking system for every stage of production. This approach replaced the previous RFID/QR code system with a more direct, accurate solution.
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- Counting Scales Integration: We deployed Ohaus weighing scales at each key production stage—cutting, stitching, checking, ironing, and packing. The scales are connected to Raspberry Pi, automatically capturing the weight and count of fabric bundles at each stage.
- Automatic Cut Sheet Generation: When bundles are weighed, the system automatically generates a cut sheet with details such as the number of pieces, lot number, roll number, style, color, and size. This cut sheet is printed and attached to each bundle, ensuring the information is always accurate and readily available.
- Real-Time Dashboard: The data from each production stage is transmitted to a centralized dashboard, providing managers with real-time visibility into production progress. This allows for quick identification of bottlenecks and enables better decision-making.
The Results
The transition to counting scales brought significant improvements to the factory’s production process:
- Increased Efficiency: By eliminating the need for manual scanning, the factory reduced production tracking time by 40%.
- Real-Time Visibility: Managers gained real-time insights into the status of each bundle, enhancing decision-making and optimizing workflow, improving production efficiency by 30%.
- Paperless Operations: The automatic generation of cut sheets eliminated manual paperwork, saving time and reducing human errors by 25%.
- Improved Accuracy: With precise weight and count data from the counting scales, the factory saw a 15% reduction in errors related to bundle counts and production stages.
How It Works
The process flow is as follows:
- Cutting Stage: After fabric is cut, the workers attach the cut sheet, which includes essential details. The bundle is weighed on the Ohaus scale, and data is sent to the Raspberry Pi.
- Stitching, Checking, Ironing, and Packing: As bundles progress through each production stage, they are weighed again, and the system automatically updates the real-time dashboard, providing visibility into progress at every step.
- Label Printing: After each weighing, the system prints the cut sheet, which is attached to the bundle. This ensures that each stage of the process is tracked accurately, with no need for manual data entry.
Why It’s a Game-Changer
By replacing the previous RFID/QR code system with counting scales, GAG Nexus enabled the factory to achieve a more reliable, accurate, and efficient tracking system. The integration of counting scales with Raspberry Pi technology has transformed garment production tracking, providing real-time data, reducing manual intervention, and improving overall operational efficiency.
This solution is not limited to garment manufacturing—it can be applied to other industries such as material tracking, inventory management, and warehouse management, where accuracy and real-time tracking are crucial for optimal performance.
This solution is not limited to garment manufacturing—it can be applied to other industries such as material tracking, inventory management, and warehouse management, where accuracy and real-time tracking are crucial for optimal performance.
Your Production Tracking Edge with GAG Nexus
This case study highlights the power of counting scales in revolutionizing production tracking. By replacing RFID and QR codes with more efficient and accurate technology, GAG Nexus has created a solution that enhances efficiency and accuracy. Ready to optimize your production process with cutting-edge technology? Contact us today to learn how we can transform your operations with our smart tracking solutions.
