Warehouse to Cutting room: Rise of automated logistics in garment manufacturing

In today’s fast-paced garment industry, efficiency is no longer just a competitive advantage—it’s a necessity. From global fashion brands to local apparel manufacturers, businesses constantly seek new ways to streamline operations, reduce labor dependency and minimize errors. One of the biggest transformations reshaping the manufacturing floor is the integration of automated logistics, from the warehouse to the cutting room.

 This shift is powered by cutting-edge technologies like Automated Guided Vehicles (AGVs), RFID-tagged inventory systems and robotic role handling solutions. These innovations are no longer just part of futuristic visions, they are already revolutionizing how garments are produced.

 Why automated garment logistics? 

The traditional logistics flow in garment manufacturing often involves high manual labor, repetitive handling and time-consuming tasks. This leads to challenges such as 

• Inefficient material movement between departments 
• Inaccurate inventory tracking
• Increased the chances of material damage or misplacement
• Labor shortage and rising wages

 Automating logistics helps eliminate these bottlenecks. With the smart system in place, manufacturers can enjoy seamless material flow, better space utilization, and significant time savings.

  AGVs-Smart Fabric transporters

Automated Guided Vehicles (AGVs )are robotic vehicles that move material across the factory without human drivers. They navigate through predefined routes using sensors, magnetic tape or lasers.

How AGVs work in the garment industry-

In garment manufacturing, AGVs are typically used to:

•  Move fabric roll from the warehouse to the cutting room 
• Transport cut panels to the swing departments 
• Deliver finished goods to the packaging stations

 AGVs are programmed to pick up materials at scheduled times and deliver them with pinpoint accuracy. This reduces the need for manual trolleys or forklifts and keeps the floor organized.

 Advantages-

•  Labor efficiency: A single AGV can replace the need for two to three workers dedicated to manual material movement 
• Consistency: AGVS ensures timely and consistent delivery of material, improving the overall workflow. 
• Safety: Equipped with obstacle detection and emergency stop features, AGVs reduce the risk of workplace accidents. 

Case Example:

 Leading textile manufacturers in China and Vietnam have adopted AGVs in large-scale facilities. One such manufacturer reported a 25% increase in material flow speed and a 40% reduction in labor cost within one year of AGVs integration.

RFID-Tagged Inventory – Smart Tracking

RFID (Radio Frequency Identification) uses radio waves to identify and track tags attached to fabric roles or garments. Unlike barcodes, RFID tags can be scanned without direct line-of-sight and from several meters away.

How it works-

Every fabric role is tagged with a unique RFID chip containing data like:

•  Fabric type and color
•  Batch number 
• Supplier details 
• Roll length and weight

 Fixed or handheld RFID readers scan these tags at various points during storage, dispatch or cutting.

 Advantages-

•  Real Time Inventory -Instantly view available stock on digital dashboards.
•  Error Free- Produces manual entry mistakes and Misplacement of materials.
• Faster Audits- Warehouse can be audited in minutes using mobile RFID scanners

Use in the Cutting Room 

When fabric rolls arrive at the cutting table, RFID ensures the right material is used for the right order.  This avoids mix-ups and helps maintain production accuracy.

Sustainability Angle 

By preventing overstocking and reducing fabric waste, RFID contributes to more sustainable production, the growing demand in the global apparel market.

Robotic role handling- Automation with precision

Handling large and heavy fabric rolls manually is not only labor-intensive but also poses a risk of injury and role deformation. Robotic role handling systems are designed to automate this process with precision and care.

 (Figure 4: Integration of robotic systems for intelligent material movement in garment factories- Image collected)

core features:

•  Robotic arms with vacuum or clamps grippers to lift fabric rolls
•  Sensors for weight, diameter and orientation detection
•  Integration with conveyors, AGVs, and storage racks.                                   

These robots can:

• Pick up Rose directly from the delivery pallets
• Place them into particular horizontal storage racks
•  Feed rolls to spreading or cutting machines with millimeter accuracy.

 Impact on production quality:

 Robotic handling. Minimize the risk of-

•  Fabric edge damage,
•  Wrinkling or distortion.
•  Incorrect roll placement. 

Additionally, this system can operate continuously, supporting 24/7 production with minimal supervision.

The Power of Integration 

While each technology is powerful on its own , the real impact comes when they are combined.

 For example-

• An RFID reader detects the need for a certain fabric roll.
• The system signals an AGV to bring the roll from the warehouse. 
• The robotic arm receives the roll and loads it into the cutting machine.

 These seamless chain eliminates wait times, reduces coordination errors and improves production speed, something manual processes simply cannot match.

Challenges to Consider 

Adopting automation isn’t without its hurdles:

•  Initial Investment: AGVs, RFID system and robotic handlers requires capital 
• Technical Training:Workers need to be trained to manage and maintain automated systems.
•  System Integration:All technologies must connect smoothly with existing ERP or production systems

 However, most manufacturers report ROI within 1-2 years, thanks to reduced labor costs,better inventory control and faster production cycles.

 The garment industry is moving towards Industry 4.0, where machines, systems and data work together in real time. In future smart factories, we will see:

•  LoT-enabled machines
•  AI-based production planning 
• Fully automated warehouses

 From the warehouses to the carting room, logistics will be driven by data and machines, with humans focusing more on design, supervision and innovation.

Written by: 

Farhana Zaman Tithi

Innovation Apprentice, Textile Today Innovation Hub

 Relatable image-https://drive.google.com/drive/folders/1S-t8spWZAdKCj5Wkm3SeBaWFMiwnYoLv?usp=sharing