D-TASE: AI-Driven Efficiency and Quality in Textile Manufacturing
AI-based Early-Stage Defect Detection in Fabric Rolls
ROK is a leading Turkish textile manufacturer, producing both denim and non-denim apparel for globally recognized brands such as H&M, Zara, and Mango. Known for its large-scale production capacity and quality standards, ROK continuously seeks innovative methods to enhance sustainability and operational efficiency.
Through its participation in the D-TASE experiment, the company adopted advanced technologies to optimize resource use and improve product quality.
Textile Production Optimization
AI-driven quality and efficiency
- Enhance energy efficiency and optimize operational processes;
- Early flaw detection to reduce garment wastage;
- Improve product quality;
- Enhance worker safety;
- Gathering high-quality annotated data for precise and accurate defect detection;
- Integrating AI into existing industrial processes ensuring minimal disruption.
Using advanced computer vision D-TASE developed an AI application for automated fabric defect inspection within ROK Tekstil’s production lines. High-resolution cameras capture real-time images of fabric rolls as they move across the quality control station.
A machine learning based AI system detects and classifies multiple types of textile defects on the captured images such as foreign fibres, missed wefts/warps, stains, and more. A user-friendly dashboard visualizes detection results, types of anomalies, frequency, and defect ratings for each fabric roll.
- 10–15 % Energy Savings:
- Implementation of D-TASE solutions enabled significant reductions in energy consumption, aligning with global sustainability goals;
- 25 % Reduction in Second-Quality Product Output:
- Enhanced quality control processes helped minimize defects and improve overall product standards;
- 12 Million Litres of Water Saved:
- Water savings were achieved specifically in the production of garments that would have otherwise been classified as second-quality;
- Up to 20 % Reduction in Workplace Incidents:
- Operational and process improvements contributed to a safer work environment, lowering accident rates.
Following the success of the D-TASE implementation, ROK aims to further integrate AI across additional production lines to maximize quality control and reduce energy use across its operations.
The company also plans to explore predictive maintenance and real-time process optimization tools, leveraging the same data infrastructure established during this project. These steps are expected to not only improve sustainability but also strengthen ROK’s competitive position in the global textile market.