Quality monitoring with added value through AI

This continuous process of data analysis and optimisation enables us to improve our QMS on an ongoing basis, informs Florian Wurzel.

With the Quality Monitoring System (QMS), KM.ON offers the warp knitting industry a product that takes quality control to a new level.

The innovative solution detects fabric defects during the production process and is safe, reliable and user-friendly. The basis for the exceptional performance is the combination of a state-of-the-art camera system with artificial intelligence (AI).
The innovative QMS celebrates its premiere for the retrofit market at ITM from June 4 to 8 in Istanbul. Details about the benefits for customers and initial experiences from practical applications are already available. They were the subject of an interview conducted by Mark Thomas (MT), Marketing Manager, KM.ON, with Florian Wurzel (FW), Cluster Lead Quality Assurance at KM.ON.

MT: Can you explain how the QMS works?

FW: As a special feature, our QMS works using advanced artificial intelligence (AI), which is specifically designed to monitor the production process. This innovative approach is based on thousands of high-resolution images taken during the production process on our machines. In the event of defects or deviations from quality standards, the images are forwarded to textile experts within the Karl Mayer Group for analysis. Their specialist knowledge flows directly into the further development and improvement of our AI systems.

This continuous process of data analysis and optimisation enables us to improve our QMS on an ongoing basis. Over time, the system can reliably monitor an increasingly wide range of product groups. As a result, it ensures that our customers’ product quality always meets the highest standards and that they can respond effectively to specific challenges.

MT: Let’s take a look at the specific advantages of the QMS. What can the KM.ON solution do better than its conventional counterparts?

FW: With our QMS, we bring together the best of two worlds: KM.ON’s software and AI expertise and the immense textile knowledge of the Karl Mayer Group’s experts. This combination has enabled us to develop a product that reliably detects even the smallest defects that are difficult to recognise, and this for the entire production area. Every millimetre of the textile is monitored during the production process. Our QMS is also much more robust against external interferences such as changing light conditions than conventional solutions. This means that comparative products often trigger false stops, which have a negative impact on production quality. Furthermore, our QMS is much easier to operate. No expert knowledge is required to configure the system, and the AI allows the solution to adapt itself to the specific conditions. The uncomplicated handling was very important to us. It is our answer to the demands of the market in view of the shortage of skilled workers.

MT: Developing such a clever solution was certainly not easy. How did you go about it?

FW: The development of software that can be safely rolled out worldwide is one of KM.ON’s strengths. During the work on our QMS, we were supported by the mechanical engineering/textile specialists from Karl Mayer. We carried out intensive tests with our colleagues in our development centre. Finally, we collaborated with pilot customers to verify if our solution truly meets the daily challenges of our customers.

MT: Let’s take a closer look at the practical trials. What results have been achieved so far?

FW: I am a big fan of demonstrating the performance of our QMS directly in a practical environment rather than just listing the benefits on a presentation slide. Accordingly, we have carried out many customer demonstrations in which we explicitly asked about the defects or errors that are not reliably detected by today’s systems. In most cases, we are able to demonstrate good performance during such a demonstration. If this is not the case, we discuss the necessary steps on site so that our AI can meet the requirements in future.

MT: What does the market launch look like? What steps are planned and when will the solution be available?

FW: The market launch is planned as a retrofit solution for existing machines for selected launch customers in the second half of 2024. From the beginning of 2025, our QMS will then also be available to an extended customer base.