A graduate from NED University in Karachi has developed a revolutionary artificial intelligence-driven system designed to solve one of the most pressing challenges in Pakistan’s textile industry—detecting fabric defects before production. The innovation, called IntelliInspect, uses AI technology to identify fabric quality issues in real-time, potentially saving millions annually by reducing wastage and improving the quality of textiles. This system is particularly valuable for Pakistan’s textile sector, which is one of the largest contributors to the country’s export revenue but has struggled with consistent quality control. The ability to identify defects early on in the production process could significantly reduce the risk of rejected consignments in export markets, where faulty textiles are a recurring problem.
Suboohi Arif, the creator of IntelliInspect, who specializes in automation and application engineering, believes the system is the world’s first of its kind. She sees it as a potential milestone for the improvement of Pakistan’s textile sector. Unlike traditional inspection methods that often detect defects only after the fabric has been dyed or printed, IntelliInspect analyzes unprocessed (grey) as well as dyed and printed fabrics in real time. The system is capable of identifying various types of defects such as broken threads, stains, tears, and holes. The implementation of such technology in production lines is expected to drastically reduce inefficiencies and costs associated with fabric defects, which are typically only discovered later in the production process.
Tests on over 3,000 fabric samples, including both knitted and woven fabrics, have shown that IntelliInspect can detect fabric flaws with an impressive accuracy rate—above 95% for knitted fabrics and 90% for woven fabrics. The system detects defects in as little as 40 seconds to a maximum of 77 seconds, a quick turnaround that is far more efficient than traditional methods. This speed not only saves valuable time in the production cycle but also ensures that manufacturers can take corrective actions almost immediately. As a result, faulty fabric can be identified and discarded before it proceeds to more costly stages of production, such as dyeing and finishing.
The system relies on high-speed sensors and cameras installed along textile manufacturing lines, which continuously monitor the fabric as it moves through the production process. By identifying fabric defects early, the system reduces the need for manual inspections or post-production corrections, both of which are expensive and time-consuming. The ability to catch defects early also improves profitability for manufacturers by minimizing production losses and reducing the likelihood of wasted materials. This early intervention can lead to higher-quality products that are more likely to meet export standards, potentially boosting the country’s textile exports.
IntelliInspect is versatile, offering applications across various segments of the textile industry, including garment production, automotive textiles, home furnishings, and industrial textiles. The system’s ability to work with both grey and processed fabrics makes it adaptable to a wide range of manufacturing processes. Manufacturers of high-end garments, automotive textiles, or even upholstery for the furniture industry can benefit from the improved efficiency and accuracy IntelliInspect provides. Suboohi is also eager to collaborate with industry stakeholders to bring this technology to textile factories across Pakistan. She believes that the integration of IntelliInspect could significantly enhance the quality of products, reduce production costs, and, ultimately, improve the profitability of businesses in the textile sector.
Suboohi is not only focused on reducing costs but also sees IntelliInspect as a tool for fostering data-driven decision-making in the textile industry. By providing manufacturers with real-time data on fabric quality, the system allows them to make more informed decisions, adjusting production processes on the fly to avoid further defects. The data generated by IntelliInspect could also open doors for deeper analytics, helping businesses optimize their operations and identify potential areas for improvement in their manufacturing processes.
The textile industry in Pakistan, which accounts for more than half of the country’s exports, has long faced challenges with quality control. If IntelliInspect were to be adopted on a large scale, it could mark a significant transformation for the industry. Suboohi envisions a future where the system helps Pakistan’s textile sector become more competitive on the global stage. The ability to consistently produce high-quality textiles could help Pakistan regain a larger share of international markets, particularly in the face of competition from other countries with more advanced manufacturing technologies.
As the textile industry continues to evolve, the integration of AI-driven technologies like IntelliInspect offers a glimpse of what the future holds. The potential for increased productivity, reduced waste, and improved product quality presents a compelling case for investment in such innovations. With the right support and collaboration from industry players, IntelliInspect could revolutionize textile manufacturing in Pakistan, driving the sector toward a more efficient, competitive, and sustainable future. Suboohi’s invention could be the catalyst for a new era of innovation in the textile sector, helping Pakistan build a stronger reputation for quality in the global textile market.
