In factories, certain processes that appear very minor can conceal less visible bottlenecks that directly affect labor productivity. Arising from practical production challenges, the initiative titled “A Sensor System Combined with Relays for Button Surface Classification” was developed, introducing a new approach to automation: when small improvements are repeated thousands of times, they become powerful levers for productivity gains.
An Idea Born from the Smallest Things
Button classification on garment sewing lines is a manual process that is highly prone to errors due to the small size of the items, high handling frequency, and tight production schedules. Based on this reality, Mr. Vo Nhat Duy (Hue Textile Garment Joint Stock Corporation) proposed and implemented a “button surface classification system using optical sensors and relay control” to fully automate this operation, improve accuracy, and reduce reliance on manual labor.
The system employs color sensors, PLCs, and pneumatic mechanisms to automatically identify and sort buttons. It was piloted from January 3rd, 2025, on sewing lines 8 and 10, with initial results demonstrating clear potential for efficiency improvements and scalability across the entire factory.
Behind an Innovation
The system’s greatest challenge was ensuring the accuracy and stability of the sensors when distinguishing between two nearly identical button surfaces at high speed, while maintaining precise synchronization among the sensors, PLC, solenoid, and pneumatic components without disrupting the automatic button feeding system. During the initial pilot phase, there was hesitation from both workers and managers due to long-standing reliance on manual operations. However, after receiving proper guidance and witnessing the system’s practical effectiveness, it demonstrated higher processing speed, eliminated classification errors, reduced workload, and helped stabilize sewing line operations, ultimately receiving positive feedback.
Operational Efficiency
The deployment of the sensor-and-relay system has fully automated the button classification process, reducing labor requirements, increasing productivity, shortening operation time, and significantly reducing technical errors caused by misclassification. The system helps lower costs, enhance product quality, is easily scalable, and contributes to strengthening the enterprise’s competitiveness.
In the coming period, the author plans to further upgrade the system toward a smarter solution with data connectivity and deeper integration into Industry 4.0 production lines. The initiative was recognized with a Third Prize at the “Good Initiatives – Share Immediately” competition in 2025, organized by the Vietnam Textile and Garment Trade Union.
By: Viet Hai – An Khanh
