CEO Randy Carr talks to Textile World about the use of AI at embroidered patch maker World Emblem and how it has helped his company.
TW Special Report
World Emblem, Ft. Lauderdale, Fla., was founded in 1993 by Jerold Carr. Led today by Carr’s two sons — Randy and Jamie — this family-owned business has blossomed into one of the largest patch and emblem producers in the world. World Emblem manufactures and ships some 250 million products each year that are produced on its 4,250 embroidery heads located in 1 million square feet of manufacturing space in the United States, Mexico, Canada and Europe. The company employs 1,200 associates, and its embroidered patches are used for sports headwear, footwear, sports garments and uniforms, among other applications.
Randy Carr became World Emblem’s president in 1998. As the current CEO, he said: “I try to embody passion, insight, and a forward-thinking approach that I believe has helped transform the industry and positions World Emblem at the forefront of innovation. I strive to be more than just a CEO, but also a driver of motivation— a testament to what one can achieve with hard work, a supportive family, and the will to always aim higher.”
Part of Carr’s forward-thinking approach includes the use of artificial intelligence (AI) technologies in his business. More and more textile companies are beginning to embrace the use of AI to give them a competitive edge, and industry organizations such as the Atlanta-based Americas Apparel Producers’ Network are encouraging their members to jump in and get started using AI sooner, rather than later (See “Generative AI: Understanding Fears & Embracing The Innovations,” TW, this issue).
Carr recently spoke with TW about World Emblem’s use of AI and the ways it helps the company.
TW: You’ve stated that AI will make the manufacturing apparel industry unrecognizable in the next three to five years. Can you share specific examples of how you foresee AI transforming key processes within the industry?
Carr: Absolutely. AI will indeed dramatically transform the manufacturing apparel industry. Firstly, AI-powered predictive maintenance tools will analyze machine data in real time to predict equipment failures before they occur. AI also will revolutionize supply chain management by optimizing inventory levels, predicting demand, and identifying potential disruptions. The industry also will be able to make use of robotic process automation (RPA) and cobots to take over repetitive, manual tasks. AI-driven computer vision systems will enhance quality control processes by automatically detecting defects in products on production lines. In addition, AI will enable hyper-personalized and on-demand manufacturing by analyzing customer preferences, market trends, and product feedback in real time.
TW: What areas of apparel manufacturing have you already integrated AI into, and what measurable impacts have you observed so far?
Carr: For starters, all of this is still very new. However, we have selected four areas of the business we are enhancing using AI:
- Customer experience— AI chatbots and virtual assistants are used to handle customer inquiries, provide real time access, assist in ordering processes and offer personalized product recommendations based on past orders.
- Production efficiency and automation —AI will be crucial in connecting production machines, sensors, and systems to analyze performance data in real time. This can help optimize production lines, reduce defects and adjust for bottlenecks.
- Quality control — AI-based computer vision systems can inspect emblems and labels for imperfections in real time. These systems are capable of detecting misprints, alignment issues, and color mismatches at a faster rate than human inspection, leading to fewer rejected batches and higher product consistency.
- Customization —AI is already enabling our designers to use intelligent software for creating custom emblems and labels.
TW: Can you talk about backend processes that AI can optimize, and how that translates into cost savings or operational efficiencies?
Carr: AI is revolutionizing backend processes in numerous ways, from demand forecasting to personalized customer interactions. By predicting inventory needs and optimizing pricing through data analysis, AI enhances inventory and supplier management. Production schedules are now generated automatically based on order priorities, machine availability, and workforce capacity, streamlining operations. Predictive maintenance enables machinery performance monitoring, addressing issues before they result in downtime. Financial tasks such as bookkeeping, cash flow forecasting, and man-aging accounts payable and receivable are automated, reducing errors and ensuring timely payments. Customer communication is more personalized, with automated follow-ups and tailored recommendations. In human resources, AI scans resumés, shortlists candidates, and even assesses interview responses, expediting the hiring process. Real-time data analysis and reporting offer decision-makers valuable insights, while business intelligence tools identify trends and inefficiencies. Through predictive analytics, companies can anticipate future production, sales, and market conditions. Order processing, fulfillment, and tracking are fully automated, minimizing errors and providing real-time updates to both customers and teams, ensuring a smoother, more efficient operation overall.
TW: How do you think AI will impact the speed-to-market in the apparel industry?
Carr: Logo design to completion is already get-ting disrupted. However, we believe that rather than taking anywhere from one to two weeks, sometimes even longer, for a client to complete their logo project, this will be done in real time.
TW: What key advantages do you think companies leveraging AI will have over those that don’t, and how soon do you expect this divide to become apparent?
Carr: Companies that leverage AI will reap several advantages over those that do not. Operational efficiency advantages include streamlined repetitive tasks, reduced human error and improved speed of processes across the board using AI-driven automation. Companies using AI can reduce costs and improve productivity by optimizing resource allocation and minimizing downtime.
There also is a data advantage that improves decision making. AI enables companies to process and analyze large amounts of data in real-time, offering insights that lead to better decision making.
AI provides a personalization and customer experience advantage since it allows businesses to offer personalized experiences at scale.There also is a cost reduction and scalability advantage because AI can reduce labor costs by automating manual tasks and enabling scalability.
The impact of these advantages is immediate.
TW: In terms of customer satisfaction, on what specific AI-driven innovations are you focusing?
Carr: At World Emblem, we are implementing several AI-driven initiatives to greatly enhance the customer experience. We can offer automated order tracking and notifications using AI. Real-time order tracking and status updates can be powered using
AI giving customers more transparency throughout production and shipping.
AI also can analyze past customer interactions to predict when customers might need help and preemptively offer solutions. Chatbots or virtual assistants can answer common questions, resolve simple issues and escalate more complex problems to human agents efficiently.
In addition, AI tools can assist customers in the design and customization process, offering suggestions for colors, layouts, and patterns based on current trends or customer preferences. AI can also generate previews in real-time to show what the finished product will look like.
TW: Why have you chosen to invest heavily in AI technology?
Carr: World Emblem has always been about investing in the best technologies to improve the customer experience and drive our business forward. We believe our investment in AI will reap benefits in operational efficiency and automation, an enhanced customer experience, data-driven decision making, and in product innovation and customization.
AI-powered design tools allow for greater customization giving our clients more control over the final product.
TW: What challenges have you faced in adopting AI and how have you overcome these hurdles?
Carr: World Emblem, like most forward-looking companies, has experienced some minor challenges with the adoption of AI. We have experienced some issues with technical implementation. Challenges integrating AI systems with existing infrastructure and processes is complex. Data quality and availability is also a hurdle as AI models need vast amounts of high-quality data to be effective. However, we are overcoming it with phased rollouts, improved data management, and partnering with experts.
Employees also resist AI adoption due to fears of job loss or a lack of understanding of how AI will impact their roles. However, we are overcoming the same with education and training, clear communication, and involvement in the process.
AI adoption often requires a cultural shift in how decisions are made, and this cultural change has been challenging.
Additionally, there are cost and return on investment (ROI) concerns. These upfront costs of AI technology and the uncertainty around the ROI were overcome through pilot projects with measurable outcomes, focusing on high-impact areas.
TW: Looking ahead, what new technologies or AI-driven solutions are you excited about that have the potential to reshape the industry?
Carr: We are very excited about the potential of AI and see great promise for its utilization in areas such as AI-powered sustainable manufacturing, AI-driven customization and on-demand production, 3D design, smart supply chains with AI and blockchain, and generative design and AI creativity tools. AI can optimize the use of materials and energy leading to more sustainable manufacturing practices. It also can enable hyper-personalized products and on-demand manufacturing allowing customers to design and order customized labels and emblems in real time. AI-powered 3D design tools are already making an impact by enabling designers to create virtual prototypes and run simulations. In addition, AI tools that use generative design algorithms can assist in creating new designs by exploring all possible combinations of shapes, materials, and patterns based on certain design constraints. AI can also learn from historical design data and customer feedback to suggest new trends.
TW: For companies that are hesitant or slow to adopt AI, what do you think are the most significant risks they face over the next few years?
Carr: Companies must continually adapt to the times, including changing customer preferences and technical innovations. They must always be for-ward-looking, otherwise they will fall behind. Those that don’t change could face the following issues: loss of competitive advantage; decreased operational efficiency; missed opportunities for data-driven decision making; inefficiency in customer experience and personalization; and an inability to scale effectively. Companies not embracing AI also may have to find themselves competing with a company like World Emblem that is embracing the technology.
2024 Quarterly Issue IV
