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Made-to-Measure in the Industry 4.0 Era

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The apparel industry plays a critical role in the global economy but continues to face persistent challenges related to fit accuracy, overproduction, inefficiencies, and limited digital integration. These issues are particularly evident in made-to-measure (MtM) manufacturing, where manual processes, fragmented digital tools, and weak data continuity hinder scalability and sustainability. This study aims to identify the key barriers to MtM 4.0 adoption and propose a digitally integrated workflow capable of supporting efficient, sustainable, and customer-centric apparel production. A systematic review of Industry 4.0 technologies and MtM practices is conducted to structure the problem and derive the requirements for a next-generation workflow. Based on these insights, a three-stage MtM 4.0 workflow (connecting design, product development, and production) is developed and operationalized in a functional prototype, MtM Lusitano 4.0. The prototype integrates a web configurator, a rule-based pattern engine, and ERP/MES connectivity, enabling full digital continuity from customer input to shop-floor execution. Results from industrial deployment confirm functional improvements, including increased measurement accuracy, reduced manual interventions, and stable production release flows. The study concludes that the proposed MtM 4.0 workflow strengthens operational efficiency, supports sustainability goals, and provides a structured pathway for digital transformation in the apparel sector.

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Publisher Copyright: © 2025 by the authors.

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Industry 4.0 Made-to-measure Sustainable production Computer Science (miscellaneous) Geography, Planning and Development Renewable Energy, Sustainability and the Environment Environmental Science (miscellaneous) Energy Engineering and Power Technology Hardware and Architecture Computer Networks and Communications Management, Monitoring, Policy and Law SDG 7 - Affordable and Clean Energy

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