[pageLogInLogOut]

#Industry 4.0 / Digitalization

Joachim Hensch Consulting unveils program to enable Smart Factory applications

The next industrial revolution will leave its mark as well on apparel creation, manufacturing and sourcing. Though lagging a bit compared to other industries, the fashion industry is on the verge of a huge digital technology revolution. Today, everyone in the apparel arena – from major players to small start-up labels – is talking about Industry 4.0 creating what has been called a Smart factory.

To walk the talk – to building and scaling the smart factory – on a broad basis for apparel a lack of knowledge and experience has to be tackled: Professional and managerial training is downright precarious. While technical and higher education institutions are still adapting its curricula, there is a lack of required expertise - now. Added to this is the need to create the mindset, necessary for the paradigm shift at management level.

Profound guidance to now be available with an inverted (online) class room program, offered by one of the few, who know what they are talking about, from someone who has made the Digital Lean Factory concept a reality - with sustainable success.

Leveraging untapped potential

The protagonist under whose leadership a prime example of clothing feasibility in broad scale industrial environment came true is Joachim Hensch. “It took my team and me five years to turn the Hugo Boss Izmir factory into a real smart factory”, said Hensch, tailor for bespoken men’s wear by trade, who has had a remarkable career in product development and production up to the position as managing director for the Izmir manufacturing plant of Hugo Boss Group as of 2015.

His guest lectures at key apparel industry events around the globe on the process remain legendary. Today Hugo Boss brand to as well represent leap forward from more traditional automation to a fully connected and flexible system — one that can use a constant stream of data from connected operations and production systems to learn and adapt to new demands.

Mission completed

After two decades with Hugo Boss Group Joachim Hensch is ready for an all new challenge: “The apparel business excites me for more than three decades now.” Said it and turned to new tasks, driven by the spirit of his knowledge and experience on the way to support brands, organizations, start-ups or single players to define their own individual digital strategy – “essential starting point for any smart factory/sourcing concept”, Hensch emphasizes.

From tailor to consultant: Joachim Hensch himself has learned at all stages of his exciting career (c) 2021 JHC
From tailor to consultant: Joachim Hensch himself has learned at all stages of his exciting career (c) 2021 JHC


These days Joachim Hensch Consulting launches the Inverted Online Class Room program, staggered with three degrees. The application protagonist’s framework for the Digital Lean Factory builds the foundation of the training, where everyone determines their individual learning pace for working through

  •  6 modules for the Bachelor
  • 12 modules for the Champion
  • and a demand-based, upwardly open number of modules for the Master degree.

Big picture learning objective: Successfully implement Industry 4.0 - in daily interactions, digital and analog. “One aim is to enable attendees to re-consider the way how to look to their structures, the processes within their organization, their assets and also workforce”, Hensch rolled out.

Joachim Hensch’s smart learning program to also include one-to-one sessions between him and each single attendee for process-related guidance – e.g. on managing their essential digital twin (c) 2021 JHC
Joachim Hensch’s smart learning program to also include one-to-one sessions between him and each single attendee for process-related guidance – e.g. on managing their essential digital twin (c) 2021 JHC



Time requirement:

  • 3-4 h/week including online meetings for guidance through the process
  • One-to-one sessions with Joachim Hensch
  • Specific expert group sessions

Extensive material plus exercise kit to be provided offline for practice purposes and reviews to be provided by JHC.

Think Big, start small and scale fast

True Industry 4.0 applications, defined as factories where physical production processes and operations are combined with digital technology, smart computing, and big data to create a more opportunistic system have remained in laboratory status to date. We encounter them at trade fairs or we read about the pilot factory by Asian e-commerce leader Alibaba in the Eastern Chinese city of Hangzhou as part of its smart manufacturing business initiative. 

One fully implemented smart factory in the Western hemisphere is represented by the Hugo Boss production site in Izmir, where suits, jackets, shirts and coats are manufactured on an area of around 65,000 m2 with 3,800 employees. Here, the market leader in menswear demonstrates what Industry 4.0 looks like in practice - with networked machines, in-depth data analyses and flexible processes. Yvonne Heinen-Foudeh


http://www.joachimhensch.com.






More News from TEXDATA International

#Texprocess 2026

Texprocess 2026: Automation, digitalisation and AI redefine textile processing

Making investment decisions in textile processing has become significantly more demanding. Increasing energy costs, a shortage of skilled labour and ongoing geopolitical uncertainties are compelling companies to focus on technologies that deliver clear gains in efficiency and process reliability. This applies equally to apparel manufacturing and to the processing of technical textiles and high-performance materials. As a result, modernisation initiatives are assessed more carefully – even as the need to upgrade production systems continues to intensify.

#Techtextil 2026

Techtextil 2026: Between innovation pressure & market reality

From 21 to 24 April 2026, Techtextil in Frankfurt am Main will once again become the central meeting point for the international technical textiles and nonwovens industry. Running in parallel, Texprocess will focus on the industrial implementation of textile processing technologies as the leading platform in this field. Together, the two trade fairs form a closely integrated presentation and working platform along the entire textile value chain – from material development to finished applications.

#Techtextil 2026

Between geopolitical pressure and industrial resilience

In this interview, Dr. Janpeter Horn (VDMA) discusses the current challenges facing textile machinery manufacturers, shaped by geopolitical tensions, regulatory developments and subdued investment. He also outlines why innovation strength, integrated solutions and strategic positioning remain key to global competitiveness.

#Texprocess 2026

Between investment restraint and modernization pressure

Texprocess 2026 takes place in a complex market environment shaped by uncertainty and innovation pressure. In this interview, Elgar Straub (VDMA) explains why the trade fair is particularly relevant this year and which technologies are driving efficiency and competitiveness.

More News on Industry 4.0 / Digitalization

#Research & Development

Textilfabrik 7.0 launched: Mönchengladbach becomes a real-world lab for sustainable textile production

With the official kick-off event of the Textilfabrik 7.0 (T7), a major transformation project for the German textile and apparel industry has been launched in the Monforts Quarter in Mönchengladbach. At the “Textile Roundtable,” an event format organized by the Zukunftsagentur Rheinisches Revier, representatives from industry, research, politics, and the regional economy came together to jointly lay the foundation for CO₂-neutral, circular, and economically viable textile production in Germany.

#Man-Made Fibers

OnceMore® from Södra brings end-to-end traceability for circular Man-made Cellulosic Fibers (MMCF) using TextileGenesis

OnceMore® from Södra, the world’s first large-scale process for recycling blended fabrics into high‐quality dissolving pulp, will begin using TextileGenesis, a Lectra company, to strengthen traceability from raw material to retail across the value chain. OnceMore® produces dissolving pulp made from blended textile waste and wood sourced from responsibly managed Swedish forests. By integrating TextileGenesis, OnceMore® supports the growing need for verified data and secure, transparent tracking throughout increasingly complex supply chain.

#Denim

Jeanologia launches Billy

The new AI extracts precise laser designs from a garment image in minutes, transforming how vintage denim is recreated for production. If Jeanologia’s laser changed the way jeans were made at the end of the last century, its AI now takes the next step: moving from reproducing wear to designing it. / archive photo © 2026 Jeanologia

#Dyeing, Drying, Finishing

Monforts unveils interactive digital platform for textile finishers

Monforts has launched a new digital platform designed to give textile manufacturers faster, more intuitive access to the company’s finishing technologies, technical expertise and aftersales support worldwide.

Latest News

#Techtextil 2026

Techtextil 2026: KARL MAYER impresses as an innovative sector partner

KARL MAYER looks back with satisfaction on its participation in Techtextil 2026. From April 21 to 24, the international industry leader used the trade show in Frankfurt to meet with numerous key customers at its booth and, at the same time, establish many new contacts. Most visitors came from Germany, followed by major markets such as Poland, the United Kingdom, Turkey, France, and Portugal.

#Associations

BTMA backs global growth while investing in future UK leaders

As one of a number of new initiatives launched this year, the British Textile Machinery Association (BTMA) is launching the UK-India Textile Machinery Coalition. The UK-India Free Trade Agreement, signed in July 2025, has implications that extend across sourcing, competitiveness and long-term trade dynamics, believes BTMA CEO Jason Kent.

#Raw Materials

China projected to increase cotton production, yields, and imports in 2026/27

World cotton production in the 2026/27 season is projected at 25.9 million tonnes, exceeding global consumption of 25.2 million tonnes, according to the May 2026 issue of Cotton This Month. That means both production and consumption are expected to remain close to current season levels, while global cotton trade is projected to decline by 2.7% to approximately 9.6-9.7 million tonnes.

#Raw Materials

ICAC launches Carbon Credits Initiative to deliver new income streams to cotton farmers

The International Cotton Advisory Committee (ICAC) has announced a new initiative designed to unlock additional income streams for cotton farmers through participation in carbon credit markets, linking sustainable production practices directly to financial returns.

TOP