Textile

KNITTING YOUR FUTURE

Globalization has increased the commoditization of kitting and garment manufacturing. Our clients face ever-increasing pressures on their operations, staff and profitability.

The pressures have resulted in consolidation that leaves less room for middle-market operators to survive.

The solution? Execute at the highest level. Focus on operational efficiencies, implement defence strategies that will see your company rise above others, and use the additional cash to invest in growth.

What can we do for you?

Solutions

  • Capacity-based programming tool to prioritize production according to schedule.

  • Full-detail production plan by production cell and machine.

  • New sales order policy to align commercial strategies with production capacity.

  • Inventory policy that regulates cycle counts.

  • Implement thread ordering process in line with production plan, including safety stock and a control of supplier service level.

Benefits

  • Increased compliance to plan and provided real-time visibility of plan execution.

  • Reduced metric tons of thread stock.

  • Increased supplier service on-time and in- full.

  • Real-time accurate visibility of in-stock threads.

Solutions

  • Dyeing programming system tied to knitting programming.

  • Create routing tables to select dyeing equipment based on capabilities.

  • Implement formulation-based inventory deductionand control systems.

  • Implement strict chemical and color cycle counts.

Benefits

  • Reduced dyeing errors.

  • Reduced chemical inventory errors.

  • Reduced Chemical share of cost $/kilo.

  • Increased on-time and in-full deliveries.

Solutions

  • Product coding system specifying knit type, caliber, mix, composition, quality, weight, width and finish.

  • Implement preventative maintenance program, a metric of compliance to plan, and daily cleaning schedules.

  • Oil and needle consumption tracking by machine and a schedule.

  • Installed downtime and OEE (TVQ) metrics at each work station.

  • Kanban cards to control product flow from Dyeing to Shipping.

  • Productivity and rework dashboards.

  • Implemented Supervisor Routine and Shift Change Meetings

Benefits

  • Reduction of contamination-related stoppages.

  • Reduction of needle breakage and oil consumption.

  • Reduced knitting machine and dyeing downtime.

  • Increased dyeing overall equipment efficiency.

  • Standardized speed at which machines operate , increasing equipment yds/min standard speeds.

  • Increased in-house cutting capacity utilization, reducing average finished garment costs.

  • Reduced overtime costs in all areas.

Solutions

  • Analysis of macro and micro structure, balanced workload and supervisors’ span of control.

  • Implement Expense Continuous Improvement Committee (Expense COPAC) .

Benefits

  • Savings in electricity, gas, reduction of express shipments, increase of recycling and reuse of packaging materials.

Our customers

snc
textufil
tekpop
becktel
colorsiete
tennis
lacoste
cannon
liztex
  • “The project has helped systematize our processes. We have seen good results in all areas and our work culture is different and improved.”

    Mario Becker | Operations Director Becktel, S.A. de C.V. (Mexico) (Perú)
    ROI 4.1 to 1