Lean Transformation – an apparel manufacturing case

November 21, 2016


“What do you mean by Optimization?. Easy to understand real examples of how we helped factories optimize manufacturing processes.

Context: men’s shirts and woven women’s tops factory looking to increase their capacity while reducing overtime and lead-time (cutting to packing).

Duration: 6 weeks from the assessment to the conclusion of the Kaizen Blitz project.

We advised to integrate one line “sew to pack”. For this we implemented a “just-in-time” production system. We redesigned the line layout with Lean concepts, using the right combination of man-machine-method, and balanced it according to Takt* time. During the whole project we trained the workers to understand and apply Lean techniques and concepts. We also trained them in MDI (Managing for Daily Improvement), problem solving and continuous improvement tools, to ensure the sustainability of the Lean transformation of this production line.

*In this case, average production time to produce a garment

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Machines being moved during the layout change



The new integrated line sews 34% more pieces and packed 23% more with the same human resources. The overtime was reduced by 73%, same as the lead-time (from 14 to less than 4 days). Also the sewing productivity improved by 36% (pieces/person/hour)

The factory obtained six-digit amount of savings and the return of their investment in Impactiva’s fees was less than two months, optimizing only this one production line.

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The factory CEO and production team were very pleased with the achievements.

Stay tuned for more Impactiva optimization solutions.