Project Description

$52k Monthly Savings Achieved

COMPANY PROFILE

A manufacturer of quality cotton shirtings and fabrics with a client base that includes several high street brands.  Achieving a $200m turnover in 2013, this prestigious company has over 30 manufacturing bases throughout Asia and supplies leading retailers and brands across Europe and the USA.

THE PROJECT

A “Textile Process Health Check”  was developed and undertaken at the company’s facilities, to capture the strengths and weaknesses of current operations and to identify where improvements could be made.  The focus of the health check was to look at the laboratory processing and the subsequent reproducibility in bulk production.

PROJECT TYPE

•  Optimisation

How did Textile Consult help?

A “Textile Process Health Check”  was developed and undertaken at the company’s facilities, and consisted of a detailed bench marking and comparison evaluation to capture the strengths and weaknesses of current operations and to identify where improvements could be made.  This was achieved through a combination of pre-visit questionnaire, onsite consultations and was followed up with a detailed recommendation report.  The focus of the health check was to look at the laboratory processing and the subsequent reproducibility in bulk production.

The pre-visit questionnaire provided information on infrastructure, staff, dyestuff stock and usage.   The factory audit identified that the colour laboratory   was performing a high number of matches and re-dyes per week, with each lab match process attracting a significant cost per test.  This was mainly as a result of multiple customer rejections and subsequent rework, resulting in a high cost, timewise and financially, to achieve customer acceptance.  This extensive rework also resulted in a change of recipe by as much as 40%, in some cases, creating extra work for the in-house lab team to recreate formulas.

The Solution
Our team recommended and introduced procedures for colour management and measurement during the visit.

Implementation of these procedures reduced laboratory processing and rework  by 31% in the first week, resulting in savings of $52,000 per month.  By following our recommendations,  ‘Right-First-Time’ processing in the factory increased from 85% to over 91% in the first month after our team visit:  this level of production efficiency had never been achieved at the factory site before.

The Benefits of Working with Textile Consult
Deep industry knowledge within our company, plus years of experience,  provided this factory with a speedy solution to an entrenched problem – helping to improve lab efficiency, the customer experience, and achieve significant cost savings for the business – there were lots of smiles when the figures came in!

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