Skip to content

Case Study 1 - Tackling Delays in Production Schedules

Problem

CCS Apparel faced significant delays in our production schedules due to frequent machine breakdowns. This not only impacted our ability to meet delivery deadlines but also increased operational costs due to unscheduled maintenance and overtime pay for our workers.

Solution

To address this issue, we optimized our production by identifying the strengths of each person in the workstation and saw better results through task specialization.

Innovative Aspect
  • Strength Identification: We conducted assessments to identify the specific strengths and skills of each worker in the production line.
  • Task Specialization:
    Based on these assessments, we assigned tasks that aligned with each
    worker’s strengths, ensuring that everyone was working on tasks they
    excelled at.
  • Team Collaboration: Encouraged a
    collaborative environment where team members could share their expertise
    and assist each other, leading to a more cohesive and efficient
    workflow.
  • Skill Enhancement: Provided
    additional training to further hone the skills of workers in their
    specialized tasks, increasing overall productivity.
Outcome:

By focusing on the strengths of each worker and implementing task specialization, we were able to:

Reduce Delays: Minimize production delays by streamlining the workflow and reducing bottlenecks.

Increase Efficiency: Improve production efficiency and reduce the frequency of errors and rework.

Enhance Morale: Boost worker morale and job satisfaction as employees were able to focus on tasks they were skilled at and enjoyed.

Satisfaction: Meet delivery schedules more consistently, thereby enhancing customer satisfaction and loyalty.

Case Study 2 - Improving Quality Control and Reducing Waste

Problem

CCS Apparel struggled with maintaining consistent quality across our products. A high rate of defects led to increased waste and rework, which affected our profitability and customer satisfaction.

Solution

We adopted a digital pattern-making system. This system utilized CAD (Computer-Aided Design) software to create precise patterns for our cutters.

Innovative Aspect

Digital Pattern Making: The use of CAD software allowed for precise pattern creation, reducing errors associated with manual pattern drafting.

Integrated Quality Control:
The system included a quality control module that could detect and correct minor defects during the cutting process, preventing defective pieces from moving to the sewing phase.

Efficiency: The automation reduced the cutting time by 50% and decreased fabric waste by 30%, leading to significant cost savings.

Outcome:

The integration of digital pattern-making and automated cutting systems enabled us to improve the consistency and quality of our products. This not only reduced waste and rework but also enhanced customer satisfaction by ensuring high-quality products. Additionally, the cost savings from reduced waste and increased efficiency contributed to higher profitability for CCS Apparel.