Success story · Manufacturing (textile and apparel)
The lean stitch (textile and garment)
A full order book and a loss on every shipment.
The challenge
Drowning in overhead
A legacy garment factory producing for Western brands lost money on every shipment through inefficiency, high rejection rates and a bloated middle management. The owners were considering closure because they could not meet payroll.
Our solution
A strict lean turnaround
The focus was the cost per minute of the production line.
01
Management delayering
Six management layers between floor and CEO became three. Forty middle-management roles without direct production value were made redundant.
02
Line balancing
Re-engineered sewing lines removed bottlenecks, and a piece-rate incentive linked pay to productivity.
03
Quality at source
Quality checks at every fourth station instead of at the end cut final rejects from 12% to 2%.
The outcome
More than 1,000 jobs safeguarded
Productivity rose 22% in the first quarter without new hires. Lower rejects saved thousands of dollars in fabric every month. The factory moved from a monthly loss to a sustainable 6% net margin and kept more than 1,000 people in work.
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Read the lean stitch caseConfidential · Senior-led · Fixed fee to start
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