Title: REACH Technologies Customer Solution Case study
1 REACH Technologies Customer Solution Case Study Integrated Solutions Increase Efficiency and Reduce Was in Clothing Manufacturing te This solution maximizes our use of fabric. Were Overview Country or Region India getting between 0.5 and 2 percent more garments Industry Manufacturing out of the same fabric rolls. Customer Profile Sunil Masand Managing Partner Vigosa Exports Bangalore India based Vigosa Exports is a midsizemanufacturer of clothing for buyers around the world. Its products are sold in Vigosa Exports wanted to increase the efficiency with which it CA stores in Europe as well as Wal-Mart Target and other stores in the United manufactures clothing for buyers in the United States and Europe. States. By deploying a suite of products from REACH Technologies Business Situation Vigosa has reduced fabric consumption by as much as Vigosa wanted to find a way to reduce the 5 percent per order. It has decreased the time to resize amount of waste at the end of a long roll of fabric. It needed a solution that would clothing patterns from 30 hours to 4 and all but eliminated resizing optimize the layout of clothing parts to be errors. And it has gained the ability to optimize the allocationfo cut from a fabric roll. pattern layouts to fabric rolls which has increased the overall yield Solution of fabric rolls by as much as 2 percent. Over the course of a year Vigosa implemented REACH CAD and REACH Cut Planner these improvements add up to a significant improvement in Vigosas profitability. Benefits 625 percent faster pattern resizing Dramatic reduction in resizing errors Up to 2 percent increase in roll yields 5 percent less fabric required Improved inventory accountability 2 Our pattern makers Situation their largest single cost and thereby Even in the age of high technology the increasing company profitability. now have time to do intricacies of clothing manufacturing still more things to develop Solution involve innumerable manual processes. Clothing designs are often initially drawn by Turning to REACH Sewn Technologies more styles. Its a great handand drawing a detailed pattern might Consulting a based in Bangalore Vigosa productivity take 24 hours or more. An individual might found two applications that could help it then take that master pattern and resize or optimize fabric use and reduce the time enhancement. grade a medium to its small large and required to fulfill customer orders extra-large dimensionsa process that could REACH CAD and REACH Cut Planner (RCP). Sunil Masand Managing Partner take a grader one to two more days partic- Vigosa Exports Design Automation ularly if the grading needs to be redone in order to fix a resizing error. Then all the REACH CAD is a software tool for pattern pieces in the pattern must be laid out in a engineering grading and marker planning. marker which shows a cutter just where to It helps minimize fabric consumption and cut the pieces from a swatch of fabric. facilitates supplying the sewing lines with accurately cut parts. It automates a range of Because fabric constitutes 60 to 70 percent design processes including pleat turning and of the cost of clothing manufacturers want to balancing grain line adjustments pattern ensure that they optimize their use of fabric. flipping seam allowance adjustments But in a manual world no one really has time grading and many others. to optimize the layout of markers in order to get the most clothing out of each roll. A Using a REACH CAD Web service fashion company such as Vigosa Exports based in designers in the United States and Europe Bangalore India might receive hundreds of can upload precise information about gar- rolls of fabric to meet a customer order and ment fit to Vigosa. Once that information is in few if any of those rolls will be of equal REACH CAD the pattern designer at Vigosa length. One roll might be 100 yards long uses the automation features to grade the another might be 101.36 yards long. While pattern prototype to required sizes (S M L the cloth manufacturer does provide detailed and so on). REACH CAD can lay out pattern information about the length of each roll the markers for optimal fabric use and even huge amount of variation always made it optimize piece positioning to line up plaid simpler for Vigosa cutters to roll out the fabric and stripe patterns (the designs for which can and just start cutting markers without regard be scanned into REACH CAD for analysis). for the amount of waste that might result at REACH CAD can send patterns and markers the end of a roll. directly to a plotter for pattern/marker printing it can also send output directly to an Vigosa managers wanted to find a way to electronic cutting machine. optimize manual processes. They wanted not only to design clothes faster but also to min- imize waste on the cutting-room floor. If they could accomplish both goals they could deliver clothing to their customers faster which would improve customer sales and repeat business. If they could optimize fabric use they might be able to order less fabric and still meet customer ordersthus lowering 3 Flexible Infrastructure Cut Planning RCP performs the complex calculations REACH CAD users can create patterns and that enable Vigosa to optimize the yield markers in one or more locations and share from each roll of cloth. The solution has them with one or more cutting rooms located a Web service that enables a fabric anywhere in the world. Similarly an RCP manufacturer to upload information about report for one line of clothing can be distributed the fabric rolls it is shipping to Vigosa to one set of cutting rooms while an RCP (including roll width length and so on) as report for another line of clothing can be XML input. RCP can also import this infor- distributed to another set of cutting rooms on mation from a Microsoft Word or Microsoft a different continent. Excel document as well as accept XML input from REACH CAD that describes the markers to be cut from the roll. RCP takes the marker Benefits information plus the information about the individual rolls and determines which com- For Vigosa Exports the new solution is bination of markers should be cut from each providing many benefits. With the help of individual roll to minimize waste and meet a REACH CAD the manufacturer is saving customers order. significant development time and effort and With REACH CAD Vigosa can pattern designers are far more productive. quickly lay out markers from With REACH Cut Planner Vigosa is reducing differently sized clothing patterns fabric waste as well as improving roll yield to optimize fabric use. inventory management and company profitability. Improving Productivity With REACH CAD Vigosa has increased the efficiency with which it can create a pattern and prepare that pattern for production. With REACH CAD a pattern designer can create a pattern grade it to all its sizes and prepare it for cutting in as little as 4 hours. To accomplish the same thing manually would take between 20 and 30 hoursand then only if there are no errors. REACH CAD is working brilliantly for us says Sunil Masand Managing Partner at Vigosa Exports. Once the pattern has been approved by the buyer REACH CAD grades it perfectly to all the other sizes. All the mistakes associated with grading a pattern 4 manually have been eradicated. It used to be Reducing Waste With REACH Cut Planner that we wouldnt discover a grading problem Automated grading and optimized placement until we sewed a test garment. Then we When you add up the of garment pieces within a marker are power- would have to go back and fix the pattern and ful benefits but optimizing the mapping of savings over the course resew a test garmentand that would take the markers to the different rolls of fabric is another day or two. REACH CAD can save us of a year a 5 percent the key to optimizing fabric consumption and one to two days of work right there. We still lowering costs. With RCP Vigosa cutters savings in fabric per check to make sure our grading is correct know just which combination of markers to but 99 percent of the time its perfect. order is significant. use to get the most out of each roll of fabric. Our pattern makers now have time to do Sunil Masand Managing Partner more things to develop more styles Vigosa Exports says Masand. Its a great productivity enhancement. REACH CAD automatically grades new clothing patterns to the entire selection of sizes. 5 This solution maximizes our use of fabric Masand notes that it would be possible to cut For More Information says Masand. It allocates a fabric roll to a each roll so as to minimize end bits without a marker length thereby minimizing the end tool like RCP but it would involve so much bit of each fabric roll. For Vigosa that has preparation work that it simply would not be For more information about REACH Sewn improved fabric use by between 0.5 and 2 cost-effective to do it. You could spend a Technologies Consulting products and percentwhich means were getting between whole day figuring out how to optimize fabric services call 91 (80) 6599 6111 or visit 0.5 and 2 percent more garments out of the use for just a small orderlet alone a large the Web site at same fabric rolls. oneso it simply would not be worth doing. www.reach-tech.com Once youve got the roll length details into RCP RCP figures out what to do in a matter of seconds. Realizing Bottom-Line Benefits RCP delivers other benefits to Vigosa as well. Built-in stock accounting features enable Vigosa to account for each fabric in inventory which helps the company eliminate theft of fabric rolls. We might have more than 500 rolls in stock at any time says Masand so having a system in place to account for every roll is an added benefit. With optimized marker layout and mapping to fabric rolls of differing length Vigosa has found that it can reduce fabric consumption by as much as 5 percent per order. When you add up the savings over the course of a year says Masand a 5 percent savings in fabric per order is significant. Im now won- dering why we didnt do this a long time ago.
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