Lectra Case Studies TAL Group Hong Kong Improves Pre-Production Efficiency with Lectra Technology
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TAL Group Hong Kong Improves Pre-Production Efficiency with Lectra Technology

Lectra
Functional Applications - Inventory Management Systems
Functional Applications - Manufacturing Execution Systems (MES)
Apparel
Process Manufacturing
Quality Assurance
Inventory Management
Manufacturing System Automation
Process Control & Optimization
System Integration
Software Design & Engineering Services
The global challenge for TAL was to hold their dominant place in a competitive market by constantly innovating. This meant increasing pre-production efficiency by harmonizing orders, with the benefit of saving on fabric consumption and maximizing human efficiency.
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Headquartered in Hong Kong, and with 10 factories in South East Asia, the TAL Apparel Group has 25,000 employees and an output of over 55 million pieces a year. With a focus on quality, TAL treats orders coming from over thirty of the world’s most well-known brands. TAL is a major player in the garment manufacturing industry, with 90% of its orders placed by US clients. The company has a long history, having been established as a family textile mill in 1946, and has grown to become a leader in the industry by constantly adapting to and anticipating market needs.
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In 2012, TAL adopted Lectra’s cut plan and order management solution, Optiplan, to improve the organization and control of the pre-production process, optimizing fabric and labor. Lectra has become an important component of an innovative automated supply chain replenishment system, benefiting around 30% of TAL’s clients. TAL's president and CTO, Dr. Delman Lee, emphasizes the importance of competing on quality and apparel services, and the need for innovative technologies to distinguish themselves from other suppliers. The adoption of Lectra's technology has allowed TAL to automate the cut plan process, which was previously done manually, leading to significant improvements in efficiency and consistency.
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Lectra’s Optiplan has significantly reduced the time required to create cut plans, from half an hour or more to just 10 minutes.
The automation of the cut plan process has minimized human error and provided consistent results, reducing dependency on individual skill levels.
Lectra’s technology has improved the management of the pre-production stage by unifying orders from different clients into coherent and manageable data.
TAL estimates year-on-year fabric saving at $2.1 million USD, equivalent to 1% of fabric consumption.
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