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

Edit This Case Study Record

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

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

Lectra

Technology Category	Functional Applications - Inventory Management Systems Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries	Apparel
Applicable Functions	Process Manufacturing Quality Assurance
Use Cases	Inventory Management Manufacturing System Automation Process Control & Optimization
Services	Software Design & Engineering Services System Integration
Challenge	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. Read More
About Customer	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. Read More
Solution	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. Read More Log in to view content
Contents

Technology Category

Functional Applications - Inventory Management Systems

Functional Applications - Manufacturing Execution Systems (MES)

Applicable Industries

Apparel

Applicable Functions

Process Manufacturing

Quality Assurance

Use Cases

Inventory Management

Manufacturing System Automation

Process Control & Optimization

Services

Software Design & Engineering Services

System Integration

Challenge

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.

About Customer

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.

Solution

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.

Impact #1	Lectra’s Optiplan has significantly reduced the time required to create cut plans, from half an hour or more to just 10 minutes.
Impact #2	The automation of the cut plan process has minimized human error and provided consistent results, reducing dependency on individual skill levels.
Impact #3	Lectra’s technology has improved the management of the pre-production stage by unifying orders from different clients into coherent and manageable data.

Impact #1

Lectra’s Optiplan has significantly reduced the time required to create cut plans, from half an hour or more to just 10 minutes.

Impact #2

The automation of the cut plan process has minimized human error and provided consistent results, reducing dependency on individual skill levels.

Impact #3

Lectra’s technology has improved the management of the pre-production stage by unifying orders from different clients into coherent and manageable data.

Benefit #1	TAL estimates year-on-year fabric saving at $2.1 million USD, equivalent to 1% of fabric consumption.

Benefit #1

TAL estimates year-on-year fabric saving at $2.1 million USD, equivalent to 1% of fabric consumption.

Download PDF Version

Overview

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

Operational Impact

Quantitative Benefit