This intensive workshop is designed for apparel professionals committed to building sustainable operational efficiency by optimizing people, machines, and materials while aligning productivity with the natural pace of workers. The focus is on advanced tools and techniques that enable agility across cutting, sewing, finishing, and packing, equipping participants to respond quickly to fluctuating demand without sacrificing flow, balance, or performance.
Key Challenges Addressed
End-to-end optimization gaps that leave factories vulnerable during order changeovers (with performance losses of up to 4 days).
Chronic inefficiencies in resource deployment, line balancing, and operational stability.
Lack of proven system design approaches to sustain agility and responsiveness.
Learning Approach
The workshop combines theory, case studies, simulations, and group exercises, ensuring participants gain both knowledge and hands-on experience.
Day 1 Focus – Streamlining Operations & Resource Optimization
Lean-Agile principles applied across cutting to packing.
Flow optimization and cutting room efficiency.
Product family segmentation for line design.
Worker & machine optimization in sewing.
Simulation game: bottleneck management under variable demand.
Day 2 Focus – Enhancing Agility & Order Responsiveness
Agile techniques for quick changeovers. Finishing & packing optimization.
Embedding continuous improvement into daily operations.
Using KPIs and metrics for performance tracking.
Collaboration, innovation, and practical integration strategies.
Key Outcomes
By the end of the workshop, participants will be able to:
- Optimize resource utilization (machines, workers, materials).
- Minimize delays and design disruption-free flows.
- Build agility to adapt quickly to order changes.
- Improve inter-departmental integration across cutting, sewing, finishing, and packing.
- Apply Lean-Agile tools such as fixed-worker positions, quick changeovers, and pull-driven scheduling.
