Revolutionizing Apparel Manufacturing: The Power of Aptean Shop Floor Control

With operating costs steadily rising as the main external pressure in the coming years, fashion and apparel industry leaders must innovate to stay ahead of the competition. To withstand the challenge, forward thinking businesses are embracing technology to boost operational efficiency through automation. Reflecting this trend, 60% of surveyed industry leaders have adopted shop floor control (SFC) software to streamline production management.

If you’re constantly dealing with higher operational costs, you’re not alone—71% of the surveyed apparel brands from the same report cite this as a top external pressure. Whether you operate your own apparel manufacturing facility or contract with third-party manufacturers (3PMs), your mission is to fulfill customer demands in a timely fashion—providing the right products at the right price.

Conquer your industry-specific challenges. In this blog, you’ll gain a comprehensive understanding of Aptean Shop Floor Control, its features and benefits. We’ll also explore the complementary software solutions that can help future-proof your business. Use our free ROI calculator to discover your potential savings.

Specialized MES for Apparel Manufacturers

When exploring solutions to boost operational efficiency, you’ve likely compared Shop Floor Control with Manufacturing Execution Systems (MES). SFC is a specialized MES with tailored features essential for apparel businesses to efficiently manage and optimize shop floor activities.

SFC software enhances efficiency by tracking production progress throughout sewing operations, giving supervisors, managers and workers real-time actionable insights, including work in progress (WIP) notifications. With capabilities like real-time data tracking and specialized labor management tools, SFC facilitates precise operational control and enhanced productivity.

While SFC is a standalone solution that seamlessly integrates with most enterprise resource planning (ERP) systems, forward-thinking businesses like yours implement apparel-specific ERP and integrate SFC software instead of adopting a generic MES. Additionally, sourcing solutions from a single vendor ensures smooth integrations, especially if part of your digital transformation journey includes adopting apparel-specific complementary solutions. This strategic upgrade enhances efficiency and ensures your business remains competitive in the ever-evolving apparel industry.

Achieve Shop Floor Mastery with Aptean Apparel SFC Features

To stay ahead in a competitive market, mastering your shop floor operations is crucial. Explore how the innovative features of SFC software can transform your production processes, enhance efficiency and give you the control you need to meet industry demands effectively:

• Real-time data collection – Harness real-time insights with off-the-shelf Android devices and wireless networking, all managed through a dynamic web-based dashboard for instant updates.

• Worker performance feedback – Boost productivity with feedback on individual and team performance, complemented by pacing tools and seamless document delivery in any format.

• Time attendance and payroll – Automate payroll calculations and export to third-party services, while supporting both individual and team incentives for precise compensation.

• Off-standard time accounting – Track and manage off-standard time with alerts and approvals, streamline code management, and monitor training progress for continuous improvement.

• Plant floor visibility and control – Achieve full visibility with real-time order tracking and line balancing tools, enhanced by advanced production planning for optimized operations.

• Quality control – Ensure quality with swift issue management, visual controls with images, and detailed performance reports for consistent product excellence.

Unlock the Advantages of SFC: Elevate Your Apparel Manufacturing

Discover how SFC software revolutionizes apparel manufacturing with its powerful benefits. From enhanced efficiency and productivity to streamlined operations, this solution empowers your business to tackle challenges unique to apparel manufacturing head-on.

These are some of the notable benefits you can unlock with SFC software:

• Boost operational efficiency – Streamline processes with real-time data tracking and modern management tools, achieving up to 72% reduction in overtime.

• Enhance productivity – Leverage specialized work management features to maximize worker performance and shop floor output, resulting in 37% productivity gains.

• Improve cost management – Minimize costs by automating payroll, tracking off-standard time and optimizing production planning.

• Increase visibility and control – Gain comprehensive oversight of shop floor activities with real-time updates and detailed reporting.

• Elevate product quality – Implement robust quality control measures to quickly address issues, ensuring consistent product excellence with a 44% improvement in quality.

• Support informed decision-making – Access actionable insights and analytics to make data-driven decisions that drive continuous improvement and competitiveness.

Proven by successful apparel brands, SFC software has consistently enabled companies to achieve their operational goals and excel in a competitive landscape.

Success Story: Carhartt

Known for its signature outerwear, including jackets and overalls, Carhartt has expanded its workwear products to serve and protect hardworking men and women both on and off the job in all weather conditions.

When the company entered a period of rapid growth, it lacked the strategic technology base needed to scale up and fully support its manufacturing operations. Additionally, its old system didn’t provide real-time production visibility and couldn’t offer enough flexibility in variable operator pay calculations.

Carhartt chose Aptean Shop Floor Control for its user-friendly system that enhances operator experience while offering the comprehensive, industry-specific functionality their operations require. With Aptean Shop Floor Control, Carhartt was able to increase average production line efficiency by 13% across seven manufacturing plants, gain real-time visibility to eliminate bottlenecks and save 320 person hours per payroll, cutting costs by approximately $60,000 annually.

“To continue to scale, we needed to get to the root cause of some of the production bottlenecks and really address those permanently.” – Katrina Agusti, CIO, Carhartt

Success Story: Propper

Propper is one of the largest official suppliers to the United States armed forces known for manufacturing the U.S. Navy’s “Dixie cups” or the iconic white sailor caps. Established in 1967, the company has manufactured over 60 million garments for the U.S. Department of Defense, Army, Air Force, Navy, Marines, Coast Guard and Special Forces.

Even with half a century of experience, Propper found itself facing a plateau in plant efficiency. Outdated methods for tracking work-in-progress (WIP) and piece-rate payroll had locked the company in a cycle in where unproductive time and manual procedures significantly impacted daily operations.

Implementing Aptean’s specialized shop floor control software has led to double-digit efficiency gains for Propper and brought heightened operational visibility to both managers and production workers. The company gained faster access to actionable information, enhanced managerial visibility into work-in-progress across multiple sewing lines and streamlined time tracking with QR code badges, leading to a 15% average improvement in sewing operator efficiency.

“It’s [Aptean Shop Floor Control] helping us be faster and more accurate with everything we’re doing right now. Instant feedback motivates workers to achieve higher performance levels.”— Victor Acosta, IT Lead for Business Analysis, Propper

Achieve Rapid ROI in Apparel Manufacturing With SFC

As a manufacturer, your goal is to maximize production and SFC software can help you achieve that. With invaluable, real-time insights into the production floor, you can achieve shop floor excellence and optimize machine use, inventory, staffing and other variables. This leads to greater efficiency and more streamlined operations.

Aptean Apparel SFC is easy to install and deploy in any environment, regardless of the existing tech infrastructure. The software is user-friendly, allowing staff to quickly adapt and integrate it into their daily routines. This rapid implementation means factories start seeing results in just a few weeks.

Find out how much you can save with our free ROI calculator.

Achieve Shop Floor Excellence with Aptean’s Advanced Solutions

In the dynamic and highly competitive apparel industry, you need a partner who understands your unique operational challenges and delivers innovative solutions for success. Aptean stands out with its Shop Floor Control software, including the blend of proven expertise and cutting-edge technology, specifically designed to address the needs of apparel manufacturers.

With extensive industry experience, Aptean provides solutions that resolve key pain points, utilizing the latest advancements for real-time insights and seamless integration. This ensures smooth, efficient operations, positioning your business for growth and a competitive edge.

Our clients consistently report significant improvements in production efficiency, cost savings and overall productivity, as evidenced by numerous success stories. Aptean’s user-centric design, featuring an intuitive interface and mobile access, facilitates easy adoption and maximizes benefits for your team.

Additionally, Aptean is dedicated to your long-term success, offering comprehensive support and continuous updates to maintain peak operational performance. Choosing Aptean means partnering with a leader committed to enhancing your business's efficiency and profitability.

See the difference shop floor control software can make—use our free ROI calculator to discover your potential savings or book a personalized demo for a closer look at how SFC drives efficiency.