We foster strong partnerships with our clients while focusing on results by providing customized, simple, and practical solutions
We identify, in a clear and prioritized way, the set of organizational and technological improvements required to establish efficient and coherent management
We foster strong partnerships with our clients while focusing on results by providing customized, simple, and practical solutions
We identify, in a clear and prioritized way, the set of organizational and technological improvements required to establish efficient and coherent management
The company Generos de Punto Montoto S.A. is a leading company in the manufacture of knitwear in Spain. Since its beginnings more than 50 years ago, it has maintained a constant evolution, experiencing strong business growth in recent years.
Due to the growth experienced in recent years and the projected forecast of maintaining this increase in the coming years, including the opening of new production centers and incorporation of new brands, the company decided to initiate a business reorganization project aimed at improving management effectiveness and efficiency.
The project has been structured to improve three main areas: weaving, clothing, and the raw material warehouse.
In the weaving area, manufacturing processes were enhanced, and human resources were reorganized. An in-plant weaving performance control system was established, which is now fully integrated into the weaving process. After this step, we proceeded to analyze the manufacturing flow and establish mechanisms to increase the performance and traceability of the garment within the area. Subsequently, the integrated logistics control system was implemented in Montoto’s central warehouse. The system is based on a method of location and area management. From the moment the raw material is received, there is total traceability, as the yarn is identified from the beginning and is in a warehouse position, categorized by color, quality, and dyeing.
After completing this project, the company now has daily plant performance control in the weaving area, with awareness of the performance by model, machine, group of machines, shift, and operator. In the tailoring area, a list of operations is coded by bar code, forming a “tailoring roadmap”. This enables obtaining the daily production output by operation, section, and operator.
Finally, the raw material warehouse is now fully integrated into the production process. When a production order is issued, the system displays the available yarn kilos by color/quality/dye level and indicates their location. As a result, the yarn search time has significantly reduced, allowing for automatic retrieval of the yarn’s location.
In conclusion, all manufacturing processes –from packaging to storage- are now more efficient, optimizing resources and increasing productivity.