Rebuilding mill-to-finishing flow for 24% throughput lift.
Vertical mill operation had spinning, knitting, dyeing, and finishing under one roof — but each operated as a silo. We rebuilt the flow.
+24%
Throughput lift
18%
WIP reduction
$22M
Annualized savings
37%
Lead-time reduction
The starting condition.
Spinning, knitting, dyeing, and finishing operated as functional silos. Each was efficient locally; the value stream was 38% efficient end-to-end. Lead times on flagship programs were 11 days longer than competitor benchmarks.
What we did,
in order.
- 01
End-to-end value stream mapping across four functions.
- 02
Pull-based scheduling system between dyeing and finishing.
- 03
Capacity rebalancing across three knitting halls.
- 04
Daily integrated planning meeting structure across the four functions.
- 05
Cross-functional KPI tree replacing functional silos.
What was sustained,
at month twelve.
- +24% end-to-end throughput lift
- 18% WIP inventory reduction
- $22M annualized savings, validated by client finance team
- 37% lead-time reduction on flagship programs
- Cross-functional planning structure now standard practice
Your operation,
your case study.
Engagements like this one start with a 45-minute conversation and a written brief — before either of us commits to anything.
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