The Challenge
Every morning started with phone calls to supervisors asking what happened on the previous shift. Sewing line counts were updated on paper at the end of each shift. By the time the production head knew a line had fallen behind, hours were already lost. Buyer packing deadlines were tracked in a shared WhatsApp group with the merchandising team. Fabric consumption per style was unknown in real time, which made it impossible to flag shade-lot mixing before it reached finishing.
What We Did
Fleek was configured with style-wise work orders for each active buyer order. Sewing line operators logged hourly bundle completions from their Android phones, with no dedicated hardware and no scanning equipment. The production head's dashboard showed every line's live count, target, and efficiency without a single phone call. Shade-lot fabric allocation was tracked from cutting: each roll was tagged with its shade lot, and the cut plan kept rolls separated by shade lot within each size group to prevent mixing.
Results
- Production head stopped making status calls; the live line dashboard replaced every morning WhatsApp update
- Buyer packing deadlines met consistently since go-live, with no late shipments in 4 months
- Shade-lot mixing caught at the cutting stage before it reaches sewing, so shade-variance rejection at finishing is gone
- Hourly sewing line data enabled same-shift correction when any line fell behind its daily target
- Go-live completed in 18 days, with operators trained and live on the app in 2 days during Week 2
Before Fleek, I had to call my supervisor every 2 hours to know where each line stood. Now I open my phone and it's all there: line count, who's behind, what's in QC hold. We haven't missed a buyer packing deadline in 4 months.
Your factory could be next
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