Factory Setup & Layout
INDIAN DESIGNS
Key Result:800 → 1,410 Machines in the reengineered knit unit 3.2 → 5.0 LAKH Monthly production capacity 218 → 147 SQ FT Space per machine UP TO 76% Increase in installed machines Short Summary
A leading Indian apparel exporter needed to expand capacity across multiple factories without relying entirely on new buildings. Cent Edge reconfigured factory roles, consolidated compatible units and redesigned material and production flow. The programme increased machine capacity, improved space utilisation, integrated value-add processes and created a more scalable manufacturing network within the available footprint.
Lean Manufacturing
LEADING EXPORTER FROM INDIA
Key Result:3.7% FABRIC SAVINGS
A common control system improved fabric accountability across four factories, increased average process adherence from 58.5% to 90.3%, and delivered 3.7% documented fabric savings.
Factory Setup & Layout
EAST MAN
Key Result:Turning local workforce insights into a practical greenfield launch strategy
Identified a primary manpower catchment within approximately 5–6 km of the proposed location.
Established indicative monthly wage benchmarks of ₹12,000 for sewing operators and ₹8,000 for helpers.
Highlighted safe, reliable transport and suitable working hours as critical enablers of workforce participation.
Recommended a phased start with 300–400 machines, with a two-shift operating model to be evaluated against recruitment readiness and workforce preferences.
The outcome
Factory Setup & Layout
Integrated Denim & Casualwear Producer
Key Result:Lead time: 45 → 28 days
End-to-end value stream mapping and production layout redesign. On-time delivery improved from 61% to 94% within the project period.
