The engagement began with a factory-wise assessment of the complete fabric-control cycle. Cent Edge evaluated not only fabric consumption figures but also the operating discipline behind those figures—from fabric receipt and physical verification to cut planning, spreading, lay-record accuracy, cutting-store control and final reconciliation.
The assessment revealed that the challenge was not limited to marker efficiency. Consumption performance was being influenced by inconsistent data entry, uncontrolled splice joints, differences in factory practices, limited leftover visibility and delayed reconciliation. These gaps made it difficult to explain why an order had consumed more or less fabric than planned.
Cent Edge therefore established a common control framework across all four factories. Daily cut plans were linked with fabric issues, lay lengths were checked against marker requirements, splice joints were monitored and fabric reconciliation was introduced at lay, roll, order and style levels.
Trakwel adoption was strengthened simultaneously. Formula errors in lay-slip calculations were identified and corrected, planned-versus-actual ply mismatches were controlled, consumption visibility was made available online and system errors became easier to detect and escalate. Some modules—including re-cutting and inventory linkage—were identified for further stabilization.
A weekly Fabric Consumption Review brought together approved consumption, fabric issued and achieved consumption. Deviations could now be identified while production was underway, allowing management to act before order closure.
As a result, average fabric-control process adherence across the four factories improved from 58.5% to 90.3%. The programme created a transparent and explainable fabric-consumption system, strengthened factory accountability and provided management with a consolidated view of fabric performance.
The engagement demonstrates an important principle: meaningful fabric savings do not come from marker efficiency alone. They require end-to-end control across planning, physical fabric parameters, spreading, cutting, system accuracy, reconciliation and management governance.