How to Maximize Productivity in Apparel Manufacturing with Aptean Apparel Shop Floor Control

Labor shortages continue to pose significant challenges in the apparel industry. With 622,000 manufacturing job openings reported by the U.S. Chambers of Commerce, filling job vacancies has become increasingly difficult. This issue was highlighted in a recent webinar by our own Aptean Senior Solutions Consultant, Justin Hershoran, who emphasized the need for companies to adopt innovative strategies to attract and retain skilled workers.

One effective strategy is the adoption of shop floor control (SFC) software. This technology is designed specifically for the apparel manufacturing industry, providing tools that can help companies excel in onboarding new operators while maintaining existing ones. SFC software enhances workforce management and boosts overall productivity.

In this blog, we explore the benefits of SFC software as discussed by Hershoran in our webinar “Optimize Labor in Your Plant.” Hershoran highlighted how leveraging technology like Aptean Apparel SFC can significantly improve labor management, attract new talent and retain current employees.

Read on to learn more about SFC software and how it can help you overcome common challenges such as labor shortages, low employee engagement and operational inefficiencies.

SFC Shows Everything on the Shop Floor—and More

SFC is a real-time data capture tool designed specifically for apparel manufacturers to manage and optimize shop floor activities. It streamlines production processes by providing comprehensive visibility into work-in-progress (WIP) and labor management, thereby enhancing operational efficiency. The software allows you to instantly see where your operators are, what they’re working on and how much money they’ve earned.

This empowers apparel businesses by providing immediate insights into production status and employee productivity, facilitating precise control and enhancing overall performance.

“When you have SFC, you end up with a more productive and more efficient workforce. Without SFC, you need a certain number of employees to be able to produce the required number of orders the company has,” Hershoran said.

Achieving Operational Goals With Aptean Apparel SFC

Implementing SFC can transform your apparel manufacturing operations by addressing critical challenges and driving significant improvements across the board. From boosting recruitment and retention to enhancing quality control and operational efficiency, SFC empowers your business to achieve its operational goals seamlessly.

With SFC, you can achieve the following benefits:

Better Recruitment and High Retention Rates

You can enhance your recruitment efforts—making your company more attractive to potential hires. Operators appreciate not having to manually track their work, leading to greater trust in the system and the company, which boosts job satisfaction.

"Many companies that institute SFC also institute an incentive pay system. So, with SFC, you may see a 10% boost with incentive pay. So, that’s huge for the operator, huge for the company," Hershoran said.

Improve Utilization and Quality Control

SFC enhances utilization by streamlining processes and providing real-time visibility into production activities, ensuring optimal resource use and quick addressing of inefficiencies. Quality control improves significantly with SFC, allowing for immediate detection and correction of issues, ensuring consistent product quality and reducing product defects.

“People learn quickly, if their quality isn’t up to par then they’re going to get the work back and it��s just going to make more time and eat into their efficiency, so they tend to do a better job to begin with,” Hershoran explained.

Empower Your Workforce With Training Tools

The software empowers your workforce by giving operators immediate access to training materials and technical specifications directly on the shop floor. This ensures employees are always equipped with the latest information and best practices, boosting their confidence and skill levels. The system also supports incentive pay structures, encouraging continuous improvement and higher productivity among workers.

“Our training tools allow you to use the system to not just train employees in these jobs but to reward them so they can make a little bit extra money while they’re learning that job,” Hershoran said. “Then, you retain that information for the life of an employee,” he added.

Increase Your Operator Morale by as Much as 37%

SFC creates an environment where operators feel trusted and empowered, leading to a potential morale boost of up to 37%. They can easily access their performance history and see their contributions reflected on screen, eliminating the need for cumbersome note-taking. This transparency fosters a positive work atmosphere, allowing your team to concentrate on their tasks while reaping the benefits of incentive pay and enhanced efficiency.

“Anytime they want to look at what they’ve done, they can easily pop onto a screen that will show them their history. Everything that they’ve worked on, every order they’ve done, or what their efficiency was on each scan,” Hershoran explained.

Real-Time Tracking, Scheduling and Reporting

Gain access to real-time tracking, scheduling and reporting that transform your production management. You can easily see what tasks to prioritize and when to tackle them, allowing for a more efficient workflow. Imagine receiving timely reports on employee performance and production status directly to your inbox—keeping you informed and ready to make crucial decisions without the hassle of searching for information.

“Look at it [data], and then you can do what you need to do with that to be able to stand on top of the important things in production,” Hershoran said.

Boost Productivity of Supervisors, HR and Management by 23%

HR tasks are streamlined, reducing the need for multiple personnel and automating payroll processes, seamlessly integrating with providers like ADP. Supervisors can shift their focus from manual data entry and report creation to managing and optimizing production, enhancing overall efficiency and output.

Hershoran explained the efficiency gains, saying, “Many companies we work with, for example, have a thousand operators and typically require four or five HR personnel. Once they implement a solution like SFC, most of these companies can reduce that need to just one person, or even less. SFC automates many manual tasks, allowing payroll to be automatically generated and ready for approval at the end of the pay period.”

SFC Is a Superior Upgrade to MES

Unlike traditional manufacturing execution systems (MES), which often require tedious manual input and physical interaction with consoles, SFC is an upgrade that offers a streamlined approach that simplifies operations. With SFC, you can scan and manage production details directly and efficiently, reducing time and effort for operators and supervisors. This modern system seamlessly integrates with existing systems like enterprise resource planning (ERP) software, handling complex processes behind the scenes and allowing you to focus on what matters most—enhancing productivity and accuracy.

“It’s [MES] kind of like the tip of the iceberg, where’s Aptean Apparel SFC system is everything beneath the water surface,” Hershoran said. “So, there’s so much more involved in production, in capturing all those details, he added.”

Achieving Operational Excellence With Aptean Apparel SFC

In an industry constantly facing labor shortages and efficiency challenges, Aptean Apparel Shop Floor Control stands out as a remarkable innovation. This software optimizes workforce management and enhances overall productivity by providing real-time data capture and visibility into shop floor activities. By streamlining processes and improving employee engagement, SFC empowers apparel manufacturers to achieve unparalleled operational excellence.

Choosing Aptean as your Shop Floor Control provider means partnering with a leader in manufacturing solutions tailored specifically for the apparel industry. Aptean's proven track record, seamless system integration, and dedication to customer success make it the ideal choice for businesses aiming to enhance productivity and efficiency.

Watch the recorded webinar to learn how Aptean Apparel SFC can help you achieve operational excellence or schedule your personalized demo today.