Customer stories

Going lean: Wacoal America maximizes its productivity and profitability with Lectra’s cutting room management approach

Top lingerie brand’s Dominican Republic branch increases production by 20%-30% in response to growing consumer demand brought about by its international expansion.


Wacoal America’s growing market share is due to both increasing US demand and international expansion throughout the Americas and Europe/Australia. As a result, Wacoal looked to their Dominican Republic manufacturing site to increase production. The challenge was to produce more without increasing costs.

Wacoal’s path to cutting room optimization

Lectra  has  helped  Wacoal  implement change by providing expertise  on  how  to  optimize  material  use and improve flow, as well as operator training.  This enabled   process   streamlining   and increased productivity as a result.  They also implemented Vector Lingerie  ix6 that cuts with a zero buffer and provides  metrics to monitor  performance.

Cutting room management expertise and solution that increased productivity by 20% 

On Lectra’s advice, Wacoal increased cost  savings   and   productivity   by   refining   their   process.   These   improvements  were  possible  by  taking  a  lean approach  to  the  cutting  room  as  well  as  upgrading  to  a  Vector  Lingerie  cutting  machine.  According to Virgilio Estévez, the site’s  plant  manager, this project resulted “in  substantial   improvement   in   quality,   cleaner   processes  and  technologies  that  allow  the  cut  of  different  types  of  materials  and  shapes,  as  well  as  an  increase  in productivity of 20%.”.

Customer Voice

Lectra is a company with expertise in cutting technology. I am really impressed with their lean approach to the cutting room. It’s the best I’ve seen in my professional career. I see a very strong future relationship with Lectra, as our growth cannot be sustained unless we are supported by a company that produces high quality technology and constantly strives to improve productivity.

Ramon Enrique Rivera

Vice President of Manufacturing

Download Wacoal Customer story

Download the full customer story to discover how Wacoal increased productivity by 20% with Lectra’s cutting room expertise and Vector Lingerie ix6.

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