Longworth Industries Optimizes Military-Grade Garment Production with Lectra’s Advanced Technology
As a trusted manufacturer of high-performance base layers for the US military, Longworth Industries has built its reputation on delivering top-quality products that meet the stringent standards of Berry compliance.
To remain at the forefront of the industry, they recognized the need for innovative solutions that would allow them to enhance capabilities and maintain superior quality.
The Challenge: meeting military specifications with precision
As a Berry-compliant manufacturer specializing in military-grade base layers, Longworth Industries needed to:
- Increase Production Speed: Deliver products faster without compromising on quality.
- Ensure Exact Specifications: Uphold the stringent standards required for military-grade fabrics.
- Optimize Fabric Utilization: Reduce waste while managing complex patterns efficiently.
- Expand Capabilities: Support growth into more technically complex garment designs.
The Solution: Lectra's Integrated cutting room technology
To tackle these challenges, Longworth Industries adopted Lectra’s cutting-edge technology, which transformed their production process:
- Lectra Vector Cutting System: This innovative system enabled continuous cutting, significantly speeding up production without sacrificing accuracy.
- Gerber Accumark Pattern Design Software: Advanced design tools provided the precision needed for military specifications, ensuring each garment met the highest standards.
- Cloud-Based Marker Making: Enhanced fabric utilization through intelligent layout optimization reduced waste and maximized resources.
Impact: Achieving efficiency and accuracy in every ut
The implementation of Lectra’s solutions led to remarkable results:
- 3-4% Reduction in Fabric Waste: A notable improvement in resource efficiency that translates to cost savings.
- 75% Faster Cutting Time: A dramatic decrease in cutting time from over 2 hours to just 15 minutes, enabling quicker turnaround for clients.
- Improved Pattern Accuracy: Consistency across all garments, ensuring compliance with military requirements.
- Enhanced Flexibility: The ability to adapt to complex designs allowed Longworth Industries to meet evolving market demands.
- Predictive Maintenance: Downtime was minimized with proactive maintenance alerts, keeping production lines running smoothly.
"To get on the leading edge of manufacturing, especially with more complex garments, we chose Lectra’s latest technology to drive efficiency at every level. With tools like Accumark and Cloud-based nesting, we’ve achieved precision from the largest to the smallest part, significantly boosting our overall productivity."
“Upgrading to our latest Lectra solutions, everything is more accurate to the spec, everything is more accurate to the cut, even down to the notches. We are achieving 95% uptime, due to our mistakes not the Lectra solutions.”
Tim Whitley, Director of Manufacturing, Longworth Industries
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