Zie Garment

Background

Zie Garment is a growing Muslim fashion manufacturer based in Tasikmalaya, West Java, producing gamis and modest wear for Indonesia’s e-commerce market.

With approximately 200 sewing operators and strong online sales channels, the company operates at medium industrial scale and continuously seeks operational improvements to maintain competitive pricing in a margin-sensitive market. Before automation, their cutting process relied entirely on manual methods.

Original Production System

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Manual Cutting Setup:

Straight knife cutting
Cardboard patterns drawn manually on fabric
6 cutting lines
2 operators per line (spread and cut)
Total: 12 operators

Performance Baseline:

120 rolls per day (20 rolls per line)
Each 20 rolls produced approximately 1,620–2,100 pieces
5 hours spreading (20 rolls)
1 hour cutting
2 hours bundling and numbering
Avg marker length: approximately 6 meters

Solution

2 Automatic Spreaders
1 Harmony Auto Cutter
12 sections (14.4m table)
OPTITEX CAD system implementation

The production layout was restructured in phases to optimize both manpower and equipment utilization. After workflow adjustments and system balancing, final output reached 160 rolls per day.

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Process Change

Installation duration extended to one month due to electricity infrastructure upgrade requirements. During this period, a generator set was deployed to ensure setup continued without unnecessary delay.

Training required one week. Initial operator resistance related to computer familiarity was addressed through operator reassignment and focused training.

Technical support ensured machine downtime did not exceed $7 \times 24$ hours, supported by spare parts availability through a regional technical hub in Bandung.