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
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 1,500 pieces
5 hours spreading (20 rolls)
1 hour cutting
2 hours bundling and numbering
Avg marker length: approximately 6 meters
Solution
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 2x24 hours hours, supported by spare parts availability through a regional technical hub in Bandung.
Equipment Used
Results
per Marker