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UK textile firm C&C expects 40% productivity boost with Made Smarter
12 May '21
4 min read
Pic: Cookson & Clegg
Cookson & Clegg (C&C), a UK textile manufacturer, is expecting a 40 per cent productivity increase, greater efficiency, less waste, and more profit, after investing in technology support by the Made Smarter North West Adoption programme. Made Smarter is an industrial digitalisation movement to drive productivity and growth of manufacturing industries.
Over its 160 year history, Cookson & Clegg (C&C), based in Blackburn, has gone from producing leather products and manufacturing military apparel to premium brand clothing and protective wear such as medical scrubs, gowns, and reusable face coverings. C&C is now embarking on a major data and systems integration project which will capture real-time data from every part of the production process and enable the leadership team to make informed decisions to identify efficiencies, generate more accurate pricing, and increase profitability, according to a press release by Made Smarter.
The new system also aims to stimulate a cultural revolution within the business, improving the pay and job satisfaction of its skilled team machinists, a key part of its 40 strong workforce. C&C has been supported by the Made Smarter North West Adoption programme which for the last two years has worked with 1,200 makers in every corner of the region providing advice, expertise and financial support to help them grow their business, increase competitiveness and reduce inefficiencies through digital tools and technology, Made Smarter said.
C&C’s first step with Made Smarter was to complete a digital transformation workshop, a fully funded, practical session which identified key business challenges and digital tools to overcome them. It created a bespoke roadmap involving some key projects including adopting a digital workflow system, future phases of automation, and introducing a smart factory layout.
C&C is now implementing Galaxius, a production management system that documents the whole journey of a garment from sampling to delivery. Data is transmitted, processed and then displayed in real-time on a web-based management platform, which gives the leadership team visibility of the production line. By breaking down a garment’s production into separate elements and applying a timing for each part, the business will know exactly how long it will take to produce a set number of garments and the manufacturing cost. C&C will be able to plan its production effectively, accurately assess factory capacity and provide customers with realistic delivery dates. The simpler production planning system will enable the factory manager to focus on improving processes further. The improved efficiency will remove the need for overtime, reducing factory running costs by up to 20 per cent during peak periods, according to Made Smarter.
In addition, as every stage of the critical path is tracked, C&C will be able to offer its customers full traceability of their garment through the factory and provide information for ethical and sustainable audits on who made their clothes.
“With the support and advice of Made Smarter we have been able to pursue our ambitions of improving both productivity and cost control across our operations by adopting digital technology. At the heart of this new system is the introduction of well-informed decision-making based on accurate and real-time data. By combining better production control and incentivising our workforce we believe we could increase productivity by 40 per cent, while maintaining the highest quality,” Patrick Grant, managing director of C&C said in a statement.
“C&C are the perfect example of a heritage business who are moving with the times while maintaining their identity as a traditional manufacturer. Data and systems integration is central to the fourth industrial revolution, so I am extremely pleased that C&C, like so many SME manufacturers, are putting data at the heart of their own digital journeys and recognising that using these tools can empower them to grow their business and increase efficiency. C&C is among hundreds of manufacturers in the region grasping the opportunities offered by Made Smarter which include expert, impartial technology advice, digital transformation workshops, a leadership programme, and funded digital technology internships,” Donna Edwards, Made Smarter adoption programme director, North West said.
Over its 160 year history, Cookson & Clegg (C&C), based in Blackburn, has gone from producing leather products and manufacturing military apparel to premium brand clothing and protective wear such as medical scrubs, gowns, and reusable face coverings. C&C is now embarking on a major data and systems integration project which will capture real-time data from every part of the production process and enable the leadership team to make informed decisions to identify efficiencies, generate more accurate pricing, and increase profitability, according to a press release by Made Smarter.
The new system also aims to stimulate a cultural revolution within the business, improving the pay and job satisfaction of its skilled team machinists, a key part of its 40 strong workforce. C&C has been supported by the Made Smarter North West Adoption programme which for the last two years has worked with 1,200 makers in every corner of the region providing advice, expertise and financial support to help them grow their business, increase competitiveness and reduce inefficiencies through digital tools and technology, Made Smarter said.
C&C’s first step with Made Smarter was to complete a digital transformation workshop, a fully funded, practical session which identified key business challenges and digital tools to overcome them. It created a bespoke roadmap involving some key projects including adopting a digital workflow system, future phases of automation, and introducing a smart factory layout.
C&C is now implementing Galaxius, a production management system that documents the whole journey of a garment from sampling to delivery. Data is transmitted, processed and then displayed in real-time on a web-based management platform, which gives the leadership team visibility of the production line. By breaking down a garment’s production into separate elements and applying a timing for each part, the business will know exactly how long it will take to produce a set number of garments and the manufacturing cost. C&C will be able to plan its production effectively, accurately assess factory capacity and provide customers with realistic delivery dates. The simpler production planning system will enable the factory manager to focus on improving processes further. The improved efficiency will remove the need for overtime, reducing factory running costs by up to 20 per cent during peak periods, according to Made Smarter.
In addition, as every stage of the critical path is tracked, C&C will be able to offer its customers full traceability of their garment through the factory and provide information for ethical and sustainable audits on who made their clothes.
“With the support and advice of Made Smarter we have been able to pursue our ambitions of improving both productivity and cost control across our operations by adopting digital technology. At the heart of this new system is the introduction of well-informed decision-making based on accurate and real-time data. By combining better production control and incentivising our workforce we believe we could increase productivity by 40 per cent, while maintaining the highest quality,” Patrick Grant, managing director of C&C said in a statement.
“C&C are the perfect example of a heritage business who are moving with the times while maintaining their identity as a traditional manufacturer. Data and systems integration is central to the fourth industrial revolution, so I am extremely pleased that C&C, like so many SME manufacturers, are putting data at the heart of their own digital journeys and recognising that using these tools can empower them to grow their business and increase efficiency. C&C is among hundreds of manufacturers in the region grasping the opportunities offered by Made Smarter which include expert, impartial technology advice, digital transformation workshops, a leadership programme, and funded digital technology internships,” Donna Edwards, Made Smarter adoption programme director, North West said.
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