Organization
Define the right organogram. Recruit with an effective methodology. Train at every level. Plan incentives.
Garment factory consulting, India
Factories engineered for productivity, quality and profit.
BENCI Consulting is a management consulting firm for textile, apparel and retail. We take on strategy, implementation, skill development and transaction advisory assignments.
- 55–60%line efficiency within a year
- 2.0 or lessman-to-machine ratio
- Up to 40%operator efficiency within 6 weeks of training
- About 50%lower inventory through lean manufacturing tools
What we deliver
We help apparel manufacturers and investors
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Turnkey
Start a factory that runs right from day one.
Turnkey establishment of an engineered apparel factory, with the right organization, technology, infrastructure and processes designed together.
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55–60%
Raise productivity and line efficiency.
Trained operators reach up to 40% efficiency within 6 weeks, and lines reach 55–60% within a year.
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−24%
Cut cost per piece and working capital.
A re-engineering project for a women's wear exporter reduced cost per piece by 24%. Lean tools bring inventory down by about 50%.
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99%
Hold quality and compliance.
A 99% cut-to-ship ratio for standard products, with full compliance to Safety, Health and Environmental norms.
The hidden cost
Seven mistakes that cost an apparel investor money every year
Most of them are made before the first machine is switched on: flawed layout, wrong technology spend, weak training and overstaffing, no information capture, excess working capital, and the wrong software.
For a 250 machine set-up, these mistakes mean a loss of
2.5 lakh pieces of production
and Rs. 2.5 crore in profits
every year.
BENCI Engineered Factory
One factory, four pillars
An engineered apparel factory has trained manpower, optimum technology, ideal infrastructure and rationally designed processes. BENCI designs and builds all four together, so the factory performs from the first production day.
Technology
Select the right machinery and the right software. Use work-aids and attachments well.
Infrastructure
Build the right infrastructure. Plan the physical layout to the product mix. Plan utilities.
Processes
Design and implement department-wise SOPs. Set up quality control, industrial engineering, training and MIS. Implement the software systems.
Measured outcomes
Results delivered for manufacturers
Women's wear exporter
Home textile manufacturer
Andhra Pradesh, India
Why BENCI
Experience on the factory floor, in several countries
Projects in India, Bangladesh, Vietnam and Ethiopia, in factories from 150 to 6,000 machines.
150 to 6,000machines per factory
- India
- Bangladesh
- Vietnam
- Ethiopia
Planning a new factory, or fixing the one you have?
Tell us the machine count, the product mix and the target. We will come back with how the Engineered Factory approach applies.
Talk to our team