AUTOMATING MADE TO MEASURE AND REENGINEERING SIZE FIT ISSUES & RETURNS
Category
Returns Management, Value Stream Mapping, Data Mining & Analysis, Develop Algorithm, Design Interface input, Product Categorization
Applications
Gerber technology , MINITAB, MS EXCEL
Year
2020
OBJECTIVE
Fixing high returns from a specific demographic are hindered specifically in coats hem, causing discomfort and functional issues. Communication gaps between dealers and customers result in incorrect size inputs, neglecting proper ease considerations where customer could not understand the fit preference ease they receive.
OUTCOME
Reduced process cycle time eliminated non-value-added (NVA) time of 40hrs/week through automation embedding nested formulas for sizing verification avoiding manual errors.
Provided dealers and product users with visibility to products for alteration by developing interface CRM, flexibility to customize alterations, and consistent data fields, improving customer experience.
Enhanced efficiency in addressing customer complaints by using the tool to identify root causes and quantify return issues. Analyzed variance in garment fit for various body types and formulated solutions, resulting in a 15% reduction in product sales returns and a $1.4M boost in manufacturing revenue.
Defining Body Type of Demography with Waist Hip Ratio
Analyzing ease across different body types reveals variations that pinpoint where special alterations are necessary to address sizing issues effectively. This analysis is pivotal in identifying areas where adjustments are needed to ensure optimal fit and comfort for each individual. By understanding these variances, we can implement targeted alterations that resolve size discrepancies, thereby enhancing the overall garment fit and customer satisfaction. This meticulous analysis forms the cornerstone of our sizing strategy, allowing us to tailor solutions that cater to the diverse needs of our clientele.
FUNCTIONAL MAP FOR AUTOMATION TO CHOOSE BASE PATTERN
Our decision-making algorithm compares size input values to determine the appropriate base pattern and associated special alterations based on the discerned body type. This process ensures precision in tailoring garments to fit individual shapes and sizes, enhancing customer satisfaction and optimizing the design process.
CHALLENGES WHEN HIP = WAIST
When a customer's hip/waist measures smaller than or equal to 45/40, and the hip measurement is smaller than the base size indicated in the chart, the hip measurement is disregarded. Instead, the customer's waist measurement is used as the base size. This adjustment is made to ensure accurate sizing for individuals with smaller hip measurements. Additionally, when the waist measurement exceeds the chosen base model's hip measurement, it is compared with the chest measurement to determine the sweep, resulting in increased hem ease to accommodate this difference.
VALUE STREAM MAPPING OF SIZING PROCESS
