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Tukatech

A Case Study

Advanced Garments Through Advanced Production Methods

About EAM Maliban

Established in 1974 Over 12000 employees 14 Manufacturing facilities in Sri Lanka and Jordan Specializing in high-quality shirts, blouses, pants, skirts, and wet processing Utilizing TUKAcad and SMARTmark Company Vision "Proactively develop our competency and technology to the increasingly competitive global market." Customers include GAP, Banana Republic, Land's End, Marks & Spencer, Kohl's, Eddie Bauer, Dillard's, Sears, Burberry, Westside

EAM Maliban produces stylish, high-quality women's tops and blouses. Founded in 1974, EAM Maliban is one of Sri Lanka's largest and most technologically advanced garment manufacturers. Based out of Colombo, EAM Maliban consists of 16 factories in Sri Lanka and Jordan, and is known as one of the world's leaders in the field of wet processing and high-end, value-added garments. The company is so committed to innovation that EAM Maliban has its own product and technology development lab, where experts develop new washes and finishes to provide the company's customers with cutting edge products that can't be produced at any other company. Like many Sri Lankan manufacturers, the company has been quick to embrace technology of all types, which has helped them gain a strong foothold in the competitive garment industry. With more than 12,000 employees, EAM Maliban produces a wide range of tops and bottoms for men and

Tukatech

Case Study

women for customers like GAP, Banana Republic, Land's End, Marks & Spencer, Kohl's, Eddie Bauer, Dillard's, Sears, Burberry, and Westside. Azeem Ismail, CEO of EAM Maliban, looks for experience and ability in his workers. When describing his employees and their productivity, he emphasizes that they should have a complete knowledge of how garments are made so that they can understand their role in the process and make the best and most efficient contribution to the entire process. It is this emphasis on efficiency that drew Azeem and EAM Maliban to Tukatech's systems. "If an experienced pattern maker is trained correctly on Tukatech, than I would say that that pattern maker will definitely be more productive," said Azeem. "We want our pattern makers to have a lot of practical experience with sewing and physically making patterns. Many of the newer guys don't yet have that experience." In 2005, EAM Maliban's grading and marker making was done through a competing CAD system. While Azeem was satisfied with the software, he had heard that other companies were using TUKAcad, and more fully utilizing the capabilities of CAD software, including completely digital pattern making. "In the apparel industry, we must be proactive rather than reactive," said Azeem. "When I see something that is saving time and money for other garment manufacturers in Sri Lanka, I know we need to

Azeem Ismail, CEO, EAM Maliban, at the company's Colombo headquarters.

jump on it." After meeting with Tukatech CEO Ram Sareen in 2005, Azeem decided to switch some of his CAD stations to Tukatech. Upon seeing successful results, including patterns with better accuracy, faster approval times, and a general improvement in efficiency, Azeem converted the remaincompany." "We use Tukatech for pattern making, grading, and marker making," said Sharaz Faruk, Director of Marketing for EAM Maliban "It's great because we have centralized all of these processes into one system." TUKAcad's comprehensive garment production capabilities have also allowed Azeem

"When I see something that is saving time and money for other garment manufacturers in Sri Lanka, I know we need to jump on it." -Azeem Ismail, CEO, EAM Maliban

der of EAM Maliban's systems to Tukatech. "When we bought Tukatech in 2005, we immediately saw a definite change," said Azeem. "And in those six years, we have grown significantly as a to refine the production process at his factories, allowing for better efficiency and faster turnaround times. "We never used to do grading until we were styling. With Tukatech, we are grading much earlier

Tukatech

Case Study

in our production process, and that is one of the greatest improvements we have made," said Azeem. As EAM Maliban continues to achieve new levels of production efficiency, Azeem says that he is generally satisfied with Tukatech, and that he has seen improvements across the board. "Since installing Tukatech, what we were once doing with 35 pattern makers, we are now doing with only 20," said Azeem. "Today, the business has changed, and lead times have shrunk significantly," said Sharaz. "The number of styles we are asked to do has increased, with the same large quantity for each style. Tukatech has helped us to improve our lead times significantly, and we have been able to manage the large expectations our customers have for us." "We can't specifically quantify the ways that Tukatech has improved our operation, because we have expanded so much since implementing the system," said Azeem. But he says that his staff has been pleased with the implementation of Tukatech. "We looked at Tukatech, and saw that it could save us time in our

EAM Maliban uses a variety of wet processing techniques to give their denim unique and stylish looks.

manufacturing process. We realized it could save us time on making patterns, and it definitely has." As the most advanced apparel production software on the market, Tukatech has proven time after time that it is the best choice for producers of complex, highly technical value-added garments. TUKAcad's ability to calculate shrinkage more accurately than any other competing software has rendered it an essential tool for companies like EAM Maliban that specialize in advanced washing techniques. "EAM Maliban offers a lot of variation in our product," said Azeem. "Our products offer an enormous value addition, and it is this that will continue to be our selling point." In addition to the system's shrinkage calculation capabilities, TUKAcad has proven to be excellent at cut planning, something Azeem says he is particularly pleased with. "In my eyes, Tukatech's best feature is its capability for cut planning," said Azeem. "Fabric is money, and by using Tukatech, we can save a significant amount of both." In addition to the many technical features that TUKAcad provides, Azeem said that the simple fact is that all of the factories within EAM Maliban have increased the strength of their collaboration and communication by standardizing their pattern making across the company. Additionally, Azeem explained that Tukatech has made it easier for his pattern makers to work with buyers. "It is a lot easier to communicate with our factories and our buyers using Tukatech's digital sample making software. It is simple to communicate changes and then to institute those same changes in a short amount of time."·

About

Tukatech

Tukatech is a Los Angeles-based company that provides 2D and 3D software solutions and manufacturing equipment to garment producers. It also provides web-based product development services and PDM/PLM systems, supported by brick and mortar centers strategically located in garment hubs worldwide. With over 12,000 systems sold and about 3,500 competitive systems replaced, Tukatech is the fastest growing garment CAD/CAM company in the world. Tukatech has been ranked by Apparel Magazine as the #1 Apparel software company in the world.

Tukatech

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