Textile & Apparel

Digital Transformation in Textiles: 48% Less Production Waste with SAP

From yarn to garment, Turkey’s leading textile manufacturers are no longer just producing; they’re optimizing, designing, and shifting toward sustainable growth with SAP. At OCY Consulting, we deliver end-to-end digitalization across the entire value chain, from production to design, powered by SAP S/4HANA and industry-specific modules.

 

Industry Challenges & Our Solutions

1. Production Waste Analysis

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Problem: Up to 12% waste rate in fabric cutting and sewing processes

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Solution: SAP PP combined with AI-powered waste analysis and production planning optimization

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Result: 48% reduction in waste rates and 22% savings in production costs

2. Raw Material Optimization

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Problem: Excess inventory and quality deviations in yarn production facilities managing over 300 raw materials

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Solution: SAP MM + SAP IBP combined with AI-powered quality matching and inventory planning

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Result: 30% reduction in raw material stock costs and 65% decrease in quality mismatches

3. Fast Collection Cycle

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Problem: Lengthy transition time from design to production in seasonal product lines

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Solution: SAP PLM combined with SAP Fashion Management for streamlined product lifecycle and merchandising control

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Result: Collection launch time reduced from 6 weeks to 2.5 weeks

How Apparel Producers Drive Transformation with SAP?

1. 3D Design Integration

Problem: Manual workflows and time loss during the transition from design to prototype to production

SAP Solution:

Integration of SAP PLM with 3D design tools (e.g., CLO, Browzwear)

Digital product lifecycle management across design and manufacturing

Case Study: Sample Production Time Reduced by 60% at a Sportswear Brand

2. Order & Distribution Management

Problem: Challenges in on-time delivery to global retail chains

SAP Solution:

Integration of SAP TM and SAP EWM

Route optimization and accelerated warehouse operations

Case Study: A denim manufacturer reduced shipment lead time from 72 hours to 36 hours

3. Sustainability & Recycling

Problem: Low recycling rates of production waste and increasing regulatory pressure

SAP Solution:

SAP EHS combined with SAP Waste Management

Carbon footprint and recycling dashboards for real-time monitoring and compliance

Case Study: A lingerie manufacturer increased its recycling rate from 21% to 47%

Why Choose OCY for SAP S/4HANA?

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Industry References:

We’ve provided SAP consulting to 8 of Turkey’s top 20 textile manufacturers; demonstrating our deep sector expertise and proven results.

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Customized Modules:

We design SAP configurations specifically for yarn, fabric, and garment production workflows; enabling process alignment and operational efficiency.

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Integrated Capabilities:

End-to-end digital collection management through SAP PLM, Fashion Management, and 3D design tool integration (e.g., CLO, Browzwear)