SAE-A’s supply chain is fully vertically integrated. Our capabilities include best-in-industry research, leading design work, production of garments and superior retail experience. This allows us to provide our clients with a fully complete experience from concept to product. Tracing the production of a garment from concept to completion illustrates SAE-A's work. The production of a cotton garment is best summarized in 10 processes:
From our founding, we have worked to provide customers with the highest quality products and production services. In 2001, we added design and research and development capabilities helping us best understand and integrate the customer’s vision from concept to creation. Several of the components of these efforts include:
SAE-A's apparel manufacturing process spans the entire supply chain from working with customers on design and fabric selection to the delivery of finished garments.
There are three main components of the manufacturing process:
To increase efficiency and ensuring the highest quality, SAE-A has established complete vertical integration by bringing the entire process under one umbrella. To do this, we have applied a Lean Management system.
Seeking to reduce costs, improve quality and streamline our supply chain, SAE-A has worked to realize full vertical integration. One example of vertical intergration is the Spinning Mill in Costa Rica that supplements fabric production and reduces overall production lead time.
: Will support smarter decision making by applying the MES (Manufacturing Execution System) which optimizes the management of both manufacturing and operations while making all data from the manufacturing floor immediately available and easily accessible according to the following schedule:
l Sewing automation means real-time production monitoring through sensors installed at each sewing machine
l QC automation takes the digital data from the test results and records in real-time.
l Packaging automation will automate many of the existing manual functions and also provide for real-time production flow and output monitoring
l Cutting automation will maximize efficiency through network connected machinery.
l Warehouse automation allows for real-time inventory management and optimizes operations by introducing a computerized warehouse management system.
: Provides real-time updates of the flow of materials in and out of the warehouse while optimizing the logistics of shipping, receiving and inventory management by maximizing the use of computerized equipment and minimizing space within the distribution center under one centralized warehouse management system.
Lean Management is the process through which SAE-A focuses on value and safety to achieve our goal of providing the best quality product. The company has established its own rules of Lean Management that promote best practices, process, eliminate waste, and ultimately standardize best practices. As with the majority of SAE-A's initiatives, training is critical to the implementation of these practices and we provide courses and training to all employees across the company.
SAE-A also encourage all of our facilities to provide suggestions for improving work-flow, efficiency, work experience, and quality of the end product. Suggestions from our facilities have become best practices across the company.
SAE-A’s quality assurance protocols ensure SAE-A facilities maintain the highest production standards, and in turn, highest levels of customer satisfaction.