Case Study: Carhartt achieves 13% higher line efficiency and $60K annual payroll savings with Aptean Apparel Shop Floor Control

Carhartt leverages Aptean Apparel Shop Floor Control to increase efficiency and support strategic transformation and growth

Carhartt, a leading North American workwear manufacturer with about 4,000 associates across seven U.S. and Mexico facilities, faced scaling challenges from legacy, batch-based systems that lacked real-time shop floor visibility, required time‑consuming “gum sheet” payroll processes, and offered limited flexibility for variable pay—creating production bottlenecks and slow managerial response.

Implementing Aptean Apparel Shop Floor Control—a real-time MES with an Android app and tablet interfaces—gave Carhartt live production and operator performance data, customizable incentive and training-pay rules, and an easy-to-use shop floor experience. Results included a 13% average increase in line efficiency across seven plants, elimination of manual payroll work (saving 320 hours per pay period and roughly $60,000 annually), redeployment of three payroll staff, and faster adaptation to changing production needs.

Carhartt

Katrina Agusti

Carhartt