Case Study: JA Apparel Corp. achieves increased productivity and reduced cycle times with CGS BlueCherry Shop Floor Control

Bluecherry Shop Floor Control (Formerly Leadtec) Empowers “Made In America” Strategy At Joseph Abboud

JA Apparel Corp., the maker of the Joseph Abboud JA Collection and Personal Style System, operates a 400,000 sq. ft. New Bedford facility committed to “Made in the USA.” Facing the typical challenges of domestic apparel manufacturing—high labor content, long training curves, variable order sizes, and pressure to shorten lead times—JA Apparel sought a technology partner to improve productivity, visibility, and cost management and turned to CGS and its BlueCherry® Shop Floor Control solution.

CGS implemented BlueCherry® Shop Floor Control plant-wide (350+ terminals in sewing, terminals in cutting, RFID-enabled finishing, and integration with an Eton unit production conveyor), automating time capture, individual incentives, payroll and real-time production visibility. The results: sewing efficiency rose from ~80% to over 110%, cutting productivity improved more than 40%, order-to-shipment lead times fell from 12 weeks to under 4 (made-to-measure in 7–10 days), WIP fell from 16 to 10 days and assembly inventory from 5,000 to <1,500 units, training time decreased ~30% (12 to ~8 weeks), and labor standards improved (average 5%–12% reductions), demonstrating CGS’s measurable impact on JA Apparel’s competitiveness.

JA Apparel Corp.

Anthony Sapienza

President and CEO