Case Study: Carhartt achieves 13% higher efficiency and real-time shop-floor visibility with Exenta Shopfloor Control

Leverages Shopfloor Control to increase efficiency and support strategic transformation and growth

Carhartt, a century-old North American workwear brand with over 3,500 associates across seven U.S. and Mexico facilities, needed to modernize shop floor operations to support rapid growth. The company relied on a batch-based system with paper "gum sheets," lacked real-time production visibility, and had inflexible, time-consuming payroll processes that prevented scalable customization of incentive pay.

Carhartt implemented Exenta Shopfloor Control — a real-time MES using Android tablets and dashboards — to capture production data, enable customizable pay rules, and give supervisors and managers instant visibility. The system helped eliminate bottlenecks, increased average efficiency by 13%, saved about 320 person-hours per payroll (≈ $60,000 annually) by automating pay calculations and redeploying three payroll staff, improved associate trust with transparent incentives, and supported rapid operational changes during the pandemic.

Carhartt

Katrina Agusti

Carhartt