Case Study: TAL Apparel Group achieves $2.1M fabric savings and faster pre-production with Lectra Optiplan

Tal Group Hong Kong Improves Pre-Production Efficiency With Lectra Technology

TAL Apparel Group, a Hong Kong–headquartered manufacturer with 25,000 employees, 10 factories in Southeast Asia and an annual output of over 55 million garments for 30+ global brands, needed to boost pre‑production efficiency to stay competitive. The company’s challenge was to harmonize orders, reduce fabric consumption and maximize labor productivity while maintaining high quality across a complex supply chain.

In 2012 TAL adopted Lectra’s Optiplan cut‑plan and order management solution, integrating it into an automated replenishment system. The move cut manual planning time (Lectra: 10 minutes vs. 30+ minutes manually), improved consistency and visibility, and delivered tangible savings—about $2.1M annually (roughly 1% of fabric use)—with around 30% of clients already benefiting from the streamlined replenishment workflow.

TAL

Delman Lee

President and CTO