Case Study: Wacoal America achieves 20% productivity gain and reduced costs with Lectra's lean cutting-room and Vector solution

Wacoal America - Customer Case Study

Wacoal America’s Dominican Republic site, which employs about 1,300 people and produces some 4.7 million undergarments a year (roughly 60% of the company’s international output), needed to increase production by 20–30% to meet rising US and global demand without raising costs. The plant’s fine, high-quality fabrics and small stretch pieces required more cutting capacity and a more efficient pre-production process.

Working with long‑time partner Lectra, Wacoal implemented a phased lean cutting‑room program—combining consulting, operator training and new Vector Lingerie ix6 cutting technology (with Modaris and Diamino support)—to streamline flow and eliminate non‑value tasks. The result: throughput rose about 20%, raw material use improved ~3%, machine uptime and quality increased, and the site absorbed new business without adding hours, while employee morale benefited from clearer, cleaner processes.

Wacoal America

Virgilio Estévez

Plant Manager