June 4, 2025 • 7 mins
Discover how lean manufacturing, agile supply chains, and sustainability initiatives are reshaping the t-shirt industry. Learn from case studies and expert insights to boost efficiency and resilience.
Mark as Played
Transcript
Episode Transcript
Available transcripts are automatically generated. Complete accuracy is not guaranteed.
(00:00):
Okay,so let's talk about Lean manufacturing.
(00:02):
You know, the buzzword that's everywhere,
but most people don't actually get whatit means.
Like, we're not just saying,"Work harder, people!"-we're talking real
efficiency.
The kind that can boost productivity,
what, 40, 45 percent?
Actually,
it's closer to 47.
5 percent in one case study,
and we're not pulling that number out ofthin air.
(00:23):
It's real data from a t-shirt business inLima,
Peru.
They reworked their entire productionline using Lean tools and nearly
cut idle time in half.
See, that's nuts.
And honestly, this is the part wherepeople tune out 'cause it sounds
complicated, but it's really not.
Mark, break it down-what's, like,
the easiest Lean tool to start with?
If we're keeping it simple,
(00:46):
start with 5S.
Think of it like Marie Kondo for yourshop floor.
You sort, set things in order,
shine, standardize, and sustain.
It's not just about being neat; it'sabout efficiency.
Less clutter equals fewer wasted steps,
more productivity.
Wait, wait.
So you're saying my chaotic desksituation is slowing me down?
Maybe it
is, Mo.
But here's the thing-we're not justtalking about cleaning up.
(01:07):
It's more like, where's the printer?
What tools are needed?
Where's the operator?
Are they lugging stacks of shirts acrossthe room when they could just
turn and grab 'em?
Oh, I see where you're going.
Like, if you gotta take five extra stepson every shirt,
you're throwing away time, right?
Exactly.
I actually worked with a shop that hadthis issue.
(01:28):
Their printer was way off in one corner,
forcing the operator to walk back andforth all day.
We repositioned the entire setup-printer,
Print tools, heat press,Inline shipping departments,
loading area-so it was all within arm'sreach.
And boom,
more t-shirts done, faster.
I get it.
That's productivity right there.
It's all about designing your workspace
(01:52):
to reduce waste-whether that's wastedtime,
wasted energy, or even wasted space.
These tweaks aren't expensive; you'rejust thinking smarter about the
layout.
So basically, if your workspace lookslike a tornado hit it,
fixing that could be your cheapest way toincrease output.
That's something everyone can apply.
Alright,
so we've talked about making yourworkspace more efficient,
(02:15):
but let's zoom out a bit.
What happens when the efficiency issueisn't on the shop floor but in
your supply chain?
Think about what we all went throughduring COVID-JIT sounded like the
Holy Grail until the moment those shipsstopped moving,
and everything just fell apart.
Exactly.
(02:36):
Just-In-Time is great in theory.
You know, minimal inventory,less storage space-it keeps costs low.
But when disruptions hit?
You're stranded without the materials youneed.
It's high risk.
Kinda like putting all your eggs in onebasket,
right?
Right.
You rely too much on one stream,
(02:58):
and if that stream dries up-bam,
you're in trouble.
During COVID, we had suppliers justcompletely ghost us for weeks.
That was our wake-up call to rethink howwe operated.
Wait-ghosted?
Like, no updates at all?
None.
We'd place orders,and next thing you know,
radio silence.
That's when we started looking at hybridsolutions-mixing JIT with a
(03:18):
bit of safety stock.
Y'know, keep just enough criticalmaterials on hand so you're not dead
in the water.
Okay, but doesn't that kind of kill thewhole idea of JIT
being lean?
Like, aren't we just going back toold-school stockpiling?
Not really.
You're still lean,but you're smart about it.
For example, we only stockpile certainitems-like blank t-shirts from
(03:41):
a supplier we know has long leedtimes-and we use forecasts to determine
how much.
It's not just stuffing shelves blindly.
Ah,
forecasting.
So this is where the AI stuff comes intoplay,
yeah?
Exactly.
AI-powered demand forecasting can analyzesales patterns,
seasonality, even market trends,
(04:02):
so you stock what you need,when you need it.
Companies like Walmart are all overthis-you'd be amazed at how well
they align inventory to real-time demand.
Man,
if only we had their budget, right?
But you're saying this tech's becomingmore...
what, accessible?
It is.
There are platforms designed for smallerbusinesses now.
You don't need a billion-dollarsetup-just something that helps predict
(04:26):
demand so you're proactive, not reactive.
Got it.
And if your supplier ghosts you again?
You've got backups.
That's another thing-diversifyingsuppliers.
Don't rely on just one.
Have options in different regions so ifone market's disrupted,
you can shift.
One current threat we see in the industryis two of our biggest suppliers,
Alpha Broder and S&S Activewearcombining.
Oh that is big news,
(04:50):
basically, don't marry your supplier.
I like it.
Keep 'em on their toes.
Exactly.
It's all about resilience.
You combine JIT efficiency withsafeguards like diversified sourcing,
AI forecasts, and a small buffer stock.
It's not perfect, but you're notpanicking when crisis hits.
And that's
the thing, right?
Avoid the panic.
(05:10):
Alright, so we've talked about avoidingpanic and building resilience
in supply chains,but let's zoom out even further.
Mark, how do Lean and Agile approachesfit together to drive real-world
wins?
It's simple-it gives your businessflexibility and efficiency.
Like U-shaped production lines.
Studies show they can cut SMV-standardminute value,
(05:34):
that is-by over 13%.
You can switch between products faster,
which is a game-changer, especially ifyou're juggling custom orders.
Thirteen
percent?
That's a solid chunk of time saved.
It's like hiring extra hands without...
actually hiring extra hands.
Exactly.
And it's not just about speed-it's aboutsustainability too.
(05:54):
Lean Six Sigma can reduce material wasteby 30%.
That's huge, especially now,when eco-conscious consumers are paying
attention to everything.
Oh, totally.
If your business doesn't have that greenedge,
you're kinda...
outta touch now.
I mean, "sustainable" is the new buzzword,
whether it's about shirts or coffee cups.
Right.
And big companies are already aligningwith this trend.
(06:19):
But here's the kicker-it's not just a PRmove.
Cutting waste saves money.
Like, why toss 30% of your materials?
That's literally killing your bottomline.
Yeah,
no thanks, I'll keep that money,
thank you very much.
So, what does it actually take to makeall this work,
Mark?
Beyond the numbers.
Cultural buy-in.
This is where something like Kaizen comesin-those regular improvement
(06:43):
meetings we talked about.
It fosters collaboration across teams,
breaks silos,and drives continuous improvement.
You've gotta get everyone-from the flooroperator to the managers-on
the same page.
So you're saying if my team's not onboard,
this whole shiny Lean plan is dead onarrival?
Pretty much.
But when you nail the culture,
these things stick.
(07:04):
Continuous improvement becomes,
well, continuous.
You're always one step ahead.
Alright,
I'm sold.
Lean, agile,sustainable-it's the trifecta.
And if you're listening out there andyou've been thinking about leveling
up your t-shirt game, now's the time.
Get started today-head over tocontract-dtg.
com,
where we've got your back for all yourcustom apparel needs.
And that's
(07:26):
a wrap for today, folks.
Remember, it's not just about workingsmarter-it's about building a business
that lasts.
Until next time, keep it lean and mean.
Okay,so let's talk about Lean manufacturing.
(00:02):
You know, the buzzword that's everywhere,
but most people don't actually get whatit means.
Like, we're not just saying,"Work harder, people!"-we're talking real
efficiency.
The kind that can boost productivity,
what, 40, 45 percent?
Actually,
it's closer to 47.
5 percent in one case study,
and we're not pulling that number out ofthin air.
(00:23):
It's real data from a t-shirt business inLima,
Peru.
They reworked their entire productionline using Lean tools and nearly
cut idle time in half.
See, that's nuts.
And honestly, this is the part wherepeople tune out 'cause it sounds
complicated, but it's really not.
Mark, break it down-what's, like,
the easiest Lean tool to start with?
If we're keeping it simple,
(00:46):
start with 5S.
Think of it like Marie Kondo for yourshop floor.
You sort, set things in order,
shine, standardize, and sustain.
It's not just about being neat; it'sabout efficiency.
Less clutter equals fewer wasted steps,
more productivity.
Wait, wait.
So you're saying my chaotic desksituation is slowing me down?
Maybe it
is, Mo.
But here's the thing-we're not justtalking about cleaning up.
(01:07):
It's more like, where's the printer?
What tools are needed?
Where's the operator?
Are they lugging stacks of shirts acrossthe room when they could just
turn and grab 'em?
Oh, I see where you're going.
Like, if you gotta take five extra stepson every shirt,
you're throwing away time, right?
Exactly.
I actually worked with a shop that hadthis issue.
(01:28):
Their printer was way off in one corner,
forcing the operator to walk back andforth all day.
We repositioned the entire setup-printer,
Print tools, heat press,Inline shipping departments,
loading area-so it was all within arm'sreach.
And boom,
more t-shirts done, faster.
I get it.
That's productivity right there.
It's all about designing your workspace
(01:52):
to reduce waste-whether that's wastedtime,
wasted energy, or even wasted space.
These tweaks aren't expensive; you'rejust thinking smarter about the
layout.
So basically, if your workspace lookslike a tornado hit it,
fixing that could be your cheapest way toincrease output.
That's something everyone can apply.
Alright,
so we've talked about making yourworkspace more efficient,
(02:15):
but let's zoom out a bit.
What happens when the efficiency issueisn't on the shop floor but in
your supply chain?
Think about what we all went throughduring COVID-JIT sounded like the
Holy Grail until the moment those shipsstopped moving,
and everything just fell apart.
Exactly.
(02:36):
Just-In-Time is great in theory.
You know, minimal inventory,less storage space-it keeps costs low.
But when disruptions hit?
You're stranded without the materials youneed.
It's high risk.
Kinda like putting all your eggs in onebasket,
right?
Right.
You rely too much on one stream,
(02:58):
and if that stream dries up-bam,
you're in trouble.
During COVID, we had suppliers justcompletely ghost us for weeks.
That was our wake-up call to rethink howwe operated.
Wait-ghosted?
Like, no updates at all?
None.
We'd place orders,and next thing you know,
radio silence.
That's when we started looking at hybridsolutions-mixing JIT with a
(03:18):
bit of safety stock.
Y'know, keep just enough criticalmaterials on hand so you're not dead
in the water.
Okay, but doesn't that kind of kill thewhole idea of JIT
being lean?
Like, aren't we just going back toold-school stockpiling?
Not really.
You're still lean,but you're smart about it.
For example, we only stockpile certainitems-like blank t-shirts from
(03:41):
a supplier we know has long leedtimes-and we use forecasts to determine
how much.
It's not just stuffing shelves blindly.
Ah,
forecasting.
So this is where the AI stuff comes intoplay,
yeah?
Exactly.
AI-powered demand forecasting can analyzesales patterns,
seasonality, even market trends,
(04:02):
so you stock what you need,when you need it.
Companies like Walmart are all overthis-you'd be amazed at how well
they align inventory to real-time demand.
Man,
if only we had their budget, right?
But you're saying this tech's becomingmore...
what, accessible?
It is.
There are platforms designed for smallerbusinesses now.
You don't need a billion-dollarsetup-just something that helps predict
(04:26):
demand so you're proactive, not reactive.
Got it.
And if your supplier ghosts you again?
You've got backups.
That's another thing-diversifyingsuppliers.
Don't rely on just one.
Have options in different regions so ifone market's disrupted,
you can shift.
One current threat we see in the industryis two of our biggest suppliers,
Alpha Broder and S&S Activewearcombining.
Oh that is big news,
(04:50):
basically, don't marry your supplier.
I like it.
Keep 'em on their toes.
Exactly.
It's all about resilience.
You combine JIT efficiency withsafeguards like diversified sourcing,
AI forecasts, and a small buffer stock.
It's not perfect, but you're notpanicking when crisis hits.
And that's
the thing, right?
Avoid the panic.
(05:10):
Alright, so we've talked about avoidingpanic and building resilience
in supply chains,but let's zoom out even further.
Mark, how do Lean and Agile approachesfit together to drive real-world
wins?
It's simple-it gives your businessflexibility and efficiency.
Like U-shaped production lines.
Studies show they can cut SMV-standardminute value,
(05:34):
that is-by over 13%.
You can switch between products faster,
which is a game-changer, especially ifyou're juggling custom orders.
Thirteen
percent?
That's a solid chunk of time saved.
It's like hiring extra hands without...
actually hiring extra hands.
Exactly.
And it's not just about speed-it's aboutsustainability too.
(05:54):
Lean Six Sigma can reduce material wasteby 30%.
That's huge, especially now,when eco-conscious consumers are paying
attention to everything.
Oh, totally.
If your business doesn't have that greenedge,
you're kinda...
outta touch now.
I mean, "sustainable" is the new buzzword,
whether it's about shirts or coffee cups.
Right.
And big companies are already aligningwith this trend.
(06:19):
But here's the kicker-it's not just a PRmove.
Cutting waste saves money.
Like, why toss 30% of your materials?
That's literally killing your bottomline.
Yeah,
no thanks, I'll keep that money,
thank you very much.
So, what does it actually take to makeall this work,
Mark?
Beyond the numbers.
Cultural buy-in.
This is where something like Kaizen comesin-those regular improvement
(06:43):
meetings we talked about.
It fosters collaboration across teams,
breaks silos,and drives continuous improvement.
You've gotta get everyone-from the flooroperator to the managers-on
the same page.
So you're saying if my team's not onboard,
this whole shiny Lean plan is dead onarrival?
Pretty much.
But when you nail the culture,
these things stick.
(07:04):
Continuous improvement becomes,
well, continuous.
You're always one step ahead.
Alright,
I'm sold.
Lean, agile,sustainable-it's the trifecta.
And if you're listening out there andyou've been thinking about leveling
up your t-shirt game, now's the time.
Get started today-head over tocontract-dtg.
com,
where we've got your back for all yourcustom apparel needs.
And that's
(07:26):
a wrap for today, folks.
Remember, it's not just about workingsmarter-it's about building a business
that lasts.
Until next time, keep it lean and mean.
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