How did Lipimalhas increase its productivity by 81%?

Testimonial
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“With proGrow, we collect machine data in a practical way and keep a real-time pulse on our operations.”

Customer
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Lipimalhas - Malhas e Confecções, S.A. is a company based in São Martinho do Campo, specializing in the design and production of outerwear knitwear. With a strong commitment to innovation and sustainability, Lipimalhas leverages advanced technologies to create high-quality products focused on durability and customer comfort.

The company is recognized for its ability to integrate sustainable production processes that not only respect the environment but also meet the demands of a constantly evolving market. Lipimalhas' main goal is to fulfill customer needs by delivering exceptional service and top-quality products.

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Challenge

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Lipimalhas faced challenges in obtaining reliable data to support strategic decision-making on the shop floor.

The company had limited visibility into employee performance, particularly regarding the time spent producing garments and samples. This lack of detailed insights restricted the ability to accurately assess efficiency and product costs, making it difficult to control expenses and optimize productivity.

Driven by the goal of increasing productivity and improving cost control, Lipimalhas identified the need for a solution that could monitor, in real-time, the time spent on each piece. Additionally, the company sought a way to measure employee efficiency—not only to enhance processes but also to establish a performance-based reward system grounded in real, objective data.

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Solution
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The initial adaptation of proGrow into Lipimalhas’ processes was met with a positive reception and high motivation from employees. The team embraced the new digital tools and processes, recognizing their potential impact on production control and efficiency.

However, implementing proGrow presented some specific challenges. It was necessary to install sensors and create electrical panels for many machines, as most were still "analog" and could not be digitally integrated immediately. Additionally, there was a fundamental shift in data focus—from a machine-centric approach to a people-centric one—allowing for a more detailed analysis of each team's performance.

To create a more dynamic and productive work environment, a healthy sense of competition was encouraged between factory sectors, motivating teams to achieve better results.

At first, transitioning to a digital system raised concerns among employees, particularly regarding production tracking and machine downtime recording. Moving from manual logging to automated production control represented a major paradigm shift that initially sparked hesitation.

The introduction of increased operational oversight caused some resistance among employees. However, Lipimalhas addressed these concerns through continuous training and transparent communication, clarifying that the ultimate goal was to provide more accurate and reliable cost assessments. This approach helped alleviate initial fears, ensuring a smooth integration of proGrow into the company’s culture.

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Results
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The implementation of proGrow at Lipimalhas delivered significant and measurable results, leading to a substantial increase in productivity and a reduction in unplanned downtimes.

With an 81% boost in productivity (equivalent to a 26 percentage point increase) when comparing the period from October to December 2023 with August to October 2024, Lipimalhas established a new efficiency benchmark. Additionally, unplanned downtimes were reduced by 39%, which translates to 38 fewer minutes of downtime per machine per day.

Although the initial targets were not clearly defined due to the lack of reliable data, the improvements exceeded expectations, representing a significant advancement over the previous state.

proGrow’s impact extended beyond efficiency, also improving communication and process flexibility. With real-time visibility of individual performance and production, employees can respond immediately to issues and anticipate potential delays. This new dynamic speeds up response times and fosters greater collaboration between teams, enabling a smoother and more effective operation.

The work environment also saw a significant reduction in administrative tasks, as data recording and analysis became automated, freeing up time for productive efforts. Lipimalhas’ management now benefits from enhanced visibility over production processes, allowing real-time monitoring of ongoing operations. Any management team member can now check the progress of manufacturing orders, assess employee efficiency, and proactively support those in need.

Additionally, access to historical data enables Lipimalhas to accurately calculate the cost of each piece based on actual production time. The detailed insights provided by proGrow also help identify key causes of downtime and pinpoint the employees with the greatest impact on factory efficiency. This data-driven approach supports the creation of new continuous improvement initiatives, reinforcing the company’s commitment to operational excellence.

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•  81% increase in productivity
•  39% reduction in unplanned downtimes

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