Improving Fabric Cutting Efficiency and Quality Through Automation At PT Apparel One Indonesia 3
Abstract
The manual fabric preparation and cutting process in the pre-production warehouse area of PT Apparel One Indonesia 3 leads to cycle time delays, high defect rates (dirty cuts, slanted cuts, and size discrepancies), and financial losses for the company. This study aims to design, implement, and evaluate the effectiveness of an automated dual-function fabric cutting machine (roll-to-roll and roll-to-sheet) based on digital sensors to replace manual methods in the warehouse area. The research adopts a structured four-stage approach: baseline data collection, root cause analysis using fishbone diagrams, 5 Whys, and a 5W+2H matrix, machine design and implementation, and comparative evaluation (before-after) of operational parameters. Operational trial results over three months (October–December 2025) demonstrate that the automated machine significantly enhanced cutting speed by 125%, increasing from 80 m/hour to 180 m/hour. Furthermore, accumulated fabric defects were drastically reduced by 98.1%, dropping from 126.25 m to only 2.4 m. The implementation of this automation innovation proves successful in achieving cutting size standardization while delivering a positive economic impact with cost savings of IDR 23,277,000 from material waste reduction.
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