In early 2024, Green Thread Manufacturers—a division of the Cape Union Mart Group—faced a tough reality. With operational efficiency stuck at 45%, the factory was running at a loss.
Today, Green Thread is as a profit-generating operation, with efficiency climbing to 60% in just three months. This transformation was driven by a project funded by the Localisation Support Fund (LSF) and executed with the guidance of BMA. The project utilised ‘Lost Time Analysis’ – a methodology that diagnoses the factors of lost time in production and generates solutions for it.
Tackling Problems Without Overcomplicating: Green Thread’s turnaround began with a simple but powerful principle: start with what you have. Instead of waiting for perfect data, the team used “good enough” information to pinpoint inefficiencies and tackle bottlenecks. Decisions were made faster, and resources were directed to areas where they could make the biggest difference.
Proof of concept: The project started with a model production line. This was the testing ground—a space to experiment with new ideas, refine them, and work out the kinks before rolling improvements out factory-wide. It was a low-risk way to ensure changes were effective and sustainable.
Leadership That Clears the Path: Transformations like this don’t happen without clear leadership. Factory Manager Carlien van der Vyver and Supply Chain Executive Andy Thorvaldsen kept the team focused and aligned with bigger business goals. Their consistent support and vision gave the project the momentum it needed.
A Team Effort: Leadership wasn’t the only driving force. The magic came from involving employees on the ground. From identifying problems to implementing solutions, workers played an active role in every step of the process. This approach didn’t just improve morale—it made the changes stick.
Building Momentum, One Step at a Time: The success didn’t come all at once. It grew incrementally. With each gain on the model line, the team built confidence to scale their strategies across the factory. It was a steady, deliberate process—one that transformed Green Thread’s operations without disrupting them.
What Others Can Learn: Green Thread’s story isn’t just about recovering lost time; it’s about how practical, people-centered strategies can drive lasting change. For manufacturers facing similar struggles, the lessons are clear:
- Don’t wait for perfection—use the data you have.
- Test your ideas before going all-in.
- Commit to leadership that provides clarity and focus.
- Engage your workforce—they often hold the keys to sustainable solutions.
Green Thread’s success shows that with the right mix of strategy and collaboration, even the toughest challenges can become opportunities for growth.
If you’d like to learn more about this approach, reach out to Sean Mercer, Head of Value Chain Excellence, at sean.mercer@bmanalysts.com