contents MAY volume 57/number 9 COVERSTORY This year’s crop of Innovators is on the front lines when it comes to har nessing technology to please their customers and make their businesses run better. In the profiles that follow, you’ll learn how companies are innovating in a multitude of ways, from new product ideation, to tapping into data to improve fit and maximize fabric yield, to refining garments for particular professions, to embracing BI for greater insight into supply chains and in ventory, to forging new digital strategies and much, much more. BY JORDAN K. SPEER,JESSICA BINNS,DEENA M. AMATO-MCCOY AND LIZ HARTNETT INNOVATOR . . . . . . . . . . . .PAGE INNOVATOR . . . . . . . . . . . .PAGE ABL Denim . . . . . . . . . . . . . . . . .14 Jaco & Associates . . . . . . . . . . . .40 Alchemi Labs . . . . . . . . . . . . . . .25 Jet Blue Airlines . . . . . . . . . . . . .23 Anatomie . . . . . . . . . . . . . . . . . .20 Lacoste . . . . . . . . . . . . . . . . . . . .41 Ashley Stewart . . . . . . . . . . . . . .37 Lucky Brand . . . . . . . . . . . . . . . . .9 Beija Flor Jeans . . . . . . . . . . . . .34 Madura Fashion & Lifestyle . . . .26 CCW Breakaways . . . . . . . . . . . .12 MAS Active . . . . . . . . . . . . . . . . .18 Century Place Apparel . . . . . . . .21 Nautica . . . . . . . . . . . . . . . . . . . .25 Chef Works . . . . . . . . . . . . . . . . .28 New Balance . . . . . . . . . . . . . . . .14 Chinese Laundry . . . . . . . . . . . . .47 Omega Apparel . . . . . . . . . . . . . .17 Cintas . . . . . . . . . . . . . . . . . . . . .43 Only Nine Apparel . . . . . . . . . . . .36 Columbia Sportswear . . . . . . . . .35 Patagonia . . . . . . . . . . . . . . . . . .16 Delta Apparel . . . . . . . . . . . . . . .21 Reebok . . . . . . . . . . . . . . . . . . . .10 Dropel Fabrics . . . . . . . . . . . . . . .35 SOL . . . . . . . . . . . . . . . . . . . . . . .44 DXL . . . . . . . . . . . . . . . . . . . . . . .31 Tommy John . . . . . . . . . . . . . . . .11 F&F Clothing (Tesco) . . . . . . . . . .24 Town Shoes . . . . . . . . . . . . . . . . .39 FILA . . . . . . . . . . . . . . . . . . . . . . .22 Urban Outfitters . . . . . . . . . . . . .22 Fittery . . . . . . . . . . . . . . . . . . . . .30 Venroy . . . . . . . . . . . . . . . . . . . . .45 Hardwick.com . . . . . . . . . . . . . . .19 Vivienne Westwood . . . . . . . . . .30 Herman Kay . . . . . . . . . . . . . . . .40 Zobha . . . . . . . . . . . . . . . . . . . . .46 Ivory Ella . . . . . . . . . . . . . . . . . . .42 TOP INNOVATOR SPONSORS It’s no secret that listening to the consumer is a This year’s crop of Innovators is on the front lines critical component of retail success, but the role when it comes to harnessing technology to please that technology is playing in both listening to the their customers and make their businesses run consumer and enabling solutions to meet their better. In the profiles that follow, you’ll learn how desires is at an all-time high. Consider first that companies are tapping into data to improve fit and consumers are sharing more than ever before via maximize fabric yield, to refine garments for social media. That advanced algorithms are particular professions and gain greater insight into enabling companies to yield more actionable inventory. One of this year’s Innovators is intelligence from the data they gather — which is incorporating a smart yarn into its denim that uses greater than it’s ever been before — data that can infrared technology to improve the appearance of then be fed back into the supply chain to improve cellulite by absorbing body heat. Another has everything from design to sourcing to fulfillment to stepped away from the brink of bankruptcy in part assortment planning to marketing. Apparel by tapping into the joy created by the friendships companies are also able to respond better to that had developed at the store level between consumer demands due to rapid advances in associates and customers. materials technology and IoT that are enabling the development of more comfortable and functional We honor all of our innovators for listening to their and stylish apparel. The variety of innovation in our customers, for their hard work — and for their industry is nothing short of remarkable. moments of inspiration that fuel excitement and progress for our entire industry. Lucky Brand Jeans Los Angeles, Calif. | www.luckybrand.com NOMINATED BY: NetSuite | www.netsuite.com B rand longevity and industry experience go a long way in the apparel marketplace, but when it comes to omnichannel retailing — which today, is really just retailing — new start-ups often come on the scene with a built-in advantage. That is, they’re not bogged down by cumbersome legacy systems whose siloed channels and custom inte- grations are a major hindrance to a seamless supply chain experience, for both com- pany and consumer. It’s rare that an established brand has the opportunity to start with a clean slate on which to build its IT, but that’s just what happened for Lucky Brand. The denim maker, which is positioned as “accessible premium” and was founded 26 years ago by Gene Montesano and Barry Perlman, was acquired in December 2013 for $225 million by private equity firm Leonard Green & Partners from its former parent, Fifth & Pacific Companies, now Kate Spade. Under its former owner, “IT had been one of many shared services, which Lucky Brand needed to build from scratch, in order to become an independent, stand-alone company,” says Jason Richard, who joined as the team leader five months into the two-year time- BY JORDAN K. SPEER, frame that Lucky had been given to transition off of its legacy ERP platform while building JESSICA BINNS, an entirely new IT team and infrastructure to support growth of its wholesale customers, DEENA M. AMATO-MCCOY its expanding store network and increasingly omnichannel consumers. Lucky sells direct AND LIZ HARTNETT TOP INNOVATORS to consumer via its e-commerce website and 259 Lucky Brand Akey feature of the ERP solution was the integration of inven- store locations (many of which are currently being converted from tory and financials on a unified platform — having that one sin- mall-based locations to free-standing stores), and also distributes gle version of the truth will “ultimately be the biggest game-changer,” through large department store retailers including Macy’s, Dil- he says. “In many companies, there are often timing issues, dis- lard’s and Nordstrom. crepancies or reconciliations to perform, leading to questions about How did it go? “We built an IT team while completing the entire the integrity of data at the core. The integrated foundation is key transition in 15 months,” says Richard. to helping us manage our business effectively. Lucky Brand named its program Project Leapfrog, “a mantra The trust it can now have in the integrity of its data — and hav- to everyone that we would take advantage of this unique oppor- ing just one version of it — opens up possibilities across the orga- tunity to completely reinvent the technology landscape,” says nization. Internally, says Richard “our largely-millennial user base Richard. Critical to its transformation was an ERP solution that appreciates the modern feel and response of the solution” — a could meet its immediate needs as well as one that would scale crucial point when you consider how difficult it can be to recruit with its growth, he says. and keep good talent. Millennials, in particular, do not want to be Richard, who already had experience working with cloud-based bogged down with systems that use clunky and counterintuitive applications during his tenure at Williams-Sonoma, thought technology. that Lucky would benefit from the agility and scalability the cloud The new system has also automated business activities that would offer to both its retail and wholesale businesses. After eval- were previously manual, or required multiple entries across dis- uating several ERP providers, the company selected NetSuite parate systems, he says, which frees up time for that user base to OneWorld for the technical flexibility that its cloud offering pro- focus on tasks that build value — such as expanding its channel vided, the ability to implement on a very aggressive schedule, and offerings and getting hot new product in front of Millennial shop- the overall cost of implementation, says Richard. The system runs pers quickly. business processes for financial consolidation, inventory man- Most companies don’t get the chance to start with a clean slate. agement, procure-to-pay, fixed assets, and multi-currency and Sometimes you’re just Lucky. multi-tax compliance management. —Jordan K. Speer Reebok CrossFit Apparel Canton, Mass. | news.reebok.com/GLOBAL NOMINATED BY: Alvanon | www.alvanon.com I In 2010, CrossFit®signed a 10-year part- “There’s a lot of squatting and nership with Reebok to produce the brand’s lifting and other exercises that apparel and footwear. As Reebok’s expe- build a big upper body and big rience with the sport’s athletes grew, it lower body, but in their core, became clear that the CrossFit athlete they become very lean.” hadadifferent body shape from other ath- The bottom half, with its letes, and that athletic wear designed for defined glutes and quad muscles, presents its customers’ needs across all ranges of fit- other sports was not meeting the unique the most challenges when it comes to fit. ness or athletic ability. needs of this group. “CrossFit athletes have to have almost every- While it had anecdotal evidence, there “If you talk to any CrossFit athlete, they’ll thing altered. If it fits the hips, they have was no hard, empirical data about body all say they have a tough time finding cloth- to take the waist in, and vice versa. You’d variations, and that’s when Reebok decided ing that fits their bodies, whether athletic go into a CrossFit box [that’s CrossFit par- to tap the expertise of Alvanon and Sizestream wear or jeans. They have an extreme body lance for a CrossFit gym] and see them so that it could understand the CrossFit shape,” says Michael Morganti, director of working out in tights or elastic-waist- body — not only how it differed from pattern apparel. band shorts, because they have trouble find- athletes in other competitive disciplines, Most athletes have a somewhat stan- ing woven shorts that fit.” but also how CrossFit bodies themselves dard chest-to-hip-to-waist ratio, he explains, As the relationship with CrossFit evolved were similar and different from each other but this proportion is more extreme for a and Reebok began to understand that the —and develop clothing to match. CrossFit athlete than for the general ath- sport produced a different body type, it In gathering data, Alvanon scanned the letic population, which has a lot to do with decided to take a closer and more scientific bodies of more than 500 CrossFit ath- the movements performed in wods (that’s look at the body shapes and sizes of the letes, both amateurs and professionals, CrossFit parlance for workout of the day). sport’s athletes with the goal of fulfilling many of whom were competing in the 10 MAY 2016 • www.apparelmag.com TOP INNOVATORS Reebok CrossFit games. The scanner’s 16 that accommodated the CrossFit body’s dif- the insertion of more specific zoning in infrared light points scanned each body, ferences. “It wasn’t just about increasing, terms of heat regulation and anti-abrasion generating more than 80 measurements, but enlarging in specific places,” explains protection. from which were generated 3D electronic Morganti. For example, he said, “How do Reebok launched with the reworked line avatars of each person’s body shape. you make a pair of woven board shorts fit infall 2014, and since then has been con- The company knew going in that the the hip and thigh, but also the waist when tinuing to refine and develop it, perform- CrossFit athlete had a small waist, big hips you have that extreme [variance between ing wear testing with its CrossFit athletes and a big chest, but body scanning allowed them]? You have to make sure the back rise —this is “for CrossFitters by CrossFitters,” Reebok to see distribution of muscle in detail. isn’t plunging down. Often, you’d see that says Morganti — and also employing both For example, says Morganti, “we knew that the athletes would be fine when they squat- live models and fit forms (developed specif- [CrossFit athletes’] waists were small, but ted down, and then when they stood up, ically for the CrossFit body by Alvanon) their waists aren’t smaller than other ath- the shorts would be stuck around the thigh. to ensure it is meeting the needs of athletes letes; it’s just that the ratio is greater. Their If you’re squatting with heavy weights, the in this popular sport, which is growing waists are actually getting bigger, but not at last thing you want is to be uncomfortable,” rapidly around the world, says Morganti. the rate that their chests are, so they have he says. “The amount of time and energy we put avery tapered V shape.” Generally speak- The companies worked together to cre- into developing this line is really paying ing, the CrossFit athlete has a much more ate new pattern blocks and grade rules, and off,” he says. “It’s the only apparel line extreme distribution of muscle, he says. from the data, Reebok was able to deter- developed specifically to fit, and enhance Once it had collected the data, Reebok mine such factors as the ideal placement the performance of the CrossFit athlete.” worked with Alvanon to analyze it and for cut seams, where a garment needed —Jordan K. Speer develop a unique proprietary fit standard unrestricted movement and where it required Tommy John New York, N.Y. | www.tommyjohn.com NOMINATED BY: Self D uring his five years working as a medical device salesman, Tom Patterson wore a suit and tie, and for five years, he was aggravated by the undershirts, underwear and socks that untucked easily and yellowed quickly, bunched uncomfortably and sagged. When the Great Recession of 2008 hit and Patterson was laid off from his job, it seemed the perfect opportunity to invent some undergarments that would address all of those problems. Patterson not only made it his mission to solve those problems, but to use humor to get men talking about them. After all, you on fabric (such as its micro modal that never pills and looks newer can’t really address a problem if you don’t acknowledge that it longer), fit (its patented undershirt design is guaranteed never exists. A few minutes at TommyJohn.com will get you laughing to come untucked) and function (it’s Quick Draw®Fly — well, you at the company’s video of “The Big Adjustment” (you know, the get the picture). creative ways men try to subtly, er, unbunch their underwear), tag In November, Tommy John introduced its newest product, Air, line: “You can’t un-see it. But we can make sure you never have to address the need for lighter, more comfortable, more quick- to see it again.” drying, anti-odor undergarments, and it’s been the company’s The conversation around men’s underwear has not evolved most successful launch to date. much since a gyrating Marky Mark infamously remarked, “Now “I fly 100,000-150,000 miles each year,” says Patterson. Under- that could definitely come between me and my Calvins” 25 standing the benefits of traveling light and getting “more out of years ago, says Patterson, but Tommy John is changing all that. less,” Patterson wanted to develop a product that could be washed “The Big Adjustment video really addresses a problem that guys easily in a hotel sink, for example, and that would dry quickly. have,” says Patterson. “It’s an uncomfortable experience that all Tommy John worked on the program for about two years, “liter- guys can relate to.” ally putting underwear in a bowl, taking it out, and figuring it Since its launch in 2008, Tommy John has continued to work out how long it takes to dry with a stopwatch, testing, getting guys’ with mills and factories around the globe to innovate and create feedback.” problem-solving products from loungewear to socks by focusing www.apparelmag.com • MAY 2016 11 TOP INNOVATORS Air is the result. It dries in two to four hours, and Patterson Indeed, Tommy John is definitely not your five-to-a-pack under- claims it is the lightest men’s underwear ever created. The under- wear. Its undergarments are sold in units of one at retailers such wear weighs an average 1.5 ounces, and the undershirt 2.0 ounces. as Bloomingdales, Nordstrom, Mitchell’s, Stanley Korshak and “It’s half the weight of any product we’ve created previously.” about 500 other stores across the country and Canada. It also sells “Our customer, the Tommy John guy, likes evolution, inno- online, and ships to more than 50 countries. vation. We’re never going to be the cheapest, but we’re going to Tommy John has clearly struck a chord, with the company be the best quality, and that allows us to build really high cus- growing two and a half times in the past two years, and fore- tomer loyalty,” says Patterson. “Guys always want to feel that casting 100 percent growth this year. “Men have had to take a they have an edge. We pay attention to the small details we MacGyver approach to jerry-rigging their underwear. … I’ve heard think may make a difference. … We work with manufacturers and of guys attaching garter clips from the bottom of their shirts to the mills across the world to solve problems we feel are in the mar- top of their socks to keep them in place. ket that other brands haven’t told a story about.” “Men don’t talk about [the challenges of undergarments] … That said, “we don’t launch a new product unless we have a and they can’t even remember the underwear they’re wearing, reason to,” says Patterson, who says the company doesn’t sub- but they remember the first time they wear Tommy John. When scribe to the “Cheesecake Factory menu” philosophy, i.e. there they try it, it’s an ‘a-ha’ moment: ‘Hey, this is not constricting or are so many choices that it takes forever to figure out what you smashing my important assets.’ Guys don’t like to feel restricted. want. Tommy John sticks with a strategy more resembling the We’re getting guys to talk about underwear at holiday par- menu of In-N-Out Burger — a limited number of offerings, but ties, at dinners. They’ve found something that has finally solved each the very best. “We have the best micro modal, the best cot- all of their problems,” Patterson concludes. ton,” he says. —Jordan K. Speer CCW Breakaways New Cumberland, Pa. | www.ccwbreakaways.com NOMINATED BY: Self W ecan’t all have 007’s tailor, but thanks to CCW This update improves comfort and performance, and Breakaways, law enforcement, military and secu- the products available include shorts, cargo pants, rity personnel have new clothing options specifi- khakis and jeans. The wearer can comfortably squat, cally designed with them in mind. Specially designed sit, bend over, or lie down, thanks to the placement concealed-carry pants from CCW Breakaways are also of the breakaway pocket. available to the general public. In addition to better comfort, CCW Breakaway’s Aimed at a very particular market, the CCW designs products give the wearer a tactical advantage. Con- are the result of extensive research and experimen- cealment is more complete, and deploying the weapon tation. The pants are fashionable and well made, and is much faster than with conventional holsters. Accord- they incorporate a unique holster pocket that allows ing to Jay French, this deployment is “pre-staged,” for less conspicuous and more comfortable carrying because the weapon’s position is more accessible, of weapons. The products are used in the military allowing the user to obtain a full grip while the weapon and for law enforcement, and they’re especially is still concealed. useful in “covert” situations where carriers wish to These concealed carry pants are a prime example remain inconspicuous. of a product developed to solve a specific problem. The design of these garments is so unique that the The design is unique and use of the pants has been designers, Jay and Georgeann French — both certi- shown to reduce draw time by as much as 60 percent. fied NRA instructors — have obtained five related The company reports that its customers can deploy patents. These are men’s pants with built-in holster their weapons in .66 seconds. pockets made of rip-stop nylon that have adjustable In business since 2010, the company continues depth, Velcro straps and enlargeable openings. Basi- to add new products, including belts and other acces- cally, they’re designed to make carrying a handgun sories. Plans include production of a ladies’ purse more comfortable and accessing the weapon faster for the near future. The products are currently avail- and easier, with only one hand needed. able online and at specialty events held around the These pockets replace the traditional holster, which country. hasn’t seen much change in design over the years. —Liz Hartnett 12 MAY 2016 • www.apparelmag.com TOP INNOVATORS ABL Denim Los Angeles, Calif. | www.ABLdenim.com NOMINATED BY: Self I nnovation often begins with identifying a need. Stephanie Alves was aware of the need for custom clothing design for the dis- ability community, thanks in part to watching family members cope with mobility challenges. She designed jeans for them that met their needs and were also fashionable and well made. This inspired her to launch ABL (Adaptive Brand and Lifestyle) Denim in 2013. According to the company, it is the only manu- facturer of adaptive jeans for men, women and children. As CEO of ABL Denim, Alves applies 25 years of design experience to the task, having worked at prominent fashion houses including Ann Taylor Loft. high. This makes the work very fulfilling, according to Alves, who The company caters to a niche market that represents 56 said, “We often hear ‘I haven’t worn jeans in years and finally I million Americans. People of all ages can find dressing difficult can.’” due to a variety of conditions, including multiple sclerosis, spinal The future looks bright for ABL. A $250,000 Mission Main Street cord injury, stroke, autism, tactile sensitivities and arthritis. What- grant received in 2014 helped spur development of the com- ever their condition, says Alves, “they still want jeans, like every- pany, which recently added dealers in Canada and the U.K. one else.” CEO Alves hopes to partner with rehabilitation centers and For people with such challenges, ABL Denim designs jeans and hospital shops to offer ABL products more widely. Walmart recently shorts using premium quality denim and then incorporates fea- became the first mainstream retailer to offer ABL Denim prod- tures that make them easier and more comfortable to use, includ- ucts, available online and in stores. It carries a lower-priced men’s ing: zipper access through either the front or both sides; longer jean designed specifically for those with limited mobility. The zippers with larger pulls for greater access; hook and bar easy front design incorporates strategic placement of zippers, pockets and closure; higher back waists with elastic that allows for stretching seaming, simplifying daily tasks while still providing a fashion- across the back; side pockets for catheter bags or personal items; able fit. Thoughtful details include lasso-style pull loops on zip- and ultra-soft denim material and inside-out seams to provide for pers — a boon to those with finger dexterity issues. added comfort for people with sensory issues. ABL Denim is at the leading edge of this niche market, com- One of the most popular designs is askinny basic jean with bining top quality materials with ingenious design to empower inner leg zippers to assist in getting the foot though the leg open- those with daily physical challenges. ing and/or using a catheter. The company plans new designs based —Liz Hartnett on requests that it receives, so customer loyalty and satisfaction is New Balance Boston, Mass. | www.newbalance.com NOMINATED BY: Aptos | www.aptos.com S croll through your Facebook feed and you’ll likely see smiling at their highest level and training to complete snapshots of folks in your network posing at the finish line of that goal is most important,” says business solu- some race somewhere. More than 550,000 people finished a tions manager Dave Chaput. “They may run, marathon in the United States last year, on top of the countless but they also engage in a variety of sports and fitness activities. others who entered half marathons, 10Ks, 5Ks and more. Run- They crave technology and demand performance, but aesthetic ning remains a stubbornly popular way to get fit and stay that way, carries equal weight.” or just get moving, period. New Balance’s new-for-2016 Trinamic Performance Collection This is all good news, of course, for athletic footwear and apparel strives to be just that blend of technology and aesthetics. The line company New Balance of Boston, known first and foremost as a of tops and bottoms for both women and men incorporates NB running brand. “New Balance consumers are looking to perform Flex X technology, described as a pinnacle 3D stretch technology 14 MAY 2016 • www.apparelmag.com TOP INNOVATORS that offers a close, comfortable, breathable fit. “Strategically placed Prior to the deployment, Chaput says, processes in both the laser cut perforation patterns, inspired by Data to Design thermal web and retail channels were largely manual and Excel-based. imaging, optimizes breathability and adds to the overall design and Employees wasted 500 hours each year inputting style creation modern aesthetic of the garments,” Chaput says. and UPC maintenance across both factory and corporate stores While it’s focusing on delivering innovative products for cus- combined. By automating that process and managing by excep- tomers, in recent years, New Balance has transi- tion, New Balance now frees up 400 merchandising hours annu- tioned from mostly a wholesaler and ally. What’s more, merchandise replenishment now takes only manufacturer to now running 55 stores, one hour, a drastic reduction from the 41 hours employees used including several outlets, and to spend on the top 50 styles across all stores each month. This expanding its web and licensee saves 492 additional merchandising hours that the department presence. To drive this con- can use for more meaningful work. tinued growth, the com- New Balance has also been able to improve stock rates at pany deployed Aptos size/width level while increasing order frequency. Staff spends just Merchandising, a cloud- 2,500 hours receiving footwear by carton, a 50 percent decrease. based retail platform, to The company now automates and calculates taxes more accurately, minimize its out-of-pocket saving 30 IT hours every month. And employee number setup and IT investment while giv- discount monitoring at the register go much more smoothly and ing its merchandising, quickly now, redirecting 240 back-of-house hours onto the sales operations and finance teams floor each year. robust tools to streamline the busi- As New Balance grows as a retail brand, it’s finding its social ness. It also upgraded to a new point- media voice, too, interacting with consumers on Instagram, Twit- of-sale system in order to handle ter, Facebook, Periscope, and Pinterest and targeting those con- omnichannel selling. New Balance is build- sumers by category, (such as baseball, women, or running) to build ing a foundation to support the next gen- relationships with them based on their interests. “This allows us eration of retail that includes shared item, to serve unique consumer experiences and information specific to price, inventory, promo engine, financial their lifestyle,” adds Chaput. structure, and customer across back office —Jessica Binns retail channels. See Aptos’ ad on page 15. Patagonia Ventura, Calif. | www.patagonia.com NOMINATED BY: Alvanon | www.alvanon.com I t’sno secret that Patagonia loves the earth. “Everything we make is with the environment in mind,” says product devel- opment director Alma Balling. “We try to use less harmful mate- rials and make sure that when we can, we incorporate recycled fabrics. We use all-organic cotton for styles that are cotton-based. It’s important to produce something that’s going to last forever, especially jackets and similar products that could be passed down as heirlooms.” Whereas many apparel companies today peddle fast fashion the same size in outerwear and the fit is consistent,” Balling explains, that wears out seemingly overnight, Patagonia wants customers adding that the company produces 900 styles for each of its two to enjoy its outdoor-oriented products forever, offering an Iron- seasons annually. clad Guarantee that enables shoppers to bring back purchases to “We have really loyal customers,” she continues. “You can see any of its retail stores for return, repair or refund. It’s a bold promise, in the reviews on our website that the customers are pretty vocal. and one that made Patagonia think twice about a big driver of We’ll hear feedback from them asking, ‘why did you change XYZ?’” apparel purchases: fit. Realizing there was a significant opportunity to address cus- Producing 12 categories of technical apparel products is one of tomer concerns and standardize fit across all apparel products, Patagonia’s big challenges. “If a customer comes in and he two years ago Patagonia enlisted the help of industry fit leader wears a medium in running shorts, we want to be sure he can buy Alvanon, with which it has worked in the past. Alvanon analyzed 16 MAY 2016 • www.apparelmag.com TTOOPP IINNNNOOVVAATTOORRSS Patagonia’s product lifecycle from design through sales, includ- As a result of the fit project, Balling says, Patagonia now intro- ing data such as sales by size, return figures, and customer feed- duces more styles closer to market and has product developers back. Armed with this information, Alvanon reviewed its own vast and designers working on innovation concepts earlier on in the database of consumer body scan data to determine the core size process, instead of not having enough time at the ideation ofthe Patagonia customer. phase. “That has set the bar pretty high for us,” she says. Balling says the core size for men that the two firms came up What’s more, over two years the company has improved its with was a very close match, and her team only made a few minor garments completed on time rate by 29 percent. “We’re meeting adjustments to the grading standard. Patagonia discovered, how- production schedules and not jeopardizing on-time delivery,” ever, that the core female customer has an athletic, less curvy body Balling says. It also takes 20 fewer days, on average, to secure final type, she adds. photo approval, further accelerating the design and development Involving designers, product developers, patternmakers, the process. quality team and the audit department, Patagonia successfully cre- As sales data starts to trickle in, Patagonia is looking forward ated a new fit platform for all product categories, including new to enlisting the quality team to sift through fit returns data and fit blocks and libraries that are easily distributed to its global leveraging the e-commerce and customer service teams to ana- network of vendors. “The block library is the starting point for lyze customer comments on the company website to determine if most of our products,” Balling says. “It ensures consistency and shoppers are more satisfied with the newly standardized fit. that things like arm holes are always the same size.” —Jessica Binns Omega Apparel Nashville, Tenn. | www.omegaapparelinc.com NOMINATED BY: Self T he craft of apparel manufacturing is not some- east region have the largest concentration of inde- thing you hear a lot about these days, but it’s at pendent fashion brands outside of New York and the heart of this company’ business strategy. Based Los Angeles. This seems like fertile ground for the near Nashville, Omega Apparel was established in skilled workforce that’s now being nurtured through 1994 to produce dress uniforms for the U.S. Armed the partnership. Forces. The company continues in that capacity, but Wegner believes this to be true, and said that there recently took steps to expand the scope of its oper- is support in the region for Omega’s efforts. “The ations and “lead the rebuilding of the U.S. apparel percentage of clothing Americans buy that’s made industry.” in the U.S. has dwindled to just over 2 percent,” he When budget cuts reduced the volume of work said. “People want to see apparel manufacturing coming from the military, Omega Apparel’s reaction come back. Our mission is to create more jobs in the was bold. “Instead of downsizing, we bought a industry, both for our company and others.” second building and launched a full service apparel One way that this is being accomplished is through factory, offering design, production and other ser- Omega’s diversification, which allows the company vices,” said president and CEO Dean Wegner. “We to serve small designers and entrepreneurs while plan to hire 1,000 employees over five years.” remaining the top supplier of dress uniform pants This reflects the company’s commitment to its and skirts to the U.S. Armed Forces. Encouraging stated mission, which is to create jobs in the apparel the growth of new businesses involves the pro- industry. A key part of the plan is training. Omega duction of smaller batches, and providing a full range Apparel partners with community groups to provide of services. As these new businesses thrive, they training to grow a skilled workforce that will mas- in turn provide more opportunities for jobs in the ter the craft and become a new generation of work- industry. ers for American manufacturing. Area non-profits, Wegner is optimistic about the plan, but recog- led by Catholic Social Services, provide the training nizes the challenges involved in reviving the apparel site and machinery that will prepare skilled work- industry in his region. “I never realized how hard ers for the apparel industry. this would be,” he said. “But if it were easy, every- Omega Apparel’s location may be a positive one would be doing it.” factor in the plan’s success. As StyleBluePrintrecently —Liz Hartnett pointed out: Nashville and the surrounding South- www.apparelmag.com • MAY 2016 17