Optio saves CEO over 10k steps per day

With Optio order tracking, CEO of Phunkshun Wear, Jay Badgely, no longer needs to walk the floor searching for particular orders to find out lead times and bottlenecks. His production scheduling has transformed to a more efficient ‘pull’ system and Jay has more time to get outside for his exercise.

Nikolaus Correll
December 2, 2021


Company Background

Colorado-based cut/sew manufacturer focused on sustainable, high tech production practices. Phunkshun Wear manufactures both its own branded products, primarily face gear (neck gaiters, face coverings, balaclavas), and also functions as a contract manufacturer for brands that do not produce themselves. Phunkshun keeps over 1,000,000 plastic bottles out of landfills annually by using domestically manufactured yarn made from recycled plastic bottles.


We saw an instant time savings by no longer having to stumble through physically locating orders in each part of our manufacturing facility.

Jay Badgley, CEO, Phunkshun Wear Inc.


Problem

Due to the nature of producing contract orders, white-labeled custom orders, and our own product line, we need a transparent and simple method of monitoring what stage a job is at in the manufacturing process. The process of physically going to each department and hunting down the location/stage a job is at, is extremely time consuming, inaccurate, and inefficient.


Solution

We use Optio to actively log a job as it enters each stage of production, accessing the platform using a simple tablet or web browser. By making the process of logging jobs as simple as possible, it greatly sped up the adoption of the software by Phunkshun Wear Staff. We are now able to identify what stage a job is at at any moment of the day with nothing more than a few keystrokes


Result

Most immediately we saw an instant time savings by no longer having to stumble through physically locating orders in each part of our manufacturing facility. This time savings translates into financial savings by allowing employees to focus on their primary functions. Being able to locate a jobs status at a moments notice has increased the customer service we can provide to our clients. With Optio the new workflow also provided an added sense of responsibility, and accountability to our manufacturing staff. Less quantifiable, this software has given our company management peace of mind on the day to day.


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