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Case Study

One-Year Journey with MaxobizTex AI

Factory & AI operations

Before Deployment

By late 2021, Zillion Traders faced mounting pressures: rising raw material costs, unpredictable delivery performance, and inefficiencies buried deep in production processes. Management knew margins were eroding but lacked real-time visibility on where losses were occurring.

Journey Timeline

Month 1–2: Baseline and Integration

  • Fabric waste exceeded 14% across cutting operations.
  • Shade mismatch in dyeing led to rework cycles on ~1 in 5 lots.
  • ERP data was siloed, making real-time reporting impossible.

Integration began with linking MaxTex’s AI modules to Zillion’s ERP and QC systems. Early resistance emerged from supervisors worried about “machine-driven planning.” Ahsan personally facilitated workshops to demonstrate how the system complemented — not replaced — human expertise.

Month 3–6: System Rollout on the Floor

  • Cutting Plan Generator started producing digital nesting layouts.
  • Order Sequencer balanced machine loading against delivery deadlines.
  • Adaptive Learning Engine began recalibrating based on live production data.

Training became the focus. Ahsan conducted small-group sessions with cutting staff, walking them through side-by-side comparisons of manual vs. AI layouts. Supervisors learned to interpret the waste dashboard, which now showed real-time scrap rates per style and per operator.

Month 6–9: Early Impact

  • Fabric waste reduced by 10%.
  • Re-dye cycles cut by 15%, freeing dye house capacity.
  • Weekly cost reports shortened to daily updates, enabling quicker interventions.

The turning point came when supervisors began using AI outputs proactively in morning huddles. What started as scepticism turned into demand for deeper insights.

Month 9–12: Consolidation and Expansion

  • Overall production costs dropped by 15%, verified against financial accounts.
  • Efficiency gains enabled Zillion to take on two new export buyers without adding headcount.
  • Sustainability metrics (waste and energy savings) aligned with buyer audit requirements.

The system’s regenerative AI refined its recommendations further as more data was ingested. By month 12, transformation was evident across operations, finance and sustainability.

Transformation Lead

Ahsan Sharif from MaxobizTex acted not just as a strategist but as a bridge between technology and factory reality. He handled integration issues, personally coached supervisors, and translated AI outputs into both factory KPIs and financial impact. His leadership ensured adoption across levels from cutting operators to senior management.

Get In Touch

House # 05, Gulshan View Society, opposite Adil Hospital, DHA Main Boulevard, Lahore

+92322-4233263

info@zilliontraders.com

NTN: B564154-7

Registration No: 35202-7337723-9

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