Coats Digital is delighted to announce that VTL Group, one of the largest vertically integrated textile manufacturers in the Mediterranean region, has adopted Coats Digital’s GSDCost solution to standardise production methods, increase productivity, and improve pricing accuracy across its Tunisian operations. The initiative is already showing a significant impact, with VTL reducing standard minute values (SMVs) by 15–20% and increasing line output by 10% across its three, key sewing facilities.
With over 5,000 employees and 3,000 sewing machines across 90 sewing lines, VTL Group specialises in jersey knits and denim, producing up to 20 million garments per year for world-renowned brands such as Lacoste, Adidas, G-Star, Hugo Boss, Replay and Paul & Shark. The company operates six garment production units, along with dedicated facilities for screen printing, knitting, dyeing and textile finishing. This extensive vertical integration gives VTL complete control over quality, lead-times and cost-efficiency, which is vital for meeting the stringent demands of its global customer base.
Prior to implementing GSDCost, VTL calculated capacity and product pricing using data from internal time catalogues stored in Excel. This approach led to inconsistent and inaccurate cost estimations, causing both lost contracts due to inflated production times and reduced margins from underestimations. In some cases, delays caused by misaligned time predictions resulted in increased transportation costs and operational inefficiencies that impacted customer satisfaction.
Hichem Kordoghli, Plant Manager, VTL Group, said: “Before GSDCost, we struggled with inconsistent operating times that directly impacted our competitiveness. We lost orders when our timings were too high and missed profits when they were too low. GSDCost has transformed the way we approach planning, enabling us to quote confidently with accurate, reliable data. We’ve already seen up to 20% reductions in SMVs, a 10% rise in output, and improved customer confidence. It’s a game-changer for our sales and production teams.”
Since adopting GSDCost across 50 sewing lines, VTL Group has been able to establish a reliable baseline for production planning and line efficiency monitoring. This has led to a more streamlined approach to managing load plans and forecasting. Importantly, GSDCost has given the business the flexibility to align pricing more effectively with actual production realities, contributing to greater customer satisfaction and improved profit margins.
Although it’s too early to determine the exact financial impact, VTL Group has already realised improvements in pricing flexibility and competitiveness thanks to shorter product times and better planning. These gains are seen as instrumental in enabling the company to pursue more strategic orders, reduce wasted effort and overtime, and maintain the high expectations of leading global fashion brands.
Hichem Kordoghli, Plant Manager, VTL Group, added: “GSDCost has empowered our teams with reliable data that has translated directly into real operational benefits. We are seeing more consistent line performance, enhanced planning precision, and greater confidence across departments. These improvements are helping us build stronger relationships with our brand partners, while setting the foundation for sustainable productivity gains in the future.”
The company now plans to expand usage across an additional 30 lines in 2025, supported by a second phase of GSD Practitioner Bootcamp training to strengthen in-house expertise and embed best practices throughout the production environment. A further 10 lines are expected to follow in 2026 as part of VTL’s phased rollout strategy.
Liz Bamford, Customer Success Manager, Coats Digital, commented: “We are proud to support VTL Group in their digital transformation journey. The impressive improvements in planning accuracy, quoting precision, and cross-functional alignment are a testament to their commitment to innovation and excellence. GSDCost is helping VTL set a new benchmark for operational transparency and performance in the region, empowering their teams with the tools needed for long-term success.”
GSDCost, Coats Digital’s method analysis and pre-determined times solution, is widely acknowledged as the de-facto international standard across the sewn products industry. It supports a more collaborative, transparent, and sustainable supply chain in which brands and manufacturers establish and optimise ‘International Standard Time Benchmarks’ using standard motion codes and predetermined times. This shared framework supports accurate cost prediction, fact-based negotiation, and a more efficient garment manufacturing process, while concurrently delivering on CSR commitments.
Key Benefits and ROI for VTL Group
• 15–20% reduction in SMVs across 50 production lines
• 10% productivity increase across key sewing facilities
• More competitive pricing for strategic sales opportunities
• Improved cost accuracy and quotation flexibility
• Standardised time benchmarks for future factory expansion
• Enhanced planning accuracy and load plan management
• Greater alignment with lean and sustainable manufacturing goals
• Increased brand confidence and satisfaction among premium customers
