GSD RealMotion is designed to give apparel manufacturers visibility into factory-floor execution and to replace stopwatch time studies and manual observation. Stopwatch studies record elapsed time without revealing motion-level waste, while manual frame-by-frame analysis requires roughly eight hours per operation. Coats Digital says industrial engineers can end up timing only a small sample of operations rather than improving shop-floor execution, leaving gaps between costed methods and floor reality uncorrected.

GSD RealMotion is presented as a way to speed up study creation and enable broader coverage. Coats Digital reports that industrial engineers can turn 45-minute manual timing into 15-minute video-assisted studies, then validate and refine the results in minutes. Each motion is classified as value-added, necessary, or non-value-added. The solution also includes method Gantt analysis for visual sequencing, side-by-side comparisons to pinpoint actionable method variances, and AI-assisted prioritisation of high-impact improvement opportunities. Based on internal modelling, addressing these operational inefficiencies delivers significant financial and operational impact:

• $2M-$3M in potential annual cost savings per site

• 60,000 additional garments produced per year through recovered capacity

• 12,000 engineering hours saved annually

Rahul Bhardwaj, Product Manager, GSD, Coats Digital, said: “GSD RealMotion verifies that the method your SMV is built from matches what operators run on the floor. By pairing AI detection with GSD benchmarks, manufacturers can identify method variation, understand root causes, fix the method by comparing it with the standard, and unlock the capacity to produce more pieces with time saved on the floor. Industrial engineers can focus efforts on method improvement rather than method measurement where it yields the highest return. Validated improvements transfer across comparable lines, while completed studies build a central library of reusable engineering knowledge.”