Zaco (Zahid Abid and Co)

The problem

Manual cutting and tracking before digitization

Zaco's textile manufacturing operation relied heavily on manual processes and manual labor at every stage, from receiving a purchase order through knitting, cutting, sewing, and packing. Beyond the labor itself, there was no real transparency: not even the CEO could say with certainty how much of an order had reached sewing, or how many pieces were still in process.

What we built

The Gate Pass system, live at Zaco's facility

Two connected systems. A digital gatepass system that replaces paper-approved gatepasses with an online version tied to employee IDs, so the CEO knows exactly which containers are entering or leaving the facility, when, and who approved the transport. And barcode tracking for textile bundles: each bundle is scanned every time it moves between sections, cutting to sewing, sewing to packing, giving a live picture of where every order actually stands.

What changed

The journey of every cloth bundle is now systemized, tracked automatically from cutting to sewing to packing. Gate passes are approved and logged online instead of on paper, and every container entering or leaving the facility is tied to a specific employee and timestamp, adding a level of traceability and accountability that wasn't there before. Based on how these processes worked previously, removes somewhere around 20-30 hours a week of manual checking and paperwork across the operation.