New solution transforms shop-floor video into GSD-coded method studies in minutes, helping apparel manufacturers measure critical operations at scale, protect margins, and boost plant capacity
Coats Digital today announced the launch of GSD RealMotion, an AI-powered solution that gives apparel manufacturers unprecedented visibility into factory-floor execution. By analysing shop-floor video and applying Coats Digital’s proven GSD methodology, GSD RealMotion replaces dated time-study tools and manual stopwatches—enabling industrial engineers to turn 45-minute manual timing into 15-minute video-assisted studies, spot inefficiencies, and eliminate margin leak from unverified costing.
Replacing Traditional Stopwatch Studies With AI-Powered Analysis
For decades, industrial engineers have devoted hours to timing a tiny sample of operations rather than improving shop-floor execution. Stopwatch studies record elapsed time without revealing motion-level waste, while manual frame-by-frame analysis requires roughly eight hours per operation. Consequently, comprehensive factory analysis remains unfeasible at scale, leaving gaps between costed methods and floor reality uncorrected.
GSD RealMotion transforms this process. Using AI and computer vision, the solution converts phone video into structured, motion-by-motion studies that engineers validate and refine in minutes. Every motion is classified as value-added, necessary, or non-value-added, allowing manufacturers to measure every critical operation across every production line.
Potential Financial and Operational Impact
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
Benchmarking Factory Methods Against GSD Standards
What distinguishes GSD RealMotion is the engineering intelligence behind the analysis. Rather than simply recording elapsed time, GSD RealMotion benchmarks observed floor methods directly against GSD standards held within GSDCost. Verified observed standards publish back into GSDCost under approval, ensuring future quotes reflect true floor execution.
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.”
Key Capabilities of GSD RealMotion
- AI-assisted detection and validation of GSD motion codes from video
- Automated creation of motion-by-motion method studies with observed times
- Classification of value-added, necessary, and non-value-added motions
- Visual operation sequencing through method Gantt analysis
- AI-assisted identification and prioritisation of high-impact improvement opportunities
- Side-by-side study comparisons to pinpoint actionable method variances
- Direct benchmarking against engineered GSD standards.
- Searchable central library of reusable method studies and institutional knowledge
Coats Digital Expands Practical AI for Fashion Manufacturing
Himanshu Mehrotra, Managing Director, Coats Digital, said: “We are thrilled to launch GSD RealMotion, as it will make a genuine, transformative difference to fashion manufacturing. Coats Digital is committed to investing in next-generation AI technologies that empower the fashion industry to navigate evolving global headwinds and build a resilient future.
GSD RealMotion demonstrates how practical AI can transform decades of deep domain expertise into actionable insight—giving brands and manufacturers the operational clarity needed to protect margins, elevate productivity, and thrive in an increasingly complex supply chain.”
Read more: Digital Transformation in the Apparel Industry Is Advancing Faster Than Ever
Designed for industrial engineers, manufacturing excellence teams, and production leaders, GSD RealMotion provides a scalable approach to method engineering—improving productivity, strengthening costing confidence, and embedding continuous improvement across operations.
Additional Resources:
- Learn more about: RealMotion
- Learn more about: GSDCost
