According to Coats Digital, conventional stopwatch studies record elapsed time without identifying motion-level inefficiencies, while manual frame-by-frame analysis can be highly time-consuming. GSD RealMotion uses AI and computer vision to convert video recorded on the shop floor into method studies that industrial engineers can validate and refine. Individual motions are classified as value-added, necessary or non-value-added.

The solution also benchmarks observed production methods against GSD standards held within GSDCost. Once approved, verified observed standards can be transferred back into GSDCost, helping manufacturers align costing assumptions with actual shop-floor execution.

“GSD RealMotion verifies that the method your SMV is built from matches what operators run on the floor,” said Rahul Bhardwaj, Product Manager, GSD, Coats Digital. “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.”

GSD RealMotion includes AI-assisted detection and validation of GSD motion codes from video, automated creation of motion-by-motion method studies with observed times, method Gantt analysis and side-by-side comparisons to identify method variances. Completed studies can be stored in a searchable central library for reuse across manufacturing operations.

Coats Digital also puts figures on the potential impact. Based on its internal modelling, addressing the operational inefficiencies identified by the system could deliver annual cost savings of USD 2–3 million per site, free up 12,000 engineering hours and recover enough production capacity for an additional 60,000 garments per year.

“We are thrilled to launch GSD RealMotion, as it will make a genuine, transformative difference to fashion manufacturing,” said Himanshu Mehrotra, Managing Director, Coats Digital. “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.”

The solution is designed for industrial engineers, manufacturing excellence teams and production leaders, with the aim of supporting method engineering, costing and continuous improvement across apparel manufacturing operations.