Bodynits International Pte Ltd

A faster, more realistic planning process achieved and a 20% efficiency gain after FastReactPlan implementation

A. THE CUSTOMER

Bodynits supplies the activewear sector, working with leading brands such as Adidas, Under Armour, Lulu Lemon and Puma. Within their headquarters, the team focuses on product development, materials sourcing, and purchasing. Bodynits is currently spread over 4 countries, headquartered in Singapore, and with facilities in China, Indonesia, and Vietnam.

Due to the demanding nature of the fast-growing athleisure market, Bodynits have invested in technology to ensure best practice procedures that are in place to support the entire manufacturing process. This enables them to support the synchronization of management and offshore manufacturing facilities.


B. THE CHALLENGE

Ms Nguyen Thi Thu Hong (Kitty), Factory Manager for An Thanh, BI (VN) Co. Ltd, Bodynits’s first Vietnam factory located in HCMC, explains the challenges she faced with manual planning before using Evolve [now FastReactPlan]

Our factory has 30 lines, and on average we make 80 different styles every month. Before we purchased Evolve [now FastReactPlan], it took me a lot of time to go through the schedule to find the best line for that product family, calculate the daily output and check status of material and sample approval. We used to spend 5-7 days to do this. It took so long just to get the data in one place!

On top of that, the customer started to push for a much quicker order confirmation than before, so in many cases I didn’t have enough time to check everything and had to base my response on experience only. This did not always work as we could not maintain the same product family in same line, and it hurt our efficiency when workers had to change a familiar style to another.

Ms Nguyen Thi Thu Hong (Kitty)


C. KEY FACTS

CUSTOMER
Bodynits

LOCATIONS
Singapore, Vietnam, China, and Indonesia

CHALLENGE

  • Manual planning processes time-consuming
  • Data in multiple locations
  • Customer demands for quicker order confirmations created factory inefficiencies

ROI

  • Planning time reduced from 5-7 days to 1 day
  • Planning became more productive and focused
  • Average efficiencies increased by 20%

D. THE SOLUTION

During 2014/15, Bodynits implemented Fast React Evolve’s planning solution [now FastReactPlan] throughout the group. Connecting the software solution to their Infor M3 and other MIS systems, gives the team visibility of their core data at head office through their FastReactPlan high level planning board, which subsequnetly communicates with their FastReactPlan line level planning board at each factory.

The software solution also includes FastReactPlan’s Material Requirement Planning (MRP) module which is also linked to the M3 purchasing and inventory data, which enables their factories have full visibility of material demand and supply relative to the plan and production sequence at all sites.

Kitty explains below the practical differences in planning through FastReactPlan…

By using Evolve [FastReactPlan], I only need one day to make the plan and confirm deliveries!

FastReactPlan integrates all our data, including data from our other systems, all in one place, consequnetly we are able to focus on planning rather than manually entering in multiple data sets.

It also helps me to give a more accurate daily output target as it calculates automatically, using the line capacity and efficiency by product family, any time we need it for learning or style change.

It is both quicker and more accurate than our previous process using Excel.

A further good example of how it has helped us, is when I plan I don’t always follow the final delivery date. Occasionally, to get the best efficiency and quality, I want to put one order into production earlier than the delivery date so I can keep the same product family running on a line. With FastReactPlan, I can establish if our existing material is in-house or can see the estimated date for arrival, which will allow us to produce an order earlier.

Ms Nguyen Thi Thu Hong (Kitty)


E. THE BENEFITS
Kitty summarises the benefits to her factory…

Evolve [FastReactPlan] is truly useful for top management to operate the factory effectively. I can easily make a plan which keeps most lines running the same product family and believe it is a key factor for our factory to reduce costs, increase efficiency and quality as our workers can keep sewing the same product for longer.

An additional benefit is the two key reports that are sent to me every day; The efficiency report gives me a warning if any line is above or below the agreed target. The material status report lets me know of any material delays. I can then make sure that there is no line idling whilst maintaining the same product, in the same line.

As a factory manager, I can quickly identify which line is having problems and solve that problem ensuring production can run smoothly. We no longer have last minute rushes so we don’t need to split orders in to more lines to catch the delivery. All of this has helped us an increase our average efficiency by 20% over the past two years!

Ms Nguyen Thi Thu Hong (Kitty)



F. ROI