Perform Group achieves ZERO late delivery with FastReactPlan

Manufacturing for the Dance and Gymnastics markets, Perform Group, LLC is the leader in providing high quality apparel sold throughout the world.

The Customer Perform Group, LLC manufactures products through its own plant and through domestic and international sub contractors, and ships over one million garments per year.Its world-wide customer base includes dance schools, performing arts academies, universities, as well as gymnastics schools and competition teams.

The company can also proudly boast that their apparel was worn by gymnasts from various countries during the 2008 Beijing Olympics and has also starred in high profile events such as the Super Bowl.

Yearly shipping capacity: 1 million garments
USA

The challenges

Due to the very seasonal nature of the dance wear business it is essential that Perform Group, LLC is able to carefully manage its production flow to ensure that customer demands are met. The existing business system in place was supported by a series of spreadsheets that did not give an adequate level of visibility. This resulted in excessive material inventory levels through slow production times, and low material inventory during busiest production times. Poor work Centre loading created numerous bottlenecks and caused a series of late customer deliveries.

The solution

Perform Group, LLC implemented a planning solution from Coats Digital’s FastReactPlan, which has been fully integrated with their previous systems to provide complete visibility and control over their supply chain processes.

The conclusion

Since the successful implementation of FastReactPlan the effect on material inventory levels has been profound. FastReactPlan’s plant-loading capability has also helped Perform Group, LLC to simultaneously improve its plant productivity and on-time shipping performance.

“Material inventory levels used to fluctuate wildly, with little correlationto our production plan. Effective master planning synchronises our entire supply chain. This allows us to reduce our raw material investment by 10-15% in our off-peak season, while at the same time we have decreased our quantity of RM stock outs.

Even though our current season bookings are up 30%, we haven’t shipped a single item late in overa quarter. Our performance is so good that weare starting a new guaranteed on-time or it’s freeshipping program.”
John Misner ,
CEO, Perform Group, LLC