Tusuka delights customers with significant OTDP improvements

Challenges and its solutions

Manual planning processes proved time-consuming as data was located in multiple locations; and limited visibility of forward load capacity resulted in lost orders

Prior to implementing FastReactPlan, Tusuka’s planning teams did not have the business intelligence they needed to navigate the volatile industry changes at the start of the global Covid-19 pandemic. Chaotic supply chain factors and an unexpected fluctuation of demand and capacity allocation, meant that it was difficult to optimise all factory facilities, keep staff overtime low and effectively maintain customer satisfaction with regards OTDP and quality.

Without the data insights it needed to plan successfully for an increase in varying style changes and small order requests, Tusuka found it was spending far too much time – especially senior management time – on initial start planning, which had a negative affect on overall productivity.  The demand for shorter lead times also meant opening more lines than were necessary for the same product, which resulted in a significant rise in operational costs.

Limited visibility of forward load capacity and pre-production planning meant no accurate data was available to provide meaningful lead-time projections, or a true cost of production. Tusuka consequently was unable to respond quickly to customer demands for agile order confirmations, which resulted in lost business.

Solution

Following the implementation of Coats Digital’s FastReactPlan, Tusuka’s planning and merchandising teams no longer need to cross-reference a myriad of spreadsheets, email messages, telephone conversations or meeting logs, to make important decisions about order planning and fulfilment. With all information now in one place, Tusuka’s employees are given the full visibility they need to update and respond to new information in an agile way, so they can progress orders within minutes, thanks to accurate plan-based capacity reports.

Engr. Sheikh Shariful Islam added, “Ultimately, however, FastReactPlan has created a truly happy, contented and harmonious working environment for us all. This benefit is positively impacting our customers as we have more time to deliver an outstanding customer service every time.”

Improved visibility and transparency have consequently proved instrumental in boosting staff morale and reducing absenteeism by 7%, at Tusuka, with staff able to perform significantly more efficiently, without having to resort to time-consuming and repetitive manual tasks to find and update critical information, across multiple sources.

FastReactPlan has additionally enabled Tusuka to reduce overtime costs, introduce faster order feeding processes and benefit from an overall efficiency increase of 5%, and an improvement in ODTP of 9%. This has meant that Tusuka can now increase orders and manage smaller and more varied style orders effectively and profitably.

FastReactPlan is developed exclusively for the fashion, textile and apparel industry and can be configured in multiple ways to reflect industry best practice and specific business requirements.