VT Garment Improves Productivity by 95% & OTDP by 50% with FastReactPlan

The Challenge– Inaccurate Planning Processes Negatively Impacted the Whole Business and Restricted Business Growth

Prior to implementing FastReactPlan, VT Garment found that the lack of automation and real-time visibility in the production planning process not only meant there was limited information sharing between different departments, but also that manually produced capacity plans based on unreliable historical data, were time consuming and cumbersome to produce and not accurate enough to make informed production decisions from. As a result, VT Garment’s management and planning teams found that capacity was often over-booked or under-booked, causing late deliveries and unnecessary staff overtime costs.

Insufficient tools and resources for monitoring and optimising production efficiency, lengthy reporting times and limited information sharing and coordination between departments also meant that VT Garment was unable to respond to customer demands for quicker order confirmations, resulting in lost business and poor customer satisfaction levels.  This led to increased pressure on staff, wasted resources and decreased profitability. An inability to make informed business decisions consequently not only negatively impacted overall company performance, but also its potential for growth.

The Solution – Accurate, Highly Visual Capacity Plans Have Significantly Increased Productivity, Optimised On Time Deliveries and Enabled Staff to Work on Other Business Improvements

Following the implementation of FastReactPlan, VT Garment now has the ability to view capacity plans from multiple perspectives, resulting in a comprehensive understanding of its production capabilities and limitations. The solution has enabled VT Garment to easily compare different plans and select the most optimal option based on factors such as cost, efficiency and delivery time. The automation of planning processes has also freed up time for staff to focus on other important tasks, such as improving customer satisfaction and supporting new innovations and business growth.A significant reduction in errors and a more accurate representation of its production capabilities has also led to a 92% improvement in plan accuracy which has improved VT Garment’s ability to meet customer delivery expectations. The ability to quickly review and revise plans immediately by monitoring late order requests and on-time items has also increased its OTDP performance by 50%.

Since the implementation of FastReactPlan, VT Garment is now able to quickly evaluate the efficiency of each plan variation, which has reduced the time spent on planning from four hours to 10 minutes. This has helped the company reduce planning time by 57%, reduce order plan loading by 67% and improved its overall productivity efficiency by 95% across the whole business.

The Solution – FastReactPlan Has Eliminated Overtime Hours, Improved Staff Morale and Enabled the Company to Take on More Complex Orders 

The solution has enabled VT Garment to save significant staff hours by streamlining the planning process, from order placement and checking delivery dates to tracking production activities, which has meant that extra time can be dedicated to delivering an enhanced customer experience.VT Garment found that the FastReactPlan implementation had a positive impact on staff morale by simplifying the challenging task of planning and reducing unnecessary and unplanned overtime hours, so that staff had a more consistent, stress-free working environment.  

With the ability to anticipate future plans and understand available capacity, VT Garment can now accurately calculate working hours effectively to take on additional business orders that it would have previously shied away from. FastReactPlan has also enabled the company to handle a wider range of orders, including shorter and more complex order requests, as it has the visibility and agility needed to make informed decisions based on accurate plan variation assessments. 

The Solution – FastReactPlan Helped Company Become Award Winners in Lean Manufacturing

The adoption of FastReactPlan was instrumental in helping VT Garment secure the coveted ‘Golden Award’ at the ‘Thailand Lean Award 2017,‘ – an influential government-subsidised nationwide awards ceremony covering all manufacturing industries. The annual Thailand Lean Award recognises companies that have undertaken strategic changes to their businesses to adhere to lean management principle. Award winners serve as exemplary leaders to others who are looking at adopting lean management for quality, savings, delivery and speed.

“We are exceptionally pleased with FastReactPlan. It allows us to plan better because we can choose the plan based on different factors, such as Capacity, Efficiency and OTD percentages, which has eliminated the need for manual calculations altogether. The customer experience has also greatly improved as a result of our ability to provide timely and accurate information, which is crucial for customers to make informed commissioning decisions. With the implementation of FastReactPlan, we are now able to send accurate plans and information to customers in less than two hours, rather than the usual 3 days it took before the implementation.”Chalumpon Lotharukpong, Managing Director, VT Garment

“With its many functions, FastReactPlan has enabled us to cope with all situations, whether large or small orders. In a nutshell – it is awesome. Each order is now identified by different colour codes, which makes it much easier for executives or planners to differentiate tasks, assess work in progress and act immediately if there are any issues. We can also plan activities super effectively, such as communicating the date to send a pattern file, since everyone involved in that job receives an alert when the file needs to be sent. This makes the whole production process run seamlessly and smoothly. And as an old industry saying goes, ‘if you have a good capacity plan, then half of the victory has already been achieved’. Greater resilience and agility will undoubtedly enable us to navigate through and respond quickly to supply chain shocks, and future proofing for agile manufacturing will undoubtedly be the key to our success in 2023 and beyond.” Chalumpon Lotharukpong, Managing Director, VT Garment