Top sportswear supplier MAS Active achieved substantial performance and customer service improvements, helped by the FastReactPlan solution
A. THE CUSTOMER
Sri Lanka based MAS Active, the sports & leisurewear division of MAS Holdings is the fastest growing provider of competition sportswear and leisurewear in the region, supplying to key strategic business partners Nike, Columbia sportswear, Ralph Lauren plus other leading brands.
Chief Operations Officer, Prasanna Jayasekera explains:
As an established Fast React [now part of Coats Digital] user, MAS Active has long realised the value of good planning but when the business model changes, it is vital that a solution can grow and change with the business.
The MAS Active business has changed; design and technical innovation, speed of response and flexibility are fundamental to maintaining competitive advantage in today’s sportswear marketplace. For some programs, lead times are now as short as three weeks from order to shipment.”
The FastReactPlan (formerly Evolve) solution has supported our business change and, like us, their team follows a continuous improvement approach. In our case, embellishment was one part of the manufacturing process that needed particular attention; their team listened and developed a much improved solution.
Chief Operations Officer, MAS Active
B. KEY FACTS
To achieve better on-time delivery (OTDP) with increased flexibility and shorter lead times
Reduced lead times and increased OTDP from 80% to 98%
C. THE INTEGRATION PROCESS
The FastReactPlan solution provides Division-wide capacity management, order allocation and tracking, whilst also allowing each strategic business unit to plan and manage independently.
Significantly, the FastReactPlan solution allowed the Active Division to make the move from style level to style/colour level planning, assisted by the interface to SAP, which provides full visibility of materials availability to meet the plan. The two-way interface with the SAP system also allows latest ex-factory dates from the plan to be communicated back to the wider business via the SAP system.
D. THE RESULTS
During the period since implementing Evolve [now FastReactPlan], the business has been able to manage both significant growth and increased style complexity with no increase in planning headcount. By capitalising on the information that FastReactPlan provides along with good business disciplines, the MAS Active team have:
- Reduced the time taken to plan a full ‘buy’ from a major customer from 2 weeks to around 1 day
- Reduction in raw materials inventory by around 4 days and finished goods inventory by around 5 days
- Dramatically improved performance to plan (planned vs actual performance)
- Increased factory productivity by several percentage points
- Increased On Time Delivery Performance (OTDP%) from around 80% to more than 98%, at the same time as significantly reducing lead times
- Reduced air freight costs
Shirendra Lawrence, Managing Director, commented
Evolve [now FastReactPlan] supports the business improvement process by providing visibility and coordination to minimise errors and highlights potential problems quickly, so that they can be immediately rectified before they become an issue.
The reports offered are a major benefit and are used extensively both at planner level and for decision making at director level.
Shirendra Lawrence, MD, MAS Active