Silken Sewing implement best practice planning in only six months following the installation of Evolve [now FastReactPlan]
A. THE CUSTOMER
Silken Sewing Ltd was established in Dhaka, Bangladesh in 2008 and has grown into a successful world-class knit garment manufacturer. They have 600 machines, on 26 Sewing Lines, offer a production capacity of one million pieces per month.
Their total manpower is 1,900, with a turnover, in 2018, of $19 Million. The Company supply some of the world’s largest retailers including Cotton On, Esprit, and Debenhams. They export to many countries around the world including the UK, Australia, France, and Russia.
B. THE CHALLENGE
Prior to the installation of FastReactPlan software communication and coordination between merchandising, planning and production were complicated and time-consuming.
Multiple spreadsheets and numerous emails were necessary to identify problems in pre-production activities and to understand the production status before the plan could be executed. Whilst the traditional focus of manufacturers was on production efficiency alone, the demands of the current role necessitate reliable information across the supply chain and how it relates to the core function of Supply Chain.
C. THE SOLUTION
Silken Sewing utilized FastReactPlan’s detailed line level sewing planning boards to manage production capacities, and using the pull system principle, generated T&A target dates based on the production plan.
Rukunuz Zaman, Fast React’s Dhaka based Project Manager, explains,
“The Silken Sewing project team were very active and dedicated. The team accepted FastReactPlan from project kick off and actively explored what more could be achieved. As a result, the implementation was completed within three months”.
D. KEY FACTS
Silken Sewing Limited
Complicated and time-consuming communication and coordination between departments. Numerous spreadsheets and emails required to identify problems and understand the production status.
A 25% reduction of non-productive time, 4% increase in efficiency and a 10% reduction in material inventory
In only six months we recognised the benefits of FastReactPlan. Our non-productive time reduced by 25%, we achieved a 4% efficiency improvement and we can now hold 10% less fabric inventory.
Towhidul Alam Executive, Director AFM Silken Sewing
E. THE RESULTS
Planning and coordination has never been easier with Evolve [now FastReactPlan]. It now only takes a few hours to create, review progress and adjust the plan. As a result, it has given me the opportunity to focus on aligning all departments to ensure the plan is agreed upon and then achieved.
With FastReactPlan’s detailed line level planning board and the ability to consider other production processes, together with clear visibility of the weekly loading, ensures the sewing demand is achievable. This has resulted in a 5% increase in plan vs. actual. The T&A late and failure analysis provides an insight of the root cause of any issues, which we use to support our continuous improvement. This facility also gave us a tool to negotiate with the buyers when discussing late deliveries attributed to issues within their own control.
Md. Ahsan Habib
Senior Manager (Planning and Supply Chain) Silken Sewing
It was difficult to get information to manage factory costs before we installed FastReactPlan but now I can get key reports via the software, which provides me with sewing line profitability and other necessary details.
FastReactPlan’s report generation tool has improved management’s time utilisation and we estimate that we have saved 200 man hours per month because our report templates are now created inside the FastReactPlan system. With FastReactPlan being able to create an existing financial report, I can assess which buyer is more profitable, which makes sales forecasting easier.
Abdullah Al-Mamun Factory GM – Silken Sewing
F. THE CONCLUSIONS
Before the FastReactPlan implementation, planning was only looking at sewing but now through Evolve, we have been able to monitor other operations’ capacities and T&A status, which has resulted in a more accurate and realistic plan for all departments. By using FastReactPlan, we now have established integrated planning through all functional departments. Consequently the feeding between the embellishment units through to sewing has resulted in 25% reduction of non-productive time. It only took us 6 months from project kick off to start recognizing benefits through FastReactPlan and in that short space of time we have seen a 4% factory efficiency improvement and we can hold 10% less fabric inventory.
Executive Director AFM – Silken Sewing