Coats Digital – a leading fashion manufacturing technology provider – has announced the results of its collaboration with renowned Bangladesh’s garment manufacturer Tusuka.
Following the implementation of Coats Digital’s FastReactPlan solution, Tusuka has realised an overall efficiency increase of 5 per cent, an improvement in OTDP (On-Time Delivery Performance) of 9 per cent and higher employee job satisfaction, which has resulted in a drop in staff absenteeism by 7 per cent.
According to Coats Digital, before Tusuka opted for FastReactPlan, its planning teams lacked the required business intelligence to navigate the volatile industry changes at the start of the global COVID-19 pandemic; and the ruptured supply chain factors as well as an unexpected fluctuation of demand and capacity allocation didn’t let Tusuka optimise all factory facilities.
Furthermore, 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 effect 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.
With FastReactPlan, as per the company, Tusuka’s planning and merchandising teams no longer need to cross-reference a myriad of spreadsheets, e-mail messages, telephone conversations or meeting logs, to make important decisions about order planning and fulfilment.
Tusuka’s employees, with all information now in one place, 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.
Improved visibility and transparency have consequently boosted staff morale and reduced absenteeism by 7 per cent at Tusuka and the staff is now 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.
Fayzur Rahman Badal, Managing Director, Tusuka, stated, “Since adopting FastReactPlan, Tusuka has seen significant top-line growth thanks to greatly improved planning and decision making. It is such a user-friendly tool. I can easily access a snapshot of our entire business at any time, including visibility into micro levels where required.”
Sheikh Shariful Islam, General Manager, Merchandising, Tusuka, commented, “The highly visual and easy-to-use capabilities of FastReactPlan enable us to reschedule activities at speed, enabling us to offer advanced shipments which in turn reduces our storage costs and in-transit or WIP liabilities, eliminates costly airfreight and avoids other delivery flaws.”
Ahtashamul Khan, Customer Success Manager, Coats Digital, Bangladesh, mentioned, “Tusuka’s FRP implementation was one of the fastest FRP implementation in Bangladesh, adding, “After receiving astounding benefits as a result of the FastReactPlan implementation, the partnership between Tusuka and Coats Digital has strengthened, and FRP usage has now been extended to high-level planning, where it has been integrated into Tusuka’s ERP and PowerBI systems.”
It’s worth noting here that Tusuka caters to brands such as H&M, Zara, M&S, WE, LPP and Group Dynamite. The Group does have a total workforce of 10,000 and a garment production capacity of 22,000,000 per annum.