South Asia Textiles Reduces Capacity Planning Time by 75% with Coats Digital’s FastReactPlan

PRESS ROOM

2 Jul

Written By Debbie Mckeegan

Image By Courtesy of SOUTH ASIA TEXTILES

Pugoda, Sri Lanka – June 2024 ─ South Asia Textiles, a leading manufacturer and exporter of textiles, has significantly enhanced its operational efficiency by implementing Coats Digital’s FastReactPlan.

The textile giant has achieved a 75% reduction in capacity planning time, decreased machine idle time by 74%, and improved on-time delivery performance (OTDP) by 15%.

FastReactPlan has streamlined critical planning information into a single platform, drastically reducing the average machine idle time from 380 hours to just 100 hours.

This optimization has unlocked additional capacity and improved data visibility across relevant teams, enhancing inter-departmental communication and facilitating new business growth.

Key Achievements with FastReactPlan:

75% Reduction in Capacity Planning Time: From eight hours to two.

74% Reduction in Machine Idle Time: From 380 hours to 100 hours.

15% Improvement in OTDP: Significantly enhancing delivery reliability.

Rohan Goonathilake, Managing Director of South Asia Textiles Ltd., remarked, "FastReactPlan has made a huge difference to our business. We can now make timely updates to plans, enabling all teams to adjust their production schedules accordingly—ensuring a smooth workflow at all times. FastReactPlan allows us to confidently take on increased business to fill capacity for all machine types on a long-term basis, and thanks to the data accuracy, we always deliver on time.”

Addressing Past Challenges

Prior to the adoption of FastReactPlan, South Asia Textiles faced significant challenges with production under-utilization and delivery issues. Vital capacity planning and production information were siloed across multiple sources, leading to incorrect assumptions about machine availability and inventory, and ultimately, costly mistakes that impacted on-time delivery performance.

Sameera Jayasinghe, Senior Manager Planning at South Asia Textiles Ltd., noted, “We were challenged by a serious lack of visibility of capacity plans beyond a three-day window. Our manual planning processes proved exceptionally time-consuming, which not only led to slower decision-making across all departments but also resulted in a lack of order tracking, missed orders, and regular on-time delivery failures.”

Seamless Integration and Enhanced Collaboration

The implementation of FastReactPlan has provided South Asia Textiles with access to business-critical planning and production information from a single, digitized source. This enhanced data visibility has fostered closer alignment and seamless collaboration across all levels of the organization, enabling planners to create accurate Cost-to-Make (CM) quotes based on real-time capacity availability and manage diverse orders efficiently.

Rukshan Periyapperuma, Customer Success Manager at Coats Digital, expressed, “We are delighted that South Asia Textiles has realized such significant, tangible benefits within a year of implementing FastReactPlan. The positive impact of this solution has been felt across all facets of the business, underscoring the critical role that accurate, highly visual capacity plans play in the future growth of textile and fashion apparel manufacturers.”

About South Asia Textiles

Headquartered in Pugoda, Sri Lanka, and a subsidiary of Hayleys Fabric PLC, South Asia Textiles is a leading manufacturer and exporter of textiles. The company specializes in Knitting, Dyeing, Finishing, Printing, Brushing, Sueding, and Preshrunk fabric services for global brands such as Victoria Secret, Next, Marks & Spencer, Tesco, Calvin Klein, Decathlon, Levi’s, Hugo Boss, and Adidas. Employing over 1,400 staff, the company has the capacity to produce 800,000 kg of quality textiles per month.

About Coats Digital’s FastReactPlan

Part of Coats Digital’s core Manufacturing Solution Suite, FastReactPlan is a dynamic, visual production planning and control tool that optimizes delivery, efficiency, and lead times. Designed specifically for footwear and apparel manufacturers, it integrates capacity, critical path, and materials into an efficient planning system, enabling businesses to achieve their optimization and growth objectives.