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Busana Remaja Agracipta improves planning accuracy with FastReactPlan

Coats Digital's FastReactPlan solution helps the lingerie manufacturer to maximise capacity utilisation and delivery performance.

In 1993, Busana Remaja Agracipta started to manufacture lingerie. Based in Indonesia, the underwear producer has a capacity for 24 million units of bras, briefs, bodysuits, camisoles, hipsters, leggings and thongs.

With an 80 Million (USD) turnover, and production in 4 factories in 3 locations, Busana supply leading buyers in the USA, Europe and Australia.

Their customers include Gold Choice (HbI), Maiden Form, JC Penney, H&M, Simon de Winter, Warnaco, Bonprix, Giorgio Armani, Eveden and DKNY.

  • Blue icon of a sewing machine Production capacity – 24 million garments per year
  • Outline of a T-shirt and a dress Products – bras, briefs, body suits, camisoles, hipsters, leggings and thongs
  • Blue icon of the globe Indonesia
  • icon label
    • Giorgio Armani logo
    • Bon Prix logo
    • JCPenny logo

The Challenge

The Busana Remaja team constantly strive to improve customer service levels but were facing problems due to the lack of visibility and the time taken to get updates on the latest situation, as well as quickly promising delivery dates when booking new orders. As in any fashion business, many factors must be considered during the process of building the ideal plan and promising a delivery date, from pre-production tasks, i.e. sample approval and material purchase, capacity on sewing and supporting processes, special machines availability, materials demand vs supply, etc.

Trying to consider all of this for 350 styles a month and 110 production lines, became increasingly difficult to do accurately and quickly enough with spreadsheets and emails. At management level, gathering information and being able to see all factories became challenging and timely to coordinate, and therefore led the company to seek a solution in order to centralise its planning and decision-making processes. In 2010, Busana Remaja implemented FastReactPlan solution.

The Solution

Mr. SL Uttam, President at Busana Remaja explains, Integrating FastReactPlan with the existing ERP system has improved data integrity as we can easily see in FastReactPlan what that ERP data means to the plan. That is, are we able to start production and meet the delivery. With updates on Time and Action and daily output on production, the dynamic situation in the factory can be more easily managed by my team. They can see potential production and delivery issues, and find solutions for the typical problems such as pre-production delays and material shortages, etc.”

Raja Ganapathy, Chief Planner at Busana Remaja continues, “Planning with FastReactPlan also helps us monitor machine allocation in various factories allowing us to reallocate within our 4 factories. This eliminates our past experience when production is delayed due to machine shortages and we could not see until it was too late.”

Mr Uttam then further explains how the reporting tools in FastReactPlan help the continuous improvement process, “We are now able to quickly generate reports on order status and analyse KPI performance on items such as Shipment and Plan vs Actual, and this is done within less than 10 minutes. Our old manual spreadsheets would take at least 1 week after spending a lot of time verifying data”.

“Our staff can now save 2-3 hours per day just on report generation. This means they have more time to see and solve problems and learn from the past, to avoid the same mistake happening again.”

Mr. SL Uttam, President
Busana Remaja Agracipta

The Benefits

“Our KPIs show that we are much more accurate when planning and that we achieve what we plan. We now consistently hit +/- 5%. As anyone in the fashion business will know, that kind of consistency is vital for hitting deliveries, controlling production and excess costs. That more than justifies the investment of time and money in the FastReactPlan system.”

Mr. SL Uttam, President
Busana Remaja Agracipta

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