Busana Remaja Agracipta improves planning accuracy with FastReactPlan

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”.

The Benefits