Cotton Club(BD) Boosts Annual Turnover by $250K with GSDCost
By establishing accurate Standard-Minute-Values, GSDCost has enabled Cotton Club (bd) to improve its costing accuracy by 90%; increase production efficiency by 3%; reduce material wastage by 4% and increase its OTDP by 7%.
About the customer :
Founded in 2006, Cotton Club (BD) Ltd. is a premier composite garment manufacturer in Bangladesh, dedicated to delivering innovative, high-quality garments worldwide. The company operates a vertically integrated operation which includes all knitting, dyeing, cutting, printing, embroidery, and sewing & finishing processes. Cotton Club (bd) consists of four companies, including Cotton Clout (BD) Ltd., Tropical Knitex Ltd., and Cotton Clothing (BD) Ltd., which specialises in knitted items for all ages and underwear production. The company employments a 15,000 strong workforce, operates 6,800 sewing machines ,boosts an annual turnover of 268 million USD and is targeted to reach 300 million this fiscal year. Its customers include: Kiabi, Inditex Brands , Primark, Kontoor Brands, Kohls, Target USA, Ernsting Family, Bon Prix, Being Human and Forever 21, among many others.
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Produces 268 million garments annually -
15,000+ employees -
Dhaka, Bangladesh -
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Running a factory without accurate costing and capacity data is like flying blind. Before GSDCost, we relied on outdated spreadsheets that gave us no real-time visibility. We were making big decisions based on guesswork, which sometimes meant we turned away orders we could have handled or, worse, overcommitted and had to scramble to meet deadlines. This led to costly overtime, missed delivery dates, and frustrated customers. It was a constant struggle to balance efficiency with profitability.
Md. Zubayer Mondol,
Director & Owner,
Cotton Club (bd) Ltd.
The Challenge – Poor costing visibility and unreliable production planning led to inefficiencies and costly errors
Before adopting GSDCost, Cotton Club (bd) Ltd. relied on outdated historical data spread across multiple Excel spreadsheets for cost and capacity forecasting. These manual processes made it difficult to update information in real time across costing, capacity planning, and manufacturing teams, leading to inefficiencies and costly errors.
Without accurate Standard Minute Values (SMVs) to determine Cost to Make (CM) production times, the company struggled with poor costing visibility and unreliable capacity planning. This often resulted in last-minute realisations that production floor capacity was insufficient, leading to missed delivery deadlines, increased overhead costs, and customer dissatisfaction. At the same time, the lack of accurate data caused Cotton Club to turn down new business opportunities, mistakenly believing it lacked the resources to fulfil them—when, in reality, it had the capacity to take on more orders. These challenges created significant workflow disruptions, making it difficult to manage short lead-time orders and maintain a smooth, efficient supply chain.
Coats Digital’s GSDCost Software has significantly improved the accuracy of our work measurement, ensuring that we can track projects with precision. Its features have streamlined our workflows, making operations more efficient. As a result, we’ve seen better cost control.
Md. Zubayer Mondol,
Director & Owner,
Cotton Club (bd) Ltd.
The Solution
Since adopting GSDCost, Cotton Club (bd)has seen significant improvements across its whole operation. By successfully establishing international standard time benchmarks based on standard motion codes and predetermined times, the sales, costing, planning and manufacturing teams at Cotton Club have been able to communicate seamlessly using the same language, based on a scientific method for correctly analysing manufacturing costs.
As a result of the implementation, Cotton Club (bd) has reduced the time it takes to produce its core styles by 25.6%, which has achieved a productivity increase of 5%. The company has subsequently increased its profit margins by a staggering 0.45 million USD annually as a result of a 90 percent increase in costing accuracy; a reduction in material wastage of 10 percent; a decrease in unnecessary overtime costs of 8 percent and an increase in on-time delivery performance (OTDP) of 7 percent. The company has also been able to confidently take on more varied and complex, new order requests since the GSDCost implementation, whilst significantly enhancing customer loyalty at the same time.
We are absolutely thrilled to see Cotton Club achieve such outstanding results with GSDCost. The company’s remarkable improvements in efficiency, cost accuracy, and profitability highlight the vital role of scientifically backed, data-driven solutions in today’s fashion industry. With growing pressure to produce complex styles faster while maintaining competitive pricing, manufacturers must embrace digital transformation to stay ahead.
Golam Mahbub Sikder,
Cotton Club has done exactly that—enhancing capacity planning, streamlining costing, and boosting production efficiencies to become a more agile, competitive, and future-ready business. We are proud to be playing such an important role in Cotton Club (bd)’s digital transformation journey and look forward to supporting its continued success.
Customer Success Manager,
Coats Digital
GSDCost utilises the latest cloud software architecture to provide a highly intuitive, secure and scalable SaaS solution, which helps achieve cost optimisation and sustainable improvements in productivity. GSDCost’s enhanced feature of a globalised Fair Wage Tool – with data provided by the Fair Wage Network – enables brands and manufacturers to quickly agree the fair living wage allowance for any given garment, in any factory in the world.
