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Delta Textile increases productivity by 25% with FastReactPlan

The installation of the FastReactPlan has improved visibility and prioritisation of materials to meet plan

Delta Textile is a leading apparel company, manufacturing and marketing private apparel products for men, women and children. The company produces customised, innovative fashion and basic apparel for leading retailers and brands around the world.

Since its inception in 1975, Delta has expanded to encompass design, development and manufacturing centres on four continents servicing over 50 customers in the US, UK and continental Europe, with more than 10,500 employees located worldwide. Delta provides customers with tailored vertical solutions, which encompass every stage of production, from initial design and development through manufacture of fabrics, accessories and garments to logistics, distribution and replenishment.

  • blue icon of sewing machine Daily production capacity – 80,000-85,000 pieces per day
  • Blue icon with cogs and upwards facing arrow 10% rise in production efficiency
  • Blue icon of the globe Egypt
  • icon label

Delta Textile Egypt is a vertically integrated underwear manufacturing business who manufacture a varied range of different products for customers including: M&S, Calvin Klein, Tommy, Hugo Boss, Victoria Secret, Kmart, Wal*Mart, Pierre Cardin, Dim and Target.

Delta’s production is based on a mixture of its own plant and various CMT subcontractors. With around 3000 employees across 4 factories, Delta Textile Egypt produces an average of around 80,000-85,000 pieces per day. They also have the ability to handle a high volume of small order quantities (300-500 pieces per order).

The challenge

The main business system in use at Delta is Movex, which had been enhanced through its own development. However, before FastReactPlan was installed, planning was mainly performed on spreadsheets. These largely manual based systems caused a lack of visibility and proved very difficult to amend when customer requirements changed. Planners were not able to see the knock-on effect of any changes made, which meant that much ‘fire-fighting needed to take place to ensure that customer deliveries were made on time.

The solution

The FastReactPlan solution has been installed and has been fully integrated with the Movex business system to provide a centralised and effective planning environment. The installation of FastReactPlan has removed the reliance on spreadsheet technology and has enabled the planners to focus on issue resolution as opposed to spreadsheet manipulation. A phased approach to implementation was undertaken with FastReactPlan being initially installed in a single factory with 15 lines. The implementation proved so effective that it was quickly rolled out to the other 3 factories with another 51 lines. When asked about the implementation of FastReactPlan, Mursi Shamas, IT Manager at Delta commented “The level of support provided has been excellent”.

The conclusion

Since the implementation of FastReactPlan, Delta is no longer using spreadsheets to plan. This has resulted in many business benefits being achieved including better On-Time Delivery Performance (OTDP) to customers, better staff utilisation and increased production efficiency. “Production Efficiency has increased by around 10%, through the introduction of FastReactPlan” explained Mursi Shammas.

“Production Efficiency has increased by around 10%, through the introduction of FastReactPlan.”

Mursi Shammas
IT Manager, Delta Textile

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