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Interloop reduces Work In Progress (WIP) and lead time by using FastReactPlan

South Asia’s largest sock manufacturer and exporter, substantially improves efficiency and productivity through effective planning and careful management.

Interloop currently operates 4 factories based in Faisalabad, Lahore and Bangladesh. With over 3000 sock knitting machines, they produce an estimated 360 million pairs annually.

With a determined and professional business approach and a 20 year history as an exporter, Interloop is highly regarded by its customers who include Nike, Puma, JC Penney, Tesco, C&A and Primark.

  • Blue icon of a sewing machine Production capacity – 360 million pairs per year
  • Blue icon of the globe Pakistan
  • icon label
    • Nike
    • C&A logo

35 %

rise in productivity

33 %

reduction in lead time

20 %

reduction in WIP

The challenges

The company offers a large variety of custom designed socks to its customers, honouring commitments and maintaining a high standard of quality in both products and ethics. With large demand for their products, managing customer forecasts vs. actual order receipts had become a major challenge. In addition, managing multiple critical paths through numerous spreadsheets led to poor visibility and coordination; an uncertain environment for making accurate decisions. As a result both WIP and material inventory levels were relatively high.

“For Interloop, flexibility, speed to market and cost control are the corner stones for success as a reliable supply chain partner of global retailers and brands. In order to achieve these goals and support its initiatives to become a LEAN organisation, Interloop decided to employ the FastReactPlan planning solution.”

Mr. Musadaq Zulqarnain, Chief Executive Officer

The solution

FastReactPlan has allowed Interloop to clearly prioritse and manage their activities to meet their customers often demanding requirements. This has improved coordination internally and reduced both response time to urgent queries and overall lead time.

“Since using the FastReactPlan solution, we have improved efficiency and producivity by 35%. In turn this has reduced WIP by 20% and lead time by 33%. This is a huge acheivement; we are now able to serve our customers market needs with a lot of flexibility and plan our operations much more efficiently.”

Mr. Musadaq Zulqarnain, Chief Executive Officer

The conclusion

Andrew Brown, Managing Director, Coats Digital’s FastReactPlan commented “These remarkable results show just what can be achieved by a professional and dedicated management team supported by good software. Together with the Interloop team, we have already indentified further areas of potential savings and look forward to working with them on a Continuous Improvement basis.”

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