Madura Garments increase operational efficiency by more than 7% in 2 years.

Madura Garments Exports, a subsidiary of the Aditya Birla Group, is one of the largest shirt manufacturers in India with a capacity of five million pieces of formal, wrinkle free and casual shirts.

Madura Garments Exports, a subsidiary of the Aditya Birla Group, is one of the largest shirt manufacturers in India with a capacity of five million pieces of formal, wrinkle-free and casual shirts.

With an annual turnover of nearly US $50 million Madura supplies leading UK High Street names such as Marks & Spencer, John Lewis, FCUK, Jaeger, H&M and short lead time and high fashion brands such as Esprit and Diesel.

Products – formal shirts, wrinkle-free shirts, casual shirts
Annual Turnover – US $50 Million

7.1 %

Increase in operational efficiency over 2 years

97 %

Ship/cut ratio reached with FastReactPlan

85 %

On time & in full ratio reached with FastReactPlan

Why FastReactPlan?

Mr. R. Swaminathan, Deputy COO, Madura, explains, “As we changed our market focus from the US to Europe and more into casual shirts and ladieswear, we faced much greater complexity from reduced lead times, more styles/smaller order sizes, higher work content (SMV) and lots of value addition processes (printing, embroidery, washes).

“Our manual planning systems could simply not cope with this complexity. Coats Digital’s FastReactPlan is the well respected name for providing planning solutions and effective support during implementation for our (fashion) industry. The system is very comprehensive and very flexible with all possible situations well covered.”

The Benefits to Delivery Performance

Mr. R. Swaminathan explains, “Before FastReactPlan we suffered delivery penalties totalling nearly $1.3 million in 2009. We have reduced this dramatically to less than $67k. On-Time and In Full ratio has improved from 35% in 2009 to nearly 85% in 2011 with the Ship/Cut Ratio currently at 97%.”

The Benefits in Productivity

“In our shirts production unit from FY2009 to FY2011, we have produced 34.5% more output with only 25.5% more machines/labour. That means we have improved the operational efficiency in our shirts production by 7.1% over 2 years.”
Mr. R. Swaminathan, Deputy COO
Madura Garments Exports Ltd.

The Benefits

Mr. Anshuman Bhaskar, the FastReactPlan planner explains: “These improvements have been possible because FastReactPlan provides:

- Clear visibility of the status of all orders and load on the factories
- The ability to keep pace with dynamic situations and quickly re-plan
- Transparency of information across the different business departments so we work more effectively as a team”

Mr. P. Ramesh, Agent, Coats Digital – India adds, “To take the usefulness of FastReactPlan to the next stage, we are currently integrating with SAP thereby removing duplication of data entry and further improving data integrity between departments.”

The Return on Investment

Mr. ES Sankar, CEO at Madura, concludes, “The above figures say a lot about the very quick return on investment (ROI) that FastReactPlan provides. In simple terms, removing chaos has been the biggest reason and achievement of FastReactPlan in Madura Garment Exports.”