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Panam Group Boosts Production Planning Efficiency with FastReactPlan

Panam Group use FastReactPlan’s high level capacity and detailed line level sewing planning boards to manage production capacities, which in turn links to FastReactPlan’s operation management module.

Metro Knitting & Dyeing Mills Ltd. Unit-1, Metro Knitting & Dyeing Mills Ltd. Unit-2, Beacon Knitwear Ltd. Unit-1 & Beacon Knitwear Ltd. Unit-2, are part of the Panam Group and were established in Dhaka, Bangladesh in 2001. The Panam Group have around 20,000 employees across five production sites, with 145 sewing lines, which use machines imported from Germany, Japan, Sweden, Taiwan and USA.

Since 2001, the Panam Group have grown into a successful vertical, world class knit garment manufacturer covering yarn dyeing, knitting, fabric dyeing and finishing, sewing and garments dyeing. Main customers include H&M, GU and Next Sourcing.

  • South Asia Textiles Reduced average machine idle time by 74% - from 390 hours to less than 100 hours in just six months (Jan 2023 to June 2023) Vertical, world class knit garment manufacturer
  • Blue icon of three people 20,000 employees
  • Blue globe icon Bangladesh
  • icon label
    • H&M logo

3 %

increase in efficiency

3 − 12

month increase in forward plan visibility

Manufacturing processes in a garment factory in Bangladesh

The challenge

To increase efficiency to compensate for lower FOB prices being given by customers. Communication and coordination between Marketing, Production and Planning meant it took several meetings to:-

  • be able to quote accurate delivery dates at order confirmation stage
  • to understand production status to support lead time reduction requirements from buyers

Limited visibility of forward loading and open capacity.

The solution

Panam Group use FastReactPlan’s high level capacity and detailed line level sewing planning boards to manage production capacities, which in turn links to FastReactPlan’s operation management module. Using the pull system principle, FastReactPlan automatically creates detailed schedules from yarn dyeing to finished goods packing considering style and colour variations and generates accurate T&A target dates based on the production plan.

The planners now have clear visibility of the load vs capacity for each machine group / production process well in advance so they can ensure that sewing demand is achievable and any potential problems can be reviewed during weekly production meetings to ensure staff are proactive rather than reactive.

“The Panam Group team were very active and dedicated. The team accepted FastReactPlan from project kick off and actively explored what more could be achieved to replace their previous process. FastReactPlan was quickly introduced to weekly production meetings and KPI reviews were held with Panam Group Senior Management team.”

David Lush, Director of Professional
Services, Coats Digital

The result

Rubel Kanta Deb, Senior Manager, Central Planning, Panam Group commented: “Using FastReactPlan’s high level capacity planning board we were able to plan all projection and confirmed orders to the relevant units based on customer, product type and material availability. We can now forecast more accurately for the next 6 – 12 months whereas earlier on Excel, we were able to manage a maximum 3 month’s loading. FastReactPlan’s detailed sewing line level planning board gave us the visibility of continuing planning similar product types which drastically improved efficiency.”

“It has become much easier to understand buyer trends, factory loading, plan vs. actual and overall production status. We have managed to increase our capacity utilisation by as much as 50% and improve efficiency by 3% as FastReactPlan is giving us the required visibility. This means we have reduced our order confirmation process too by being able to consider open capacity much quicker.”

Balaram Roy Chowdhury,
Executive Director, Panam Group

The conclusions

“FastReactPlan is user friendly and very easy to install when compared to other software. Our planning department picked it up very quickly and were soon communicating better with our Marketing and Production departments. Regular visits by Coats Digital staff helped us get the most out of the implementation process.”

Balaram Roy Chowdhury
Executive Director, Panam Group

Amit Kumar Biswas, DGM IE, Planning & Co-Ordination, Panam Group commented: “FastReactPlan has played a vital role in allowing us to manage different areas of the business from a single source and immediately react to the problems highlighted. This has helped make internal meetings between different departments more productive. For example, we are now able to see the material flow from supporting production departments and re-plan accordingly to prevent any non-productive time that wouldn’t be obvious pre FastReactPlan.”

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