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Seeds Intimate Apparel achieve 98% on-time arrival of raw materials using FastReactPlan

Leading intimate apparel manufacturer has reported huge improvements in performance including on time delivery and productivity

Seeds Intimate Apparel, situated in the Brandix Apparel City in Vizag, India, is a joint venture combining four leading intimate apparel businesses; Brandix, Clover Group, Limited Brands and Brandot. Supplying the Limited Brands leading lingerie brands VICTORIA’S SECRET and PINK, Seeds employs 1,400 sewing workers and produced more than 6 million pieces last year.

  • Blue icon of a sewing machine Production capacity – 6 million pieces per year
  • Blue icon of the globe India

80% − 98 %

increase in OTDP

The Challenges

Seeds started production in July 2010, by early 2011 the business had grown and it was no longer possible to manage with excel spreadsheets so moving to a business system was essential.

“Our management team debated what system we should start with; ERP, Planning or Shopfloor control. Our buyers core requirement is for speed to market so this dictated that we needed to have a tool to manage capacity, order flow and be both flexible and accurate when making decisions. This was a much higher priority than handling the basic task of order processing, accounts etc. so it made sound business sense for us to start with FastReactPlan before ERP.”

Mr. Ganesh Subramanian, CEO
Seeds Intimate Apparel

Mr. Ganesh continued, “Another plus was many of our top management had previous experience of both FastReactPlan and numerous ERP implementations and they were of the opinion that FastReactPlan could be implemented much more quickly. This would be a quick win and return on investment for us. It could give our users an easy exposure to systems in general while helping to set us up for an ERP implementation at a later stage.”

The solution

Seeds use the FastReactPlan core modules; detailed sewing line planning board with integrated critical path/pre-production management and report designer.

Planning Manager, Mr. Mahesh Rathnayake stated “Once started, within 2 weeks our planner was able to do all the key activities via FastReactPlan and did not need touch Excel again. After one month we were ready to present and roll out to our other relevant staff. We wanted to make sure the whole company used the FastReactPlan solution and that they were working as a team, giving their commitment to do all their planning related activities on time. FastReactPlan is really user friendly and has the flexibility to cater for user requirements.”

The benefits

Customer Care Manager, Ms. Renuka Subasinghe explains the results to date “Our speed and accuracy have been significantly enhanced, we are able to confirm buyer orders within 24 hours and we have reduced last minute changes to the plan. Key T&A targets are driven and monitored in FastReactPlan which means OTT (on time tracking). Before FR, target hit the 80% to 90% range, now we hit 95% to 98%. Materials now arrive on or before the target date and this has helped us to achieve 100% on time delivery for the past few months. “Management is also more effective. The system is used daily for monitoring & making decisions in advance of any impact on deliveries as we have been able to take a lot of our old manual Excel management reports such as forward loading, plan vs actual, customer WIP reports and email these direct from FastReactPlan.“

CEO, Mr. Ganesh Subramanian futher explains the impact of T&A improvement on productivity “We have been working hard on all aspects of efficiency improvement and have made dramatic improvements. Planning and FastReactPlan have been a key part of this success story. The improvement in T&A and our OTT has meant the lines can run smoothly with minimal style change allowing the IE and supervisors to focus on line balancing and best methods.”

The conclusion

“Right now we have started implementing WFX as our ERP system, once the material purchasing and inventory side is live we will be looking to move to the next level which we will be adding FastReactPlan’s Material Supply and Demand module, interfaced with our WFX ERP system.

This will give us much better control on Raw material, reduce dock to dock time and inventory levels. It will also further enhance our speed by having a plan and the visibility on FastReactPlan through the whole process for own team, our customer and our suppliers.”

Mr. Ganesh Subramanian, CEO
Seeds Intimate Apparel
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