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Son Ha Garment JSC achieves 10% efficiency gain with GSDCost & is on target to further reduce production time by 50%

The implementation of the internationally recognised Standard Minute Value benchmark, GSDCost, has also resulted in increased order visibility, enhanced productivity performance, improved on-time deliveries and a fair wage being factored into all cost negotiations with customers.

About the customer:

Established in 1969, top sportswear and knitwear manufacturer in Hanoi, Vietnam, Son Ha Garment Joint Stock Company employs a 3,400-strong workforce and exports 60 percent of its jackets, trousers, sports apparel and T-Shirts to the United States, and 30 percent to the EU.

Its customers include: Columbia Sportswear, Umbro, Walmart, Costco, Quicksilver, A&F, Kohl’s and Levi’s.

  • Icon - 3 diverse Employees 3,400-strong workforce
  • Blue globe icon Hanoi, Vietnam
  • Label Icon
    • Levi's Logo
    • Kohl’s Logo
    • Walmart Logo
    • A&F logo
The Challenge – Inaccurate data led to inefficiencies

Manually created purchase orders often got lost and cost forecasts based on inaccurate historical data resulted in reduced efficiencies and wasted people hours.

Son Ha Garment Production Prior to implementing Coats Digital’s cost optimisation solution, GSDCost, Son Ha Garment JSC suffered poor data visibility, lost purchase orders and complicated cost negotiations with customers due to the fact that its cost, sourcing and planning processes were manually created and stored across a variety of sources within different departments. The company found that its capacity and cost planning reports were often inaccurate because data was based purely on historical experiences and the information was not easy to find by all members of the team who needed it.

The lack of accurate costing data consequently, not only made it difficult to reach a definitive agreement with customers regarding order quotations, but its analogue approach also meant that it was wasting hundreds of people hours on unnecessary manual processes.

The Solution 

Son Ha Garment required a standardised solution that would accurately record Standard Minute Values through effective, standard motion digitised codes so it could optimise its costing processes, enhance manufacturing efficiencies, introduce achievable performance targets to improve staff motivation and performance, and ultimately increase sales to optimise its profitability.

Son Ha Garment JSC VietnamCoats Digital’s GSDCost method analysis and pre-determined times solution is widely acknowledged as the de-facto international standard across the sewn products industry.

The solution supports a more collaborative, transparent and sustainable supply chain, in which brands and manufacturers establish and optimise ‘International Standard Time Benchmarks’ using standard motion codes and predetermined times.

This use of a common language and standards supports accurate cost prediction, fact-based negotiation, and a more efficient garment manufacturing process, while concurrently delivering on CSR commitments.

Coats Digital’s enhanced feature of a globalised Fair Wage Tool combines the international standard time for any given style, with detailed factory efficiencies, contracted hours and the fair living wage for the country (data provided by the Fair Wage Network). This added tool enables brands and manufacturers to quickly agree the fair living wage allowance for any given garment, in any factory in the world.

The results have been fantastic. We have initially realised a 10% productivity performance increase, and expect this to elevate to over 50% in the near future.

It has made a huge difference to the business having our cost planning reports fully digitised and all in one place. Our teams now have a single view providing the access they need to make fast, informed business decisions based on accurate data, wherever they are. Son Ha Garment JSC is absolutely committed to robust equality policies, employee wellbeing and fair wages, and the adoption of GSDCost has also meant that we can factor in a fair wage into all our new, fact-based cost negotiations with our customers.

Le Huu Phong
CEO
Son Ha Garment Joint Stock Company

We are excited about our future collaboration with Coats Digital. The experience has proved a very promising start on our digitisation journey to improve our operations so that we can future-proof our business effectively and ensure we remain a leader in the fashion manufacturing sector.

Le Huu Phong
CEO
Son Ha Garment Joint Stock Company

“We are absolutely over the moon that Son Ha Garment JSC has realised such amazing efficiency results following its adoption of GSDCost.

The textile and apparel industry is becoming increasingly more competitive and with constant pressure to lower costs, whilst offering smaller orders with more style variations at the same time, the only way that fashion manufacturers can stay ahead of the game, is to digitise their processes quickly. Standardising SMV calculations is a sure-fire way to increase manufacturing efficiencies, introduce fact-based, stable cost negotiations, reduce overtime costs and material waste, whilst incentivising employees with achievable performance targets and responding to more complicated order demands in a timely way.

We look forward to partnering with Son Ha Garment JSC on a long-term basis to ensure they are well-positioned to embrace a rapidly changing industry environment with more certainty.”

Patrick Chau
Customer Success Manager
Coats Digital
Key benefits and ROI:
Increased Efficiency

Initial efficiency increase of 10%

Icon - Increased visibility

Increased order and cost planning visibility

• Fact-based manufacturing costs

Fact-based stable manufacturing costs

Increased orders

Achievable performance incentive programme

Reduction in overtime costs

GSDCost utilises the latest cloud software architecture to provide a highly intuitive, secure and scalable SaaS solution, which helps achieve cost optimisation and sustainable improvements in productivity.

GSDCost-Method time cost solution

Save Time and Cost with GSDCost

Increase profits with fact based costings using proven industry standards and methodologies.

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