Texeurop boosts productivity and OTDP with FastReactPlan

About the customer :

Texeurop (BD) Ltd. is a composite knit garments manufacturer & exporter located in Dhaka, Bangladesh, that produces approximately 54,000 pieces of cut and sewn knits per day. It serves customers such as S. Oliver, Lerros, Strauss Innovation, Gerry Weber, and Mustang.

The company has its own knitting and dyeing facilities, in addition to in-house embroidery and washing capabilities, which enables it to maintain highly competitive lead times.

Produces approx. 54000 knit garments per day
4000+ employees
Dhaka, Bangladesh

The Challenge:

As Texeurop’s business expanded, the team found it increasingly challenging to keep track of all critical planning elements using various spreadsheets. Recognising the need for a more dynamic planning tool, they sought a solution that would streamline the entire manufacturing process, from dyeing and cutting to embroidery, printing and sewing. Before adopting FastReactPlan, the lack of swift and accurate information forced the company to base order decisions on ‘assumptions’. This approach often led to either under-booking or over-booking, causing missed sales opportunities and delayed deliveries, both of which proved costly for the business.

Why FastReactPlan? Engr. M. Zulfiker Ahmed, the General Manager Operations, Texeurop, explains, “Coats Digital’s deep understanding of the apparel industry enabled us to tailor FastReactPlan specifically to our needs, ensuring that our users could easily adapt to the system as it was quickly customised to their own environment.

“Buyer confidence has increased, clearly demonstrated by the increased order quantities placed with us. Of course, no plan is ever 100% perfect, but the daily comparison of planned versus actual and quick readjustment of the plan allow us to avoid last-minute surprises. FastReactPlan reports are a real timesaver and are being used for management decision-making, including KPI monitoring and daily shipment follow-up.”

Engr. M. Zulfiker Ahmed,
General Manager Operations,
Texeurop (BD) Ltd.

The Solution :

FastReactPlan’s solution provided Texeurop with:

All the key planning elements in a single dynamic tool – providing a single point of reference for both users and management reporting, rather than having to rely on lots of Excel spreadsheets.
Effective coordination of all operations (dye, print, embroidery etc.) – to support the sewing plan with clear schedules for all areas.
An accurate assessment of machinery requirements enabling the company to understand in advance what machines are required to meet the plan in advance, thus facilitating decisions regarding machine hiring or loaning in the upcoming weeks.
Detailed monitoring of plan vs. actual, allowing for rapid re-adjustment to avoid last minute surprises.
Fast and accurate planning and re-planning capabilities, even in situations where pre-production problems arise, due to the ease and flexibility in amending the plan.

“Texeurop increased On Time Delivery Performance (OTDP) by 15%. The financial savings in airfreight and discounts alone paid for FastReactPlan within the first year. All of this has meant that we have improved our overall productivity by minimising line idle time. Consequently, we have significantly increased the utilisation of manpower and machines, enabling us to maintain the same daily output of 54,000 pieces with 170 fewer sewing operators. This is a real cost reduction of 14.2%, representing a further very significant saving!”
Engr. M. Zulfiker Ahmed,
General Manager Operations,
Texeurop (BD) Ltd.