As the world becomes more interconnected, the need for robust processes to identify and successfully manage growing supply-chain risks has become paramount. Stellium, a management consulting firm with a strong global presence in America, Asia and Europe, offers tailored services to address the unique needs of the apparel sector in supply chain, manufacturing and logistics. Stellium assists companies in deploying Internet of Things (IoT) devices such as sensors, RFID tags and GPS trackers across their supply chain infrastructure. These IoT devices capture real-time data on product location, temperature, humidity and other relevant parameters, providing visibility and traceability throughout the supply chain.
Through advanced data analytics and visualisation tools, Stellium enables companies to analyse large volumes of supply chain data, extracting actionable insights and visualising key performance indicators, trends and patterns. Its innovative in-house build solutions – Advanced Warehouse Analytics (AWA) and Advanced Transportation Management Analytics (ATMA) – exemplify this approach. Moreover, Stellium develops custom supply chain platforms and solutions tailored to the specific needs of each client. These platforms enable seamless collaboration and communication amongst supply chain stakeholders, facilitate real-time data sharing and provide end-to-end visibility into supply chain operations, ensuring traceability and transparency across the entire ecosystem. The company also specialises in the implementation of advanced features in warehousing providing complete transparency, inventory visibility and tracking of products within the warehouse.
Stellium initiated its first Generative AI automation project with a North American customer, and regardless of the industry, in the context of supply chain management, Gen AI automation can revolutionise operations by streamlining processes, optimising resource allocation and improving decision making. Stellium’s future roadmap includes the integration of Blockchain technology and Digital Twin development to foster transparency within the supply chain.
In an exclusive interview with Apparel Resources, James Jaichander, SVP Customer Success (India, APAC & ME) and Global Pre-Sales, Stellium sheds light on the company’s strategies for supply chain digitisation and transparency enhancement, along with highlighting success stories, sustainability integration efforts and approaches to mitigate future risks.
AR: Share with us a success story or case study illustrating how Stellium has helped apparel companies overcome challenges, drive innovation, cut costs or achieve significant operational improvements?
James Jaichander: Absolutely! In terms of our client portfolio, we’ve had the privilege of working with some major players like Pantaloons (Aditya Birla Fashions Retail Ltd), BESTSELLER, GMG (Gulf Marketing Group in the ME Region), Welspun, just to name a few. We have helped embark on a digital transformation journey with significant process improvements in the warehousing operations. For instance, with Pantaloons, with its extensive network of over 100 stores nationwide, we embarked on a detailed process to configure SAP EWM for warehouses in Bengaluru and three other cities. This involved using standard functionalities of SAP EWM while ensuring compatibility with their existing Infor WMS used in third-party warehouses.
The implementation involved a combination of flow-through and pure cross-dock operations for the same allocation line item. We fine-tuned processes to enable adjustment of allocated stock based on specific store requirements. Additionally, we implemented strategies for the consolidation of stock within the same bin, catering to both regular and e-commerce stock, with clear differentiation between ROD (Regular Orderable Demand) and AFS (Available For Sale) stock for enhanced inventory control.
To maintain accuracy and integrity, we established protocols for standard annual physical inventory, daily cycle counting and the seamless upload of count results from external systems. Furthermore, our system was designed to automatically trigger the physical inventory process in case of discrepancies during picking, ensuring prompt resolution of any issues. The receiving process was streamlined using RF (Radio Frequency) technology, facilitating the creation of mixed pallets and enabling count verification through scanning. Our efforts resulted in improved efficiency across picking, putaway and internal warehouse movements. We achieved a 15 per cent increase in cross-dock percentage, facilitating faster inventory turnover, fewer touches and heightened responsiveness to store requirements.
Another successful collaboration was with BESTSELLER, an international, family-owned fashion company with over 20 individual fashion brands. In a bid to enhance customer service, BESTSELLER decided to consolidate multiple smaller Distribution Centers (DCs) into a Single Central DC spanning 200,000 square feet. This consolidation effort was coupled with the configuration and deployment of SAP EWM (Extended Warehouse Management). The planned DC aimed for automation and complex processes, leveraging standard functionalities to minimise customisations while maximising efficiency. However, challenges persisted, particularly regarding stock visibility post-unloading, necessitating scanning and Goods Receipt Note (GRN) completion. Additionally, the need arose to bifurcate processes at the order level for both online and in-store orders to facilitate efficient order management. With a focus on automation, including sorters and conveyorised movements, the company sought to streamline B2C order processing, especially in handling e-commerce returns. Despite these efforts, challenges in order picking persisted, with single-delivery SKUs picked at a time, leading to longer turnaround times and impacting resource allocation and efficiency.
Nevertheless, we implemented several measures to address these issues, including the adoption of EWM features such as Dock Appointment Scheduling, Warehouse Advanced Analytics and Cross-docking, resulting in better visibility, control and significant improvements in On-Time In Full (OTIF) performance. Moreover, scalable automation scenarios were introduced, integrating conveyors and Pick-to-Light (PTL) systems for material movement and tracking, while merging strategies were employed to maximise volume per case and minimise consolidation efforts. Direct integration with conveyors and system-guided tasks further optimised resource utilisation within the DC.
AR: Sustainability is a growing concern in the apparel industry. How does Stellium integrate sustainability practices into its operations?
James Jaichander: We recognise the growing importance of sustainability in the apparel industry and integrate sustainable practices and considerations into our consulting services for clients in several ways. Firstly, in supply chain optimisation, we focus on minimising environmental impact. We assist clients in streamlining their supply chains to reduce their carbon footprint, whether that’s through optimising transportation routes, implementing energy-efficient manufacturing processes or sourcing materials from sustainable and ethical suppliers. Another crucial aspect is supplier collaboration. We believe in fostering partnerships between apparel companies and their suppliers to promote sustainability throughout the supply chain. This may involve working with suppliers to implement eco-friendly production methods, reduce waste and improve working conditions for employees. Moreover, we leverage technology solutions such as IoT and data analytics to enhance transparency and traceability in the supply chain, enabling clients to track the sustainability credentials of their products from raw material sourcing to the end consumer.
AR: Looking ahead, what are some emerging trends or areas of focus that will shape the future of the supply chain?
James Jaichander: To begin with, I believe sustainability and ethical sourcing have become paramount. Increasing consumer awareness and regulatory pressures are driving apparel companies to adopt sustainable and ethical practices across their supply chains. The adoption of digital technologies such as IoT, AI and blockchain is also transforming the apparel industry, enabling real-time visibility, predictive analytics and process automation. Moreover, the rise of e-commerce and omnichannel retailing is reshaping supply chain management and customer interactions. Furthermore, agile and responsive manufacturing strategies are becoming vital for apparel companies seeking to stay competitive in a rapidly changing market. With increasing globalisation and interconnectedness, supply chain disruptions are also becoming more frequent and severe.
