Cerie International, a renowned Hong Kong-based garment manufacturer, that owns production sites in China, Vietnam, and Cambodia and serves leading brands in the USA and Europe has successfully implemented Coats Digital FastReactPlan solution and experienced significant benefits and return on investment (ROI) through the implementation of various improvements. One notable achievement is the average 10 per cent improvement in on-time delivery performance (OTDP), ensuring timely fulfilment of customer orders.
Additionally, the company has successfully reduced shipping freight costs, optimising their logistics operations. Another key advantage is the enhanced responsiveness in accepting or modifying customer orders, resulting in improved customer satisfaction and retention.
The implementation of efficient systems has significantly reduced the monthly capacity planning time by an impressive 67 per cent, from three days to just one. Moreover, the production planning process has been streamlined, enabling the creation of comprehensive summaries within a mere 10 minutes. The introduction of plan-based capacity monitoring has facilitated real-time monitoring and adjustment of production levels, contributing to enhanced operational efficiency.
As per the press release Paul Lau, Production Director, Cerie International stated “Having all the key information in one system instead of many Excel files greatly reduces the workload for our planning teams. It also means that plans are more accurate and that our planners can spend more time optimising production schedules. This has given us greater control over our ex-factory dates and significantly reduced the amount of firefighting we consistently had to undertake. In a nutshell, FastReactPlan supports our business improvement process by providing visibility and coordination that minimises errors and highlights potential problems quickly, so that challenges can be immediately rectified before they become an issue.”
The standardisation of purchase orders, colour specifications, and delivery visibility across all departments has promoted seamless collaboration and eliminated potential discrepancies.
Notably, the elimination of costly overtime hours has resulted in substantial cost savings for the company. Overall, these improvements have driven increased productivity across all departments, and the automation of data capture and consolidation has further enhanced operational accuracy and efficiency for Cerie International.
GuoFang Shen, Planning Manager, Cerie International said: “I was involved throughout the whole process of this project from the kick-off until Go-Live. We were greatly impressed at how professional the Coats Digital team were and its international expertise with regards to project management and best practice planning processes were second to none. They also provided the ideal combination of excellent guidance and superlative training in Chinese and English.
“With FastReactPlan, we can plan around problems effortlessly and ensure we create the most effective schedule with just a few drags and drops. FastReactPlan has given us full integration with our ERP system to coordinate plans with the real-time status of available fabrics and materials. This has helped us to identify any potential problems and react quickly. We are also now able to quickly generate reports on any order status and analyse KPI performance on items such as the generation of production planning summaries which can be created within 10 minutes.”
Michael Li, Project Manager, Coats Digital, said: “We are delighted that Cerie International has realised significant benefits as a result of adopting FastReactPlan, and that we have been able to help establish robust best practice planning processes across its new facility in Cambodia. The solution has provided greater visibility and one version of the truth for core sewing planning, so that all relevant departments can communicate easily to eradicate problems quickly, and we look forward to working with Cerie to help it achieve its global expansion goals with the support of a resilient digitisation programme.”
