Coats Digital has announced that Egyptian knitted garments manufacturer Dice Sports and Casual Wear has achieved a 16 per cent efficiency increase on its production lines and reduced its core style Standard-Minute-Values (SMVs) by 11 per cent, following the successful first phase rollout of GSDCost solution.
Headquartered in Cairo, Egypt, Dice Sports and Casual Wear, that stands at US $ 155 million turnover, boasts of a 12,000 workforce and 14 state-of-the-art manufacturing facilities across six regions.
The vertically-integrated company covers all aspects of knitted apparel manufacturing – from knitting and dyeing to printing and sewing and produces over 4.5 million pieces a month.
DICE chose to adopt GSDCost at the beginning of 2022, to help it overcome a series of costing, planning and manufacturing inefficiencies. The company realised that capacity planning and subsequent order cost quotations were not founded on accurate data but were instead based on historically recorded experiences via Excel spreadsheets and emails.
Without a standardised benchmark to record accurate SMVs on the production floor, DICE, consequently, had no way of ascertaining whether its plan/cost targets reflected the reality of its manufacturing processes.
Coats Digital informs that, with no Plan vs. Actual data onboard, capacity plans often did not align to the reality on the shopfloor. The lack of a standardised method across all its manufacturing units consequently resulted in varied costings and production efficiencies, inconsistent line layouts and line balancing on the shopfloors, and lower productivity which negatively impacted both OTDP targets and overall profitability.
Seif Toma, COO, Dice Sports & Casual Wear, commented, “GSDCost is part of the first phase of our digital transformation plan, and we are delighted to have completed the initial stages of implementation successfully. By having accurate SMV data, we will be able to reduce non-value adding activities, improve costing accuracy and ultimately enhance efficiency and profitability. We look forward to using the software to help optimise processes throughout our business in our production, planning and finance departments.”
An open and transparent production capacity platform has also enabled the management at Dice Sports & Casual Wear to set achievable productivity goals based on a fair standard of working hours. The company hopes that the introduction of achievable performance incentives will make the workforce more contented and motivated, since goal-setting targets are now based on realisable targets.
Sherif Abdelafatah Amin, Sales Manager, Middle East and Africa, Coats Digital, commented, “It is fantastic news that DICE has secured such great efficiency results in the first phase of its GSDCost implementation. The company has already seen a return on its solution investment within five months and is set to achieve a significant boost to its bottom-line profits by the end of the year,” adding, “We very much look forward to working in partnership with this award-winning company to ensure it continues to drive efficiencies, profitability and best-standard working practices so that it consistently stays ahead of the game.”
