Coats Digital is delighted to announce that following the implementation of Coats Digital’s FastReactPlan solution, leading vertically integrated garment specialist, Nan Yan Textile Group has drastically reduced its planning time from three days to one and improved its OTDP by 10 percent since its adoption of FastReactPlan in 2019. The solution has enabled the company to connect and consolidate information across disparate sources into one highly visual, unified system. Management and employees benefit from a single, clear overview of the production plan, unlocking additional capacity to drive new business growth and providing the agility to respond swiftly to customer change requests.

Headquartered in Bangkok, Thailand, Nan Yang Textile Group was founded in 1958 and has now expanded to include 14 affiliated companies operating across multiple sites in South East Asia and USA. As a vertically integrated business, Nan Yang provides a range of textile solutions from spinning, knitting to apparel making. The company is dedicated to the development of cutting-edge products and processes, sustainability and value-added services across the supply chain, creating a superlative one-stop shop for its global partners. With a 360 degree view of the entire production process – from design to logistics, Nan Yang Textile Group has a unique understanding of its customer requirements and market trends, and openly encourages cross-functional innovation. The company employs a workforce of over 12,000 and its customers include: Nike, Tommy Bahama, Lululemon, Spyder Omin and Puma, among many others.

Prior to implementing FastReactPlan, Nan Yang Textile Group found that a reliance on using Excel spreadsheets to create capacity plans, resulted in significant gaps between production plans and actual production outputs – causing severe discrepancies in the plans from the initial stages to the sewing lines. The need to simplify instructions to fit line schedules on the factory floor also resulted in time-consuming meetings to make continual corrections, which diverted valuable peoplepower and time away from more strategic, value-adding activities to improve the business.

With no proactive and responsive approach to deal with deviations from the initial plan, Nan Yang Textile Group found it difficult to handle tasks with complex style variations that utilised a more diverse range of materials. Because it was such a time-consuming process to analyse problems and find the relevant information needed to solve issues, there was often not only a delay in production operations, but also a failure to meet exportation timelines.

Following the implementation of FastReactPlan, Nan Yang Textile Group quickly eradicated its reliance on spreadsheets from multiple sources completely, so that planning and scheduling teams could benefit from access to business critical planning information from the same, single, digitised source. The enhanced data visibility fosters seamless collaboration across teams, enabling them to manage diverse orders and change requests swiftly. Thanks to FastReactPlan’s automatic notifications and data alerts, the teams are able to proactively address issues and opportunities, such as predict and plan for minute-to-minute production changes that are required on the factory floor, which significantly improve forecasting efficiencies, whilst reducing the need for firefighting at the same time.

Since implementing FastReactPlan, Nan Yang Textile Group has been able to reduce its arduous planning time from three days to just one, which has meant that planners can spend 66 percent more time focusing their attention on enhancing customer service and supporting business growth. Increased efficiencies across the business have also resulted in a remarkable 10 percent improvement in OTDP – which has saved significant overhead costs in overtime and unnecessary, expedited freight costs.