IntelloCut additionally delivered BOM savings of 1.13%; overall wastage savings of 1.23%; optimised productivity and increased customer satisfaction.
Viet Vuong is committed to delivering sustainable manufacturing processes wherever possible and reducing its fabric wastage to zero is a top priority. The company has secured recognition – for being a green-friendly factory from WRAP
– a charity, working with governments, businesses and citizens around the globe to create a world in which resources are used sustainably; Better Work
– which improves global garment industry conditions – and the sustainable building programme, LEED
.
The challenge
Manual fabric assessment processes delivered incorrect data on material consumption, resulting in increased fabric wastage, costly additional fabric orders, and a litany of human errors. With no clear visibility on the cutting-room floor, management also found it difficult and time-consuming to make informed decisions about how to optimise fabric utilisation to reduce dead stock.
Prior to implementing IntelloCut, Viet Vuong used Excel spreadsheets to assess and monitor its fabric costing and utilisation processes. This manually executed operation resulted in limited visibility into accurate fabric consumption calculations and unnecessary wastage due to a lack of available data regarding material usage on the production floor.
With no robust method in place to provide an accurate breakdown of fabric wastage, the management team at Viet Vuong found it difficult to make informed business decisions about how much fabric to buy to fulfil orders. If the company purchased more fabric than it needed, it would lose profit from dead stock; and if it bought less than was actually required, it would lose profit by having to buy in more material at its own expense, as these additional costs had not been factored into initial customer quotes.
The solution
Following the implementation of IntelloCut, Viet Vuong was afforded the full visibility and tracking of fabric consumption and wastage it needed to make factual data-based decisions about the fabric it purchased and how it was utilised. By digitising these costing and cutting processes, Viet Vuong significantly optimised its fabric utilisation rate to over 98% – reducing its fabric wastage to under 2%.
The solution significantly increased production efficiencies which meant shorter lead times for customers, but also greatly reduced the time and effort planning teams required to create capacity forecasts, freeing up more time to enhance customer satisfaction objectives overall.
Fundamentally, however, the implementation had a direct positive impact on the company’s bottom line, with Viet Vuong reporting fabric savings of nearly 3% and Bill of Materials (BOM) savings of 1.13%, from November 2018 when the solution was first implemented, to 22nd February 2022.
Coats Digital’s IntelloCut is designed to give full control over fabric usage in the cutting room by optimising key processes, including: the generation of cut plans, lay plans and allocation, end bit usage, capacity planning/tracking and reporting. The solution’s automated, closed-loop approach to fabric planning reduces the amount of time and effort spent on planning and re-planning and maximises fabric utilisation on the production floor.as first implemented, to 22nd February 2022.
"Before IntelloCut, all the cutting data was spread between disconnected spreadsheets and emails, so it was difficult to compile the data to analyse key trends related to fabric consumption and wastage.
With IntelloCut, we have gained visibility over the entire cutting floor and through the intuitive real-time reports on fabric performance, we now have the ability to make data-backed decisions to optimise fabric utilisation, reduce wastage and ultimately support the sustainable growth of our business." - CEO, Viet Vuong Trading Co.Ltd
Key benefits & ROI:
- Wastage savings of 1.23%
- Fabric savings of 2.98%
- BOM savings of 1.13%
- Improved data visibility and tracking
- Wastage reduction in all areas
- Identification of wastage breakdown
- Correct calculation of consumption
- Process automation
- Improved fabric utilisation
