Coats Digital has announced the leading Vietnamese garment manufacturer Duc Hanh Garment JSC has been able to optimise its operations significantly and reduce fabric wastage by 1.95 per cent.
Duc Hanh implemented Coats Digital’s IntelloCut solution in 2018 and the results achieved are in lines of what the company targeted.
Located in the Ha Nam province of Vietnam, Duc Hanh Garment Joint Stock Company – a key production partner for prestige brands such as Polo Ralph Lauren and Chaps – is known to deliver volume without compromising on quality and has a production capacity of 2.20 million pieces a year in its 18 production lines spread across a 32,000 square metre facility.
According to Coats Digital, prior to implementing IntelloCut, the cutting floor at Duc Hanh was coordinated manually using a homegrown spreadsheet solution that didn’t serve the purpose and the company was unable to provide full visibility into the cutting operations.
As a result of the implementation of Coats Digital’s automated, intelligent, closed-loop fabric planning solution, IntelloCut, Duc Hanh was not only able to reduce wastage by 1.95 per cent soon after implementation, but was also able to save 2.20 per cent on its bill of materials, ensuring better-informed fabric bookings and improved profitability as a result.
Three years on from the implementation, IntelloCut continues to provide a visibility advantage, cutting fabric waste to just 1.70 per cent across the lifetime of the partnership between Duc Hanh and Coats Digital.
David Goh, General Manager, Duc Hanh Garment JSC, commented, “From a starting point of heavily manual workflow and very limited visibility, IntelloCut quickly enabled us to eliminate the Excel spreadsheets we had been using, providing complete, real-time visibility into the cutting process, As a direct result of implementing IntelloCut and partnering with Coats Digital, we can now accurately estimate our fabric requirements, which has allowed us to achieve much higher efficiency and productivity at the same time as cutting fabric waste. Thanks to the data centralisation and reporting capabilities of IntelloCut, we can now easily measure our efficiency and material utilisation. We now have enough confidence to buy only the exact amount of fabric that the facility needs – no more, and no less.”
Further, Duc Hanh has now been able to correctly capture the actual fabric consumption through IntelloCut that has delivered an additional benefit of consolidating and centralising the company’s cutting room data.
With the combined power of visibility and a single source of data, Duc Hanh has been able to both automate its data capture – ensuring accuracy – and rapidly produce detailed reports and order confirmation.
Jaya Choudhary, Professional Services Manager, Coats Digital, mentioned, “After implementing IntelloCut in 2018, and making extensive use of the solution’s planning automation, visibility and execution control capabilities, Duc Hanh has successfully kept its fabric wastage to below 2 per cent. We are thrilled to continue to be part of the company’s journey, and applaud the results that Duc Hanh has achieved to ensure it remains a forward-looking, innovative production partner on the world stage.”