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Case Study - PS Apparels

The Client

P.S. Apparels (PSA), a specialist in the textile industry is a one stop shop for all the garment sourcing needs for its customers. They are headquartered at Chennai, and have their manufacturing units spread across Tamil Nadu. They would like to automate their operations of Financials & Banking, Receivables & Payables management, Manufacturing, Export & Import and statutory reporting.

Business Need

  • The client's business goal was to have an understanding of his consolidated Stock, Financials - Creditors and Debtors outstanding and transactions across up to 4 locations each in the 9 companies at PSA.
  • Independent Legacy systems in each separate department meant a lack-of-complete-picture scenario. Duplication of effort and work was rampant and decreased efficiency of operations.
  • Increased market demand and high complexity of garment manufacture (Styles, designs and color, size variants) required that the product be robust and still flexible enough for the industry.
  • With several players in the market, the client wanted to become more competitive by handling a larger number of buying offices, buyer groups & buyers.
  • There was a need for faster release cycles and product stabilization to meet increased demand from clients.
  • To improve effective management of Samples and buyer orders, it was important to introduce an Order Planning engine.
  • The client wished to improve product quality and reduce defects to cut costs both for itself and its clients.

Challenges

  • Increased demand and pressure from end customers had resulted in faster product rollout and stringent timelines.
  • There was insufficient Order planning support - Purchase and Production, Subcontracting planning was all done manually.
  • Planning and Production floor targets frequently mismatched leading to frequent delivery performance issues premium freight usage.
  • Due to rapid growth, it was important to handle the rapid ramp-up in team size with knowledge of MS Dynamics NAV.

The Precision Techconet® Solution

The Precision Techconet® approach to addressing the business challenges included:

  • Configuring and implementing MS Dynamics NAV's order planning engine for better planning that automated and streamlined the Purchase, Subcontracting, production process, and improved dispatch schedule adherence.
  • The Order Planning engine implemented at PSA needed to do a variant-wise (Garment Size and Color) planning unlike the Item-level Order planning engine functionality directly available in MS Dynamics NAV.
  • A custom add-on for Garment industry adhering to standards and norms - with Workflow authorization and multiple approval levels, Manufacturing Instruction sheet for each garment, Inward receipt feature before stores receipt, Outward issue, Unit Requirements and Transfer and other such features specific to the garment industry.
  • Designing and developing a Consolidation feature for Financials, Creditors and Debtors Outstanding and Inventory into a consolidation company to allow the management a bird's eye-view of the group operations.
  • Importing the opening balances and cleanup, consolidation of the data in diverse systems into MS Dynamics NAV to enable an audit approval.

Benefits

Within weeks of commencing the partnership, Precision Techconet® moved quickly from being a vendor to a strategic partner to PS Apparels group, who provided improved value to its Buying Office clients abroad.

The Precision Techconet® solution offered the following benefits:

  • The improved production scheduling & inventory monitoring meant a quicker turn-around time in stores, production and dispatch. This is helping the client add new design and style orders, because of increased capacity in spite of the same infrastructure.
  • Significant savings through reduced operational cost and improved asset efficiency.
  • Better supplier delivery and quality performance monitoring leading to increased efficiencies in the complete supply chain.
  • Freed up internal bandwidth within the client organization to help them focus on strategic issues.