Delta Galil install FastReactPlan to improve visibility and prioritisation of materials

Posted: 12th September 2018

Prints of female models suspended in dome roof

The Customer

Delta is a leading apparel company manufacturing and marketing private apparel products for men, women and children. The company produce customised, innovative fashion and basic apparel for leading retailers and brands around the world. Since its inception in 1975, Delta has expanded to encompass design, development and manufacturing centres on four continents servicing over 50 customers in the US, the UK and continental Europe with more than 10,500 employees located worldwide. Delta provide customers with tailored vertical solutions, which encompass every stage of production, from initial design and development through manufacture of fabrics, accessories and garments to logistics, distribution and replenishment. Delta Textile Egypt is a vertically integrated underwear manufacturing business that manufacture a varied range of different products for customers including: Calvin Klein, Under Armour, Tommy John, Lacoste, Warners, Kenneth Cole, Splendid and Mack Weldon.

The Challenge

Having installed Fast React’s (now Coats Digital) FastReactPlan (previously Evolve) solution application in its cut and sew factories in Egypt, Delta identified the need to improve the visibility, demand and the planning of its material supply process in its knit and dye factories. In common with many textile operations, planning in Delta’s knit and dye factories was performed manually using multiple spreadsheets. This manual disconnected method was unable to provide visibility of changes being made resulting in incorrect order priorities and management time being spent ‘firefighting’.

Why Fast React (now Coats Digital)?

Having had experience of working with Fast React (Coats Digital) in its cut and sew factories, Delta understood the benefits of fast, detailed and accurate planning based on real time information. This together with the rapid, easy implementation, and quick return on investment drove the decision to implement FastReactPlan in its knit and dye factories.

The Solution

The FastReactPlan solution has been installed and fully integrated with M3 business system to provide an integrated, vertical planning solution. Revisions to cut and sew material requirements are passed to FastReactPlan, allowing the planners to prioritise the knitting and dying plans; in turn the plan is fed back to the system in their cyst and sew factory, allowing true, dynamic visibility of the supply chain.

“We chose the system as the planning tool for our knit and dye operations after running FastReactPlan successfully in the sewing factories for a number of years. The implementation of FastReactPlan supported us to achieve a 25% increase in productivity in the first year and gave us a seamless planning tool from yarn scheduling through to finished garments.” said, Carl Morley, Supply Chain Director at Delta Galil.

"Following the successful launch of FastReactPlan in knit and dye we are now looking at the planning solution for both our socks and Santoni seam free operations."

Carl Morley, Supply Chain Director at Delta Galil