MAS Active raises performance supported by FastReactPlan

Posted: 5th March 2019

Close up of sewing machine with yellow thread

Top sportswear supplier MAS Active has achieved substantial performance and customer service improvements, helped by the FastReactPlan (previously named Evolve).

The Customer

Sri Lanka-based MAS Active, the sports & leisurewear division of MAS Holdings, is the fastest growing provider of competition sportswear and leisurewear in the region, supplying to key strategic business partners Nike, Columbia sportswear, Ralph Lauren plus other leading brands.

Embracing change, Chief Operations Officer, Prasanna Jayasekera explains “As an established Fast React (now Coats Digital) user, MAS Active has long realised the value of good planning. But when the business model changes, it is vital that a solution can grow and change with the business.

“The MAS Active business has changed; design and technical innovation, speed of response and flexibility are fundamental to maintaining competitive advantage in today’s sportswear marketplace. For some programs, lead times are now as short as 3 weeks from order to shipment.”

“The FastReactPlan solution has supported our business change and, like us, the team follows a continuous improvement approach. In our case, embellishment was one part of the manufacturing process that needed particular attention; the Fast React (now Coats Digital) team listened and developed a much improved solution.”

The Integration Process

The FastReactPlan solution provides Division wide capacity management, order allocation and tracking, whilst also allowing each strategic business unit to plan and manage independently.

Significantly, the FastReactPlan solution allowed the Active Division to make the move from style level to style/colour level planning, assisted by the interface to SAP, which provides full visibility of materials availability to meet the plan.

The 2 way interface with the SAP system also allows latest ex-factory dates from the plan to be communicated back to the wider business via the SAP system.

The Results

During the period since implementing FastReactPlan, the business has been able to manage both significant growth and increased style complexity with no increase in planning headcount. By capitalising on the information that Fast React (now Coats Digital) provides along with good business disciplines, the MAS Active team have:

  • reduced the time taken to plan a full ‘buy’ from a major customer from 2 weeks to around 1 day.
  • reduced raw materials inventory by around 4 days and finished goods inventory by around 5 days.
  • dramatically improved performance to plan (planned vs actual performance).
  • increased factory productivity by several percentage points.
  • increased On Time Delivery Performance (OTDP%) from around 80% to more than 98%, at the same time as significantly reducing lead times.
  • reduced air freight costs.

"FastReactPlan (formerly named Evolve) supports the business improvement process by providing visibility and coordination to minimise errors and highlights potential problems quickly, so that they can be immediately rectified before they become an issue. The reports in FastReactPlan are a major benefit and are used extensively both at planner level and for decision making at director level."

Mr. Shirendra Lawrence, Managing Director, MAS Active