Some organizations in Indian textile and garments manufacturing sector have resolved the chronic operational conflicts and created a harmonious supply chain where plants are able to not only cut down lead time but also improve utilizations and on-time performance.

1. Textile Industry
Unresolved Conflicts

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A typical company in the
Indian textiles and garment
industry deals with following
chronic conflicts

3. and pays significant late
penalty charges, despite
having excess plant capacity
Suffers from poor
on-time delivery performance
(less than 70%)
despite having tried many
scheduling systems to solve
the problem
Dispatch
predictability is
very low
Copyright © 2015 Vector Consulting Group. All rights reserved.
while others
are grossly
delayed
Some orders (or part of an
order) gets completed much
ahead of actual requirement

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Rework is a perennial
problem despite having
quality systems in place.
There is continual pressure
to add workers even though
the plant overall has more
than required.

5. Copyright © 2015 Vector Consulting Group. All rights reserved.
Some organizations in Indian textile and
garments manufacturing sector have
resolved the chronic operational conflicts
and created a harmonious supply chain
where plants are able to not only cut
down lead time but also improve
utilizations and on-time performance.

6. Case Studies
1. Pratibha Syntex Ltd.
2. Raymond Zambaiti

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Pratibha Syntex Ltd.
Largest vertically integrated
textile manufacturers in India
with its value chain spanning
from fiber to fabric to garments.
The business networks
with around 30,000
farmers, 10,000 employees
and renowned global
apparel brands in more
than 20 countries.
Three major business units:
Spinning (240crores), Fabric
(25 crores) and Garmenting
(425 crores).
The products include
T-shirts, undergarments,
high fashion garments and
recycled textile products.

8. Results in last 7 months
Pratibha Syntex Ltd.
27%
The Average
Lead-time from Fabric
Knitting to Packing of a
Sales order has reduced by
On time
in full delivery
(OTIF) to Customer
has improved by 80%
and Order to ship has
increased from 97%
to more than
100%.
The Total
inventory of
garmenting unit is
reduced by 18%. The
Inventory of Finished
Garments has
reduced by
26%.
The Garment
EBIDTA has
increased by 55%
through Increased
Sales.

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Raymond Zambaiti Ltd.
Produces Exclusive cotton
shirting & bottom weight
fabrics.
Supplies its creations to
leading shirt brands world
over.
Manufacturing facility
based in Kolhapur has an
installed capacity of 21.6
million meters annually.

10. Results
Raymond Zambaiti Ltd.
50% reduction
(15 days to 7 days) in
assortment waiting time
at company warehouse has
been achieved because of
improved synchronization
and flow. This reduction
also results to improved
cash to cash cycle.
On time
delivery
performance
(at SO level) has
been improved
to 95%.
Production
lead-time is
reduced by 25%
(from 45/50 days
to 33 days) at
SO level.