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Bangladesh apparel faces $27b export hit from extreme weather by 2030: Study

The Bangladesh Garment Manufacturers and Exporters Association last year set a target to increase their exports to $100 billion by 2030.

Bangladesh’s apparel industry may face a $26.78 billion export hit from extreme heat and flooding by 2030 as workers struggle under high temperatures and factories close, according to research by Schroders and Cornell University released on Wednesday.

The study titled “Higher Ground: How Fashion Supply Chains are Being Impacted by Extreme Heat and Flooding” forecasts that under a climate-adaptive scenario, if the apparel industry moves quickly to reduce heat stress for workers, the country’s apparel export earnings could reach $122.01 billion by 2030 and $1,038.22 billion by 2050.

The Bangladesh Garment Manufacturers and Exporters Association last year set a target to increase their exports to $100 billion by 2030.

Speaking to The Business Standard on Wednesday evening, industry insiders said the exports would be higher than the target if the industry was climate-adaptive.

Along with the surge in export earnings, the study suggests Bangladesh’s employment in the apparel industry may reach 4.83 million by 2030 and 6.31 million by 2050. It mentioned that employment was 4.22 million in 2021.

Infographics: TBS

Under the non-adaptive scenario, which calculates the damage of high heat stress and flooding, export earnings will drop to $95.22 billion by 2030 and $326.90 billion by 2050. Employment will also drop to 4.57 million by 2030 and 5.04 million by 2050.

As a result, Bangladesh could face a 21.95% shortfall in export earnings, or missing out on $26.78 billion, by 2030 and a 68.51% shortfall in export earnings, or missing out on $711.32 billion, by 2050.

Extreme heat, flooding threatening Asian apparel hubs

Extreme heat and flooding could erase $65 billion in apparel export earnings from four Asian countries – Bangladesh, Cambodia, Pakistan and Vietnam – by 2030.

The study also mapped out the supply chains of six unidentified global apparel brands operating in the four countries and found all six would be materially affected. For one sample brand, that could amount to 5% of annual group operating profits.

The findings should act as a wake-up call to both an apparel industry facing significant financial costs and to investors confronted with sparse information on companies’ exposures, the report’s authors told Reuters.

“Among the suppliers and buyers we talked to, not one had their eye on these two issues (heat and flooding),” said Jason Judd, executive director of the Cornell Global Labor Institute.

“The climate response by the industry is all about mitigation, about emissions and recycling, and little or nothing with respect to flooding and heat,” Judd said.

Understanding climate-related physical risks to companies in a warming world is critical, but the process is in its infancy, with few businesses disclosing enough information and few investors undertaking proper assessments.

“There is so little data on this…There are some [apparel] brands not disclosing the factory locations of their suppliers,” said Angus Bauer, Schroders’ head of sustainable investment research.

Bauer said Schroders, which manages more than $874 billion in assets, would increase engagement with companies over their disclosures, and he called on firms to work with suppliers and policymakers to build adaptation strategies that consider the impact on workers.

Using projections, the researchers analysed future heat and flooding levels to estimate what would happen under a “climate adaptive” scenario and a “high heat and flooding” scenario.

Under the second, workers would suffer more “heat stress”, with worker output declining as the wet-bulb globe temperature, which measures heat and humidity, rises.

Flooding will also force factories to close in the four countries, which account for 18% of global apparel exports and employ 10.6 million workers in apparel and footwear factories.

The overall fall in productivity would lead to a $65 billion shortfall in projected earnings between 2025 and 2030 – equivalent to a 22% decline – and 950,000 fewer jobs being created, the study found.

By 2050, lost export earnings would reach 68.6%, and there would be 8.64 million fewer jobs.

What Industry leaders say

Shams Mahmud, managing director of Shasha Denim Ltd, said, “This is something that textile and RMG owners have been dealing with for the last few years. We have seen that due to the increased heatwave in Bangladesh, spinning and fabric weaving units have to lower their temperatures inside the units using chillers which are highly energy intensive. In a way, it also increases production costs.”

“Also, we have to closely monitor the temperature and humidity and give shift breaks frequently to make sure workers are fully hydrated,” he added.

He said because of breaks and increased humidity, the workplace environment suffers which leads to lower productivity. Also because of heat, there is a risk of fire hazards as only a small spark can lead to fire hazard situations.

In the RMG and textile industry, he said most of the machines they use are high-friction machinery, this is dangerous and also they produce a lot of heat.

“We have to think about water usage as this will inevitably in the long run. The government and industry stakeholders have to come together to take out a long-term strategy as this will be a national problem down the line,” said Shams Mahmud.

Echoing with Shams Mahmud, Pacific Jeans Managing Director Syed Mohammed Tanvir said they have invested in some sophisticated machinery to minimise workplace temperature to make a worker-friendly environment.

He further said considering the climate change effect on people’s lives and livelihood, they have also started a programme to create jobs for flood-affected people.

This project started a year ago and under this initiative they trained them and provided jobs, he added.

Mostafiz Uddin, founder and CEO of Bangladesh Apparel Exchange, said “In some cases, our industry people are not well aware about it.”

It is not a problem for only manufacturers, he said, adding, “The climate change will affect brands, retailers, manufactures and the government.”

He further said, “We all should work together to minimise potential losses.”

Mostafiz Uddin said, “We should take an action plan for the apparel industry in line with the UN climate action plan.”

Recommendations for all

The report recommended treating heat and flood events as health hazards with paid leave for events and related illnesses, and providing the right to stop work. Alter work hours, effort levels, rest and hydration based on indoor wet-bulb temperature standards.

It suggested developing social protection mechanisms and climate adaptation finance that redistributes costs and risks away from apparel workers.

Brands, employers, unions should establish binding agreements and foster formal partnerships between brands, manufacturers, unions, governments to address and adapt to climate breakdown, it added.

It also mentioned brands and suppliers need to explore return on investment from adaptation measures and support suppliers to retrofit or relocate nearby in lower risk locations.

The study recommended that investors engage with apparel companies and their stakeholders to encourage adoption of adaptation measures given the focus to date is almost exclusively mitigation.

The government needs to integrate climate adaptation and worker-rights-related factors within trade policies, it added.

A sudden surge in orders to test RMG, textile sectors’ capacity

Bangladesh might be the second-largest apparel supplier in the world, but its current installed capacity will not be adequate to meet demand if orders surge significantly as buyers shift away from countries such as China and Vietnam.

On the back of the existing capacity, the country exported garment items worth $46.99 billion in the last fiscal year, registering a 10.27 percent year-on-year growth, according to data from the Export Promotion Bureau.

China sold apparel items worth $182 billion globally and Vietnam shipped products amounting to $35 billion in 2022, data from the World Trade Organisation showed.

Bangladesh’s share in the global readymade garment trade more than tripled in the past 17 years: in 2005, the country’s share was 2.5 percent but it rocketed to 7.9 percent last year.

And local suppliers say Bangladesh’s share would grow in the coming years, a prospect that might bode well for the country’s largest foreign exchange earning sector but it could also bring about one of the stiffest challenges for the sector as well.

For example, if 10 percent orders are diverted from China to Bangladesh, this will bring businesses worth $18.2 billion for the latter. Such a volume of orders is enough to put the manufacturing capacity under strain and bring about a raw material shortage for local suppliers like they witnessed in 2021-22 after the global supply chain rebounded from the severe fallout of Covid-19.

Bangladesh’s garment shipment surged more than 35 percent in FY22.

Already, some garment-supplying countries such as Myanmar, Ethiopia, Cambodia, China, India, Pakistan and Cambodia have seen their global market share in the garment segment slash over the last few years whereas Bangladesh’s pie is expanding.

For instance, China’s share in the global apparel business fell from 36.6 percent in 2010 to 31.7 percent in 2022, owing largely to its dragging tariff war with the US.

The severe impact of the pandemic, the Russia-Ukraine war, the higher cost of production and the dearth of skilled workers have also contributed to the fall in the share for the world’s largest apparel supplier.

Mohammad Abdullah Zaber, managing director of Noman Group, said a lot of US-based orders for fabrics have come to his factory from China and India over the last one year.

So, he has already expanded the capacity.

“There is a forecast that orders may see a strong rebound next year as international retailers and brands are running out of their stocks of unsold apparel items,” said Mohammad Ali Khokon, president of the Bangladesh Textile Mills Association (BTMA).

He said Bangladesh has the capacity to supply goods against a large volume of orders, but many mills are running below capacity owing to an inadequate supply of gas and power and the dollar crisis in the banking sector.

Many of the mills that were used to produce 80 tonnes of yarn a day are producing 40 tonnes to 50 tonnes of raw materials currently, he said, adding that dyeing mills are also facing a similar situation.

“Under the circumstances, new investment is very low.”

Asking not to be named, the country manager of a retailer from the Netherlands said although more orders are flowing to Bangladesh, the volume is still slow.

He said orders are expected to see a jump if the political chaos linked to the national election does not linger.

Monsoor Ahmed, chief executive officer of the BTMA, the platform of primary textile millers, said the knitwear sector has the capacity to meet demand, but the woven sector is lagging behind as their capacity is low.

Presently, more than 500 spinning mills supply raw materials to knitwear manufacturers. Of them, only 200 are export-oriented.

The installed spinning capacity is 4,500 million kilogrammes, but they are manufacturing 2,400 million kgs of yarn currently as their full capacity can’t be utilised because of the gas and power shortage, he said.

“Spinners can’t go for expansion because of the dollar shortage,” he said, adding that only 60 weaving mills produce fabrics for the export-oriented garment sector.

In denim, Bangladesh is, however, capable of catering to any volume of orders. Local denim millers produce more than 700 million yards of fabrics per year.

According to Ahmed, setting up a new factory is time-consuming and it takes at least three years and costs Tk 700 crore to set up a medium-sized factory.

Since international buyers have cut the lead time to 45 days to 60 days from 90 days and 120 days, local garment suppliers have already come under pressure. In order to deliver products within agreed deadlines, they are using more locally produced yarn and fabrics.

Faruque Hassan, president of the Bangladesh Garment Manufacturers and Exporters Association, also said that the country may find it challenging to supply goods if orders climb suddenly.

The lingering gas crisis, a shortage of adequate skilled workers, and higher prices of yarn are major bottlenecks that may prevent Bangladesh from attracting buyers looking to move away from other countries, he said.

He thinks orders will pick up after December as the global supply chain is recovering and international buyers are coming up with an additional volume of work orders.

Mohammad Abdur Razzaque, chairman of the Research and Policy Integration for Development, a think-tank, said the capacity of the country needs to be strengthened as exports are bouncing back in line with the revival of the global supply chain.

“A lot of work orders may come to Bangladesh thanks to the China-Plus One policy adopted by many countries to reduce their dependence on a single source, namely China.”

Three textile industry expos start in Dhaka

The 22nd Textech Bangladesh 2023 International Expo, focusing on textile and garment technologies, began at the Bangabandhu Bangladesh-China Friendship Exhibition Centre in Purbachal, Dhaka on Wednesday.

At the same time, the 20th Dhaka International Yarn and Fabric Show 2023 and the 42nd Dye and Cam Bangladesh 2023 International Expo also started on Wednesday.

Textiles and Jute Minister Golam Dastgir Gazi inaugurated the exhibitions.

Over 1,675 companies from 37 countries are showcasing the latest textile products, machinery, yarn, fabric, trims, accessories, dyestuffs and textile chemicals in 2,245 booths at these exhibitions.

The exhibitions have created a one-stop platform for the buyers and sellers of the entire textile and garment industry in Bangladesh to showcase the latest and most innovative technologies, said the organisers.

These exhibitions are providing the local manufacturers direct networking opportunities with international companies related to the textile industry, which will play an effective role in creating profitable transaction opportunities in the global market of competitive apparel sourcing.

At the inauguration ceremony Golam, Dastgir Gazi, said the current government is working towards establishing an efficient, smart and competitive textile and apparel sector. For this, the textiles and jute ministry has formulated and implemented various action plans.

“The government is also providing policy support to all stakeholders in the textile sector under the ‘Textile Act, 2018’. I hope, by participating in such international exhibitions, the textile sector of Bangladesh will be able to develop into a more modern, advanced and smart one,” he added.

Asia apparel hubs face $65 billion export hit from extreme weather, study shows

Extreme heat and flooding could erase $65 billion in apparel export earnings from four Asian countries by 2030, as workers struggle under high temperatures and factories close, research from Schroders and Cornell University showed on Wednesday.

The study also mapped out the supply chains of six unidentified global apparel brands operating in the four countries studied – Bangladesh, Cambodia, Pakistan and Vietnam – and found all six would be hit materially. For one sample brand that could amount to 5% of annual group operating profits.

The findings should act as a wake-up call to both an apparel industry facing significant financial costs, and to investors confronted with sparse information on companies’ exposures, the report’s authors told Reuters.

FILE PHOTO: Labourers work at Hung Viet garment export factory in Hung Yen province, Vietnam December 30, 2020. REUTERS/Kham/File Photo

“Among the suppliers and the buyers we talked to, not one had their eye on these two issues (heat and flooding),” said Jason Judd, executive director of Cornell Global Labor Institute.

“The climate response by the industry is all about mitigation, about emissions and recycling, and little or nothing with respect to flooding and heat,” Judd said. 

Understanding climate-related physical risks to companies in a warming world is critical, but the process is in its infancy with few businesses disclosing enough information and few investors undertaking proper assessments.

“There is so little data on this … There are some [apparel] brands not disclosing the factory locations of their suppliers,” said Angus Bauer, Schroders’ head of sustainable investment research.

Bauer said Schroders, which manages more than 700 billion pounds ($874 billion) in assets, would increase engagement with companies over their disclosures and he called on firms to work with suppliers and policymakers to build adaptation strategies that consider the impact on workers.

Using projections, the researchers analysed future heat and flooding levels to estimate what would happen under a “climate adaptive” scenario and a “high heat and flooding” scenario.

Under the second, workers would suffer more “heat stress”, with worker output declining as the wet-bulb globe temperature, which measures heat and humidity, rises.

Flooding will also force factories to close in the four countries, which account for 18% of global apparel exports and employ 10.6 million workers in apparel and footwear factories.

The overall fall in productivity would lead to a $65 billion shortfall in projected earnings between 2025 and 2030 – equivalent to a 22% decline – and 950,000 fewer jobs being created, the study found.

By 2050, lost export earnings would reach 68.6% and there would be 8.64 million fewer jobs.

RMG exports to US up by 2.95% this July-August compared to last year: EPB report

During the period, the RMG exports to the US increased from $1.42 billion to $1.46 billion

Bangladesh’s apparel exports to the United States (US) went up 2.95% in July-August of the current fiscal year compared to the same period of the previous fiscal year, according to statistics released by the Export Promotion Bureau (EPB).

During the period, the RMG exports to the US increased from $1.42 billion to $1.46 billion, Bangladesh Garment Manufacturers and Exporters Association Director Mohiuddin Rubel said citing the EPB data.

Apparel exports to the EU increased by 11.81% from $3.44 billion to $3.85 billion compared to the same period last fiscal.

Exports to some major EU markets such as Spain, France, Italy, Netherlands and Poland also increased by 26.94%, 8.45%, 28.73%, 18.95% and 26.37% respectively.

However, exports to Germany, Bangladesh’s second-largest export destination, declined by 6.29% year-on-year to $994 million.

During the July-August period of FY 2023-24, exports to the UK and Canada reached $976.75 million and $243.44 million, and both markets grew by 19.14% and 7.22%, respectively.

At the same time, Bangladesh’s garment exports to non-traditional markets increased by 21.94% to $1.47 billion. Among major non-traditional markets, exports to Japan, Australia and South Korea increased by 33.97%, 49.52% and 19.51% respectively.

Meanwhile, garment exports to India fell by 3.14%.

Anti-harassment committees inactive in apparel industry: Study shows

In order to ensure a safe working environment, the speakers emphasised the proper implementation of the law, changing the attitude of the owners as well as increasing the factory level monitoring by the government.

The anti-harassment committees are not carrying out their responsibilities in the apparel industry, despite it being the largest industry with a workforce of 3.5 million people, according to a study.

Though there are a total of 2,150 anti-harassment committees in all sectors across the country, there is no specific data regarding the number of anti-harassment committees in the garment industry, the report mentioned.

As a result, the garment sector is still lagging behind in ensuring a safe working environment for the female workers, who comprise 60% of the workforce, said Associate professor Mostafiz Ahmed of Jagannath university.  He shared the findings from his study titled “Effectiveness of role played by complaint committee to protect the sexual harassment at workplace” on Monday (11 September).

Despite being subjected to sexual harassment at work, most of the workers do not speak out due to social stigma and the fear of losing their jobs, he added.

Existing laws are also not friendly to women workers.

In order to ensure a safe working environment, the speakers emphasised the proper implementation of the law, changing the attitude of the owners as well as increasing the factory level monitoring by the government.

Shamsun Nahar, member of the standing committee on the Ministry of Labour and Employment was the chief guest of the event organised by Gender Platform Bangladesh.

Bangladesh’s RMG export potential to EU $60b by 2030

In FY23, Bangladesh’s exports to the world market were more than $55 billion, where RMG’s share was $47 billion and non-RMG’s share was $8.5 billion.

Bangladesh has the potential to increase its export earnings to $22.5 billion from major non-RMG products to the European Union by enhancing its supply-side capacity, suggests a study.

Additionally, earnings from ready-made garment exports could rise up to $60 billion to the EU market through the diversification of garment items, according to the study of the Research and Policy Integration for Development Bangladesh (RAPID).

Photo: Rajib Dhar

While presenting the findings at a programme titled “Exploring Export Diversification Opportunities in the European Union” at a city hotel on Monday, RAPID Chairman MA Razzaque said, “Bangladesh has a golden opportunity in the EU market if the country successfully diversifies its export baskets.”

In FY23, Bangladesh’s exports to the world market were more than $55 billion, where RMG’s share was $47 billion and non-RMG’s share was $8.5 billion.

These estimations are based on the current supply-side capacity, demand conditions, and market access.

Currently, Bangladesh exports more than 400 types of products to around 200 countries. 

The estimations indicate that the top 45 major products have the potential to range from $8.5 billion to $22.5 billion in the EU market.

Razzaque emphasised diversification within the RMG, adding, “Bangladesh’s share in cotton fibre garments in the EU is 34.7%, while China’s share is only 14.9%.”

On the other hand, China’s share of non-cotton garment items in the EU is 41.2%, while Bangladesh’s is only 12.2%.

So, here, Bangladesh has the potential to explore more markets in the EU if the country can diversify the products within the garment items, he added.

In the report, Razzaque said Bangladesh’s apparel exports to the EU are projected to rise to $46 billion to $60 billion by 2030.

Sourcing diversification away from China may help Bangladesh’s RMG export growth, he added.

Moving towards manmade fibre can be greatly facilitated by extended EU preferences beyond LDC graduation, he said.

Non-apparel products with high export potential include footwear, leather goods, home textiles, and fish and shrimp.

The EU market, with its vast consumer base and historical trade ties with Bangladesh, can act as a catalyst, he added.

Senior Commerce Secretary Tapan Kanti Ghosh, EU Ambassador to Bangladesh Charles Whitely, and RAPID Executive Director Abu Eusuf also spoke at the programme.

Local firms equally dissatisfied with business climate

Like Japanese and Chinese companies operating in Bangladesh, domestic firms as well as those from other countries are not happy with the overall business climate in the country, said a number of entrepreneurs, heads of chambers and experts. 

Policy inconsistency, complicated customs procedures, shipment delays, lack of service-oriented attitudes among government officials, and prevalence of informal payments aimed at ensuring quick services from regulators and facilitating agencies are all blamed for the poor business environment.

Their concerns, which have lingered for a long time, reflected the challenges recently cited by Japanese and Chinese businesses that have a presence in Bangladesh.

For example, a survey of the Japan External Trade Organisation (Jetro) released on August 30 said 71 percent of Japanese companies are dissatisfied with the general business environment in the country.

On Saturday, Chinese investors pointed to the challenges they face while doing business, starting from difficulties in securing visas and work permits to opening and settling of letters of credit (LCs). They sought improved services alongside remedies to the hurdles.

The challenges faced by Japanese and Chinese investors are also applicable to all domestic and foreign companies, said Md Sameer Sattar, president of the Dhaka Chamber of Commerce and Industry.

He said due to slower-than-expected clearance of customs, importers are sometimes compelled to pay more in demurrages and imported raw materials and goods might even be found to be damaged.

As a result, entrepreneurs face cost consequences at home as well as challenges in the international market from a competitive perspective.

Businesses have to wait 11 days and six hours to have their cargo released after their arrival at seaports, according to the Time Release Study 2022 of the National Board of Revenue.

Nihad Kabir, chairperson of the Business Initiative Leading Development, a think-tank, said it is true to some extent that Japanese companies and some domestic and foreign companies don’t receive government incentives because of inefficiencies and red-tapism.

She said automation in customs procedures is not fully in place and the NBR needs to complete the process as soon as possible.

“Businesses want transparency, accountability and predictability in the regulatory framework.”

Nihad said there has to be a relentless drive to carry out required regulatory reforms in a bid to reduce the burden on businesses so that Bangladesh can attract a higher volume of foreign direct investments and domestic businesses can contribute more to the economic growth.

“A more efficient customs process will lead to an improved country branding for Bangladesh.”

Citing the Jetro survey, Md Saiful Islam, president of the Metropolitan Chamber of Commerce and Industry, Dhaka, said although there is dissatisfaction over the business environment, 66 percent of existing Japanese companies showed interest in expanding their operations in Bangladesh.

“Japanese investors stressed faster customs clearance and faster settlement of LCs.”

Mohammed Amirul Haque, managing director of Premier Cement, cited bureaucratic complexity and unfavourable policies as the main obstacles standing in the way of attracting a higher volume of FDIs.

He added inefficient port handling and complicated procedure of customs lead to slower clearance of raw materials, inflicting losses on investors.

Haque, however, lauded the intention of the government aimed at securing more FDIs and making it easier to do business in a bid to accelerate economic growth.

“We need long-term policies on tax and benefits for investors, irrespective of local or foreigners.”

Fahmida Khatun, executive director of the Centre for Policy Dialogue, says Japanese investors are very particular and have high work ethics.

“So, they want an enabling environment where they can work smoothly without facing any bureaucratic complexities.”

M Masrur Reaz, chairman of the Policy Exchange Bangladesh, says obviously there are some reasons to be dissatisfied with the business environment in Bangladesh.

According to him, the challenges are time-consuming clearance at ports, taxation complexity, a higher tax burden and import duty, poor logistics system, and an absence of modern trade financing.

Despite conducive investment policies in Bangladesh, Japanese investors are unhappy due to some reasons such as policy inconsistency, incongruous business environment, complex repatriation processes, complicated customs procedures, delays in shipments, lack of skilled professionals, and complicated foreign exchange regulations, said Yuji Ando, country representative of the Jetro.

“However, there is a potential to improve the situation by getting rid of these bottlenecks.”

Shinichi Nagata, country general manager of Sumitomo Corporation Asia and Oceania Pte Ltd, said investors move to the countries that offer benefits and tax incentives to foreign firms.

Tetsuro Kano, president of the Japanese Commerce and Industry Association in Dhaka, said the import duty of raw materials is much higher in Bangladesh than in other countries and this increases the cost of production.

He, however, said the labour cost is cheaper and this is helpful for investors.

News Sources : thedailystar

Searock Apparels adopts Coats Digital’s FastReactplan solution to digitize planning processes and boost profits

By streamlining business-critical information into a single digitised source, FastReactPlan will improve productivity, reduce material wastage, and eradicate last minute firefighting and late shipments

Coats Digital is pleased to announce that leading, ready-made garment specialist, Searock Apparels Ltd. has selected Coats Digital’s FastReactPlan to digitally transform its production processes, enabling it to create fast and accurate capacity plans to improve productivity, ensure on-time deliveries and ultimately boost profits. The solution is expected to improve productivity by 3% on implementation, greatly reduce idle production lines, firefighting and material wastage, and will ensure that Searock Apparels effectively future-proofs its business to accelerate its significant growth plans.

Figure 1: By streamlining business-critical information into a single digitised source, FastReactPlan will improve productivity, reduce material wastage, and eradicate last minute firefighting and late shipments

Founded in 2018, Searock Apparels Ltd. specialises in ready-made outerwear, denim/non-denim bottoms, workwear and uniforms. The company has two operation facilities in Gazipur and Pubail, employs over 1,800 workers and produces over half a million pieces per month. Searock Apparels has over 1,100 sewing machines and boasts a monthly turnover of 3 million USD. Its international clients include Lidl, Norma, Orn International, 5 Star and Champion Clothing.

Khandokar Fazlay Rabbi, Managing Director, Searock Apparels Ltd., said, FastReactPlan is the most renowned, trusted and effective planning tool in the garment industry. We needed to completely overhaul our manual planning process which relied on disparate pieces of information stored across multiple Excel spreadsheets, telephone conversation notes and emails. Without a fast and accurate single source of capacity planning information, our teams lacked the visibility they needed to provide precise production and shipment timelines, line availability and error-free Time & Action (T&A) and Bill of Materials (BOM) reports. As a result, we regularly suffered from over- and under bookings, unnecessary overtime and excess material costs, idle line time and consistent firefighting to meet shipment deadlines.  FastReactPlan will make a huge difference to our productivity and efficiency levels and will significantly improve our profit margins quickly, so that we can plan more effectively and drive future growth.”

Part of Coats Digital’s core Manufacturing Solution Suite, FastReactPlan is a dynamic, visual production planning and control tool that optimises delivery, efficiency and lead times. Designed and developed specifically for footwear and apparel manufacturing factories, FastReactPlan helps companies integrate capacity, critical path, and materials into a single, integrated, dynamic planning system.  The highly visual and flexible ‘drag and drop’ approach to planning allows effective master planning across multiple factories, as well as the detailed and accurate scheduling of manufacturing lines/ machines.

Mitali Chakrabartty, Business Development Manager, Coats Digital said, “We are delighted that Searock Apparels has joined our growing global family of newly digitized fashion manufacturing partners. FastReactPlan will provide greater visibility and one version of the truth for all its capacity planning teams, so it can easily optimise efficiencies and eradicate problems quickly. Once the solution has been rolled out, we expect to deliver a 3% productivity improvement, quickly.

We are honoured that FastReactPlan will play such an instrumental role in Searock’s digitization journey and we look forward to working with them on a long term basis to ensure they achieve their business goals.”

Founded in 2018, Searock Apparels Ltd. specialises in ready-made outerwear, denim/non-denim bottoms, workwear and uniforms. The company has two operation facilities in Gazipur and Pubail, employs over 1,800 workers and produces over half a million pieces per month. Searock Apparels has over 1,100 sewing machines and boasts a monthly turnover of 3 million USD, per month. Its international clients include Lidl, Norma, Orn International, 5 Star and Champion Clothing.

Its production facilities are fully certified in strict compliance with the following certifications: ACCORD/RSCSedex/SMETAAmfori/BSCIOEKO-TEX, ISO 14001 and WRAP.

Figure 2: Part of Coats Digital’s core Manufacturing Solution Suite, FastReactPlan is a dynamic, visual production planning and control tool that optimises delivery, efficiency and lead times.

Coats Digital is the leading digital transformation partner for the fashion supply chain, powering sustainable processes and high value insights through connected technologies. We leverage deep industry and technology expertise to help brands and manufacturers optimise, connect and accelerate business critical processes from design and development to method-time-cost optimisation, production planning and control, fabric optimisation and shop floor execution. Used in over 3,000 factories globally, our unmatched end-to-end apparel, footwear and textile software and SaaS solutions improve agility, speed to market, efficiency, transparency and sustainability. Coats Digital – transform with intelligencecoatsdigital.com 

Coats Digital is the software business of Coats Group, Coats Bangladesh, the world’s leading industrial thread company and a trusted industry player.  

Part of Coats Digital’s Manufacturer Suite, FastReactPlan is a dynamic, highly visual production planning and control tool to optimise delivery, efficiency, and lead time. FastReactPlan brings together capacity, critical path, and materials into a single, integrated, dynamic planning system. The highly visual and flexible ‘drag and drop’ approach to planning allows effective master planning across multiple factories, as well as the detailed and accurate scheduling of manufacturing lines/ machines. Critical pre-production activities (e.g., samples and approvals), and material requirements are dynamically driven in a LEAN pull system based on the latest plan, which supports the reduction of inventory and lead time.

FastReactPlan is typically interfaced with other business systems (e.g., ERP, PLM, inventory & shop floor). Sharing key data reduces data entry workload, improves accuracy and speeds up the planning process and response times. Developed specifically for fashion manufacturers of all sizes, FastReactPlan is quick to implement, configured to reflect industry best-practices and specific business requirements. It is proven to deliver significant and measurable improvements in speed, flexibility, and efficiency. 

News Source : textiletoday

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