Category: General
Country: South Korea
Region: Asia Pacific
FastReactPlan has also increased production line scheduling accuracy by 10%, reduced overtime costs by 5% and enabled Hojeon to accurately plan six months ahead, instead of just three.
By Laurena McKenna
GTS NewsDesk
25th March 2024
SEOUL, SOUTH KOREA and LONDON, UK – 25th March, 2024 – Coats Digital is delighted to announce that following the implementation of Coats Digital’s FastReactPlan, leading sportswear manufacturer, Hojeon Limited Corp. has achieved a remarkable 90 percent improvement in capacity scheduling accuracy across its three factories in Indonesia. The solution has enabled Hojeon to seamlessly connect and consolidate information from various sources, creating one highly visual and unified system.
This strategic enhancement has proven highly beneficial for both the management at the company’s headquarters in Seoul and the employees across its three Indonesian factories. FastReactPlan has provided them with a single, clear overview of the production plan, resulting in a noteworthy ten percent increase in line-scheduling accuracy for each factory. Additionally, the company has experienced a five percent reduction in overtime costs. Moreover, Hojeon can now plan six months in advance, a significant extension from its previous three-month planning horizon.
Headquartered in Seoul, South Korea, Hojeon is a specialist Original Equipment Manufacturer (OEM) of sportwear apparel for leading multi-national brands such as Athleta, Lululemon, Nike, The North Face and many others. The company has developed and patented a revolutionary, high-frequency seam-attachment technology that has enabled it to produce innovative, functional, all-weather garments in a myriad of style designs. Hojeon operates seven factories across Indonesia and Vietnam and employs over 15,000 workers. It produces 1.6 million pieces a month and boasts an annual turnover of over USD 370 million.
Prior to implementing FastReactPlan, Hojeon lacked a comprehensive capacity overview for all its production sites in Indonesia. Not only was capacity planning and production information fragmented across various sources in different locations, but each factory maintained its own capacity plans in Excel spreadsheets. This decentralised approach made it challenging for the headquarters’ planning team to quickly assess the capacity availability of each factory, leading to significant time spent on collating, duplicating and aggregating records. The lack of clear visibility hindered efficient production scheduling across factories, resulting in issues such as under- and over-machine utilisation, slow production rates, poor on-time delivery performance (OTDP), unnecessary overtime costs and the lack of data insights essential for informed business decisions and growth.
Eric Kim, General Manager, Hojeon Limited Corp., said: “As each of our factories had their own way of planning their production runs, not having a consolidated plan made it impossible to anticipate and address potential challenges ahead of time. As planning had always been done on the basis of average line production efficiencies, the impact of slower production outputs was not obvious until mid-way through an order, leading to a constant need for firefighting. Recognising the need for a solution to meet our complex, multi-level planning needs quickly, we identified FastReactPlan as the obvious choice to seamlessly digitise our planning processes.”
Following the implementation of FastReactPlan, Hojeon quickly benefited from access to business-critical planning and production information from a unified digital source. This single source provided a holistic view of production capacity across all its factories, including standardised visibility into purchase orders, colour, size and delivery levels. The enhanced data visibility and standardised format have consequently fostered cohesive and seamless collaboration across Hojeon’s production facilities. Master planners can now effortlessly assign the right jobs to the most suitable production operations, enhancing overall efficiency.
Eric Kim, General Manager, Hojeon Limited Corp., adds: “FastReactPlan provides us with a synchronised overview of our Indonesian factories, simplifying the management of real-time order status, product history and line scheduling. This facilitates the easy identification of factories and production lines with a positive track record of certain style processes. As a result, we can allocate jobs more effectively whilst closely monitoring how work is progressing.”
The seamless integration of the master capacity plan with detailed daily production plans has led to a notable 90 percent improvement in production scheduling accuracy rates across Indonesia. Additionally, each factory has experienced a ten percent increase in line-scheduling accuracy. Hojeon has also realised substantial cost savings, with a five percent reduction in unnecessary overtime costs since its adoption.
Oliver Kim, Assistant Manager, Hojeon Limited Corp., concludes: “The FastReactPlan system makes it easy to understand the data and history of a specific product. This enables us to easily make adjustments and quickly respond to changes in Repeat styles.
Not only have we been able to create capacity plans in rapid time, saving considerable people hours and reducing overtime costs, but we can now proactively plan six months ahead, instead of our usual three month outlook. This proactive approach ensures stability in production costs and delivery targets, contributing to a less stressful working environment for our employees.”
The implementation of FastReactPlan has been so successful that Hojeon has recently adopted Coats Digital’s award-winning GSDCost solution to establish accurate method-time-cost benchmarks that will enable its sales, costing, planning and manufacturing teams to communicate efficiently using the same language, based on a scientific method for correctly analysing manufacturing costs.
Irene Won, Customer Success Manager, Coats Digital said: “We are delighted to witness the remarkable benefits achieved by one of Korea’s premier sports and outdoor clothing manufacturers following its adoption of FastReactPlan. With numerous large manufacturing plants in Indonesia, it is fantastic that Hojeon’s technology infrastructure is underpinned by FastReactPlan. We are excited to be continuing our strong partnership, as Hojeon advances its digital transformation journey with the adoption of our method-time-cost solution, GSDCost. The award-winning GSDCost solution provides scientifically-assessed cost prediction methods and practices, promising to further boost production efficiencies and drive significant financial growth. We look forward to working closely with Hojeon to ensure it meets its digitization objectives quickly.”
Key Benefits and ROI for Hojeon
-Improved cross-factory capacity scheduling accuracy by 90%
-Increased line scheduling accuracy by 10%
-Reduced overtime costs by 5%
-Improved order imbalance between factories by 5%
-Faster identification of idle lines – increase of 5%
-Quicker response in accepting or changing customer orders
-Standardised PO, Colour & delivery level visibility across all departments
-Increased productivity across all departments
-Automated data capture and consolidation.
-Increased new business growth
-Boost to staff morale due to more stable working environment
About Hojeon Limited Corp.
Headquartered in Seoul, South Korea, Hojeon is a specialist Original Equipment Manufacturer (OEM) of sportwear apparel for leading multi-national brands such as Nike, Under Armour, Lululemon, The North Face, and Athleta, among many others. The company has developed and patented a revolutionary, high-frequency seam-attachment technology that has enabled it to produce innovative, functional, all-weather garments in a myriad of style designs. Hojeon operates seven factories across South Korea, Indonesia and Vietnam and employs over 15,000 workers. It produces 1.6 million pieces a month and boasts an annual turnover of over 370 million USD.
About Coats Digital
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 intelligence. coatsdigital.com
Coats Digital is the software business of Coats Group, the world’s leading industrial thread company and a trusted industry player.
About FastReactPlan
FastReactPlan is developed exclusively for the fashion, textile and apparel industry and can be configured in multiple ways to reflect industry best practice and specific business requirements.
FastReactPlan is the market-leading apparel production planning software solution, supporting a faster, more reliable order confirmation process and production plan which is optimised for delivery, speed and efficiency.
The highly visual, flexible ‘drag and drop’ approach to planning allows effective master planning across multiple factories, as well as fast, detailed and accurate scheduling of manufacturing lines/machines. Critical pre-production activities and material requirements are dynamically driven by the latest plan on a LEAN ‘just in time’ basis, supporting the reduction of inventory and lead times.
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