FastReact implementation goes smoothly at Lever Style

21 Jun '10

3 min read

FastReact has been integrated with the ERP system in place at Lever Style and has allowed them to make many significant cost savings and efficiency improvements.

Alex Lui Project Manager explains: “In 2007 the combined pressure of continued expansion, the need to reduce lead time, be more flexible in meeting clients' needs and beat the ever increasing competition led us to review our processes and systems to identify where we could improve further.

We had already invested in ERP and RFID shop floor data systems but we still needed to find a solution that could help us to monitor and have quick visibility of the entire production and pre-production activities. We selected FastReact Evolution as it allows us to have clear visibility of the entire process including critical path, material availability, and capacity restrictions”.

The Implementation: More than software... expert guidance in best practice
Alex Lui Project Manager: “The FastReact implementation went smoothly. The professional staff were able to provide excellent guidance and the ideal combination of training in Chinese and international expertise on project management and best practice in planning. With FastReact, we can plan around problems and give the most effective schedule with just a few drags and drops. FastReact has given us full integration with our ERP system to coordinate the plan with the material status. This helps us to indentify the potential problems and react quickly.”

The Benefits: More efficient communication = a more efficient business
Alex explains the benefits: “The system acts as the communication channel among our key departments such as procurement, planning and production; this allows them to clearly visualize the pre-production and production progress. The critical path tools enable users to quickly identify potential problems, empowering them to take corrective action before problems arise. This has greatly increased the efficiency of communication and has enabled us to understand our available capacity and plan more accurately. As a result, FastReact has allowed us to reduce lead times, improve our efficiency and improve our on-time delivery performance.”

Joe Yuen, Executive Vice President adds: "During 2008-09 we focused our LEAN project on improving our pre-production processes, especially material procurement and warehousing. FastReact's online data ensures all departments from pre-production to production have clear priorities to work to and also helps us to see & react to any changes in time. This means that material purchase, receipt and issue are now much easier to control. This has us enabled us to improve in 3 key areas compared to 2008:

• Production Lead Time: reduced by 30%.
• Production Efficiency: increased by 20%.
• Large reduction in late shipment and air freight charges

The FastReact system has contributed to these results both directly, as explained above, and indirectly by acting as an accelerator to support, strengthen and speed up our other projects. We could not have achieved such great results in such a short time frame without FastReact and are confident that we got the return on our investment in the FastReact system less than a year after it was implemented in our company."

Founded in Hong Kong in 1956, Lever Style produce casual and fully constructed woven garments for the world's top brands including Armani Collezioni, Armani Exchange, Banana Republic, Calvin Klein, Cerruti 1881, Hugo Boss, J Crew, John Varvatos, Paul Smith, Ralph Lauren and Reiss. Production capacity from the Shenzhen, Guangdong based manufacturing facilities is over 10 million pieces per year.

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