Agility 4.0 drives fashion production
Posted: Sun Jan 19, 2025 9:09 am
According to McKinsey research , the inherent technologies of Industry 4.0 have contributed to successful scaling, which makes supply chains more efficient and labor hours more productive, reduces waste in the factory, and brings numerous other benefits to employees, stakeholders, and consumers.
The study also found that six months into the pandemic, 94% of respondents said Industry 4.0 has helped keep their companies' operations running, and 56% consider these technologies critical to responding to the crisis.
Challenges
Reduce production planning lead time by half, from 6 days to 3 days, and thus cash app database more competitive in delivering your products to more than 26 thousand points of sale.
Solution
Production planning for 4 factories and approximately 300 production contractors for a product mix of over 1,500 products was a major challenge and took 6 days to complete. It was estimated that each day of lead time gained represented approximately R$5 million.
A solution was developed that searches for data generated by SAP MRP and carries out factory and outsourced planning considering more than 10 specific characteristics of the fashion segment, throughout the production chain.
The solution was developed using the most current technologies on the market and accelerated processes to the point of reducing lead time from 6 to 1.5 days. With this gain, the industry can explore other factors that generate change and the gains were maximized.
An example of this solution is that data processing for planning, which used to take approximately 4 hours, was reduced to just over 3 minutes, which allowed the company to perform more simulations and thus make planning faster and much more assertive. This assertiveness resulted in reduced operational costs for moving semi-finished products and re-planning.
The results
Agility, with gains of + 4 days in lead time;
Assertiveness in decision-making in factory planning;
Reduction of operational costs with replanning;
Possibility of carrying out simulations more easily.
The study also found that six months into the pandemic, 94% of respondents said Industry 4.0 has helped keep their companies' operations running, and 56% consider these technologies critical to responding to the crisis.
Challenges
Reduce production planning lead time by half, from 6 days to 3 days, and thus cash app database more competitive in delivering your products to more than 26 thousand points of sale.
Solution
Production planning for 4 factories and approximately 300 production contractors for a product mix of over 1,500 products was a major challenge and took 6 days to complete. It was estimated that each day of lead time gained represented approximately R$5 million.
A solution was developed that searches for data generated by SAP MRP and carries out factory and outsourced planning considering more than 10 specific characteristics of the fashion segment, throughout the production chain.
The solution was developed using the most current technologies on the market and accelerated processes to the point of reducing lead time from 6 to 1.5 days. With this gain, the industry can explore other factors that generate change and the gains were maximized.
An example of this solution is that data processing for planning, which used to take approximately 4 hours, was reduced to just over 3 minutes, which allowed the company to perform more simulations and thus make planning faster and much more assertive. This assertiveness resulted in reduced operational costs for moving semi-finished products and re-planning.
The results
Agility, with gains of + 4 days in lead time;
Assertiveness in decision-making in factory planning;
Reduction of operational costs with replanning;
Possibility of carrying out simulations more easily.