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December 10, 2021

Vietnam apparel manufacturer cuts fabric waste by 2% with AI-based system

Vietnamese apparel manufacture, Duc Hanh Garment JSC has reduced its fabric waste by almost 2% since it started using an AI-based system three years ago.

By Laura Husband

The apparel manufacturer, a production partner for Polo Ralph Lauren and Chaps, says since it started using the IntelloCut system from Coats Digital in 2018 it has cut fabric waste by 1.95% and optimised its operations significantly.

The manufacturer says it has also saved 2.2% on its bill of materials, which it believes has led to better-informed fabric bookings and improved profitability.

Prior to implementing IntelloCut, the cutting floor at Doc Hanh was coordinated manually using a homegrown spreadsheet solution that proved unfit for purpose, since it was unable to provide full visibility into the cutting operations.

David Goh, Duc Hanh Garment JSC general manager said: “From a starting point of heavily manual workflow and very limited visibility, IntelloCut quickly enabled us to eliminate the Excel spreadsheets we had been using, providing complete, real-time visibility into the cutting process.

“As a directs result of implementing IntelloCut and partnering with Coats Digital, we can now accurately estimate our fabric requirements, which has allowed us to achieve much higher efficiency and productivity at the same time as cutting fabric waste, Thanks to the data centralisation and reporting capabilities of IntelloCut, we can now easily measure our efficiency and material utilisation. We now enough confidence to buy only the exact amount of fabric that the facility needs – no more, and no less.”

The IntelloCut system is described as being backed by AI with a closed-loop approach to fabric planning. It features real-time planning, fabric optimisation and bill of materials savings.

Three years on from the implementation, IntelloCut continues to provide a visibility advantage and is said to cut fabric waste to just 1.7% across the lifetime of the partnership between Duc Hanh and Coats Digital. As well as enabling Duc Hanh to correctly capture the company’s actual fabric consumption, IntelloCut has delivered an additional benefit of consolidating and centralising the company’s cutting room data. With the combined power of visibility and a single source of data, Duc Hanh has been able to both automate its data capture – ensuring accuracy – and rapidly produce detailed reports and order confirmation.

Jaya Choudhary, Coats Digital professional services manager said: “Duc Hanh is one of Vietnam’s leading garment manufacturers – a position it has achieved and maintained because of its strong investment in modern technology and a cohesive, connected approach to production.

“After implementing IntelloCut in 2018, and making extensive use of the solution’s planning automation, visibility, and execution control capabilities, Duc Hanh has successfully kept its fabric wastage to below 2%. We are thrilled to continue to be part of the company’s journey, and applaud the results that Duc Hanh has achieved to ensure it remains a forward-looking, innovative production partner on the world stage.”

Seamless garment manufacturer Tefron is using Coats Digital’s FastReactPlan to accelerate its digitisation strategy, which includes revolutionising its planning processes and the efficiency of its supply chain. 

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