Pratibha Syntex Limited is one of the largest vertically integrated textile manufacturers in India with its value chain spanning from fiber to fabric to garments. The company embarked on a journey to transform its business of manufacturing of various textile Products such as Yarns, Knitted Fabric and Knitted Garments through the platform of 'Theory of Constraints' by partnering with Vector Consulting Group since November 2014. PSL reaped the following benefits within a short span of one year:
Leading shirting fabric manufacturing company - part of Raymond group. The objective of this assignment is to build a decisive competitive edge of High reliable on delivery performance at SO level by reducing the Production lead-time and capitalize the same in the market to increase company sales and profits. By Implementing TOC solutions Raymond Zambaiti has got the following benefits within a short span of 8 months.
1. Production lead-time is reduced by 25% (from 45/50 days to 33 days) at SO level.
2. On time delivery performance (at SO level) has been improved to 95%.
3. In this industry order assortment (multiple SKUs in one sale order) getting dispatched together on or before the agreed due date is a critical requirement of their customers.
Before TOC, production flow entity use to be at SKU level leading to desynchronized flow at SO level and more waiting time at warehouse. (First SKU waiting for the last SKU). After TOC the production flow entity has been changed to SO level. 50% reduction (15 days to 7 days) in assortment waiting time at company warehouse has been achieved because of improved synchronization and flow. This reduction also results to improved cash to cash cycle.