Case Study: Esquire Knit Composite Limited achieves 6% factory efficiency improvement with Coats Digital's FastReactPlan

Esquire Knit Composite Ltd Use FastReactPlan to Improve Control of Pre-sewing Processes Resulting in 6% Factory Efficiency Improvement

Esquire Knit Composite Ltd is a vertical knit garment manufacturer in Dhaka supplying major global retailers, producing around 1.6 million pieces per month with 95% of styles requiring embellishment. Increasingly smaller, more varied orders and poor visibility of capacity and WIP in pre-sewing areas (printing and embroidery) created bottlenecks that caused sewing-line idle time and delivery problems.

Esquire formed a centralized planning team and implemented FastReactPlan to link line-level sewing boards with operations management, automatically schedule embellishment types, and provide real-time load vs capacity, Plan vs Actual and WIP visibility. The five-month rollout smoothed feeding to sewing, reduced downtime, and delivered a 6% improvement in factory efficiency and a 5% improvement in Ship-to-Cut ratio.

Esquire Knit Composite Limited

Indunil Mahawatte

Head of MIS