Case Study: Madura Garments achieves 7.1% operational efficiency improvement in 2 years with Coats Digital

Madura Garments increase operational efficiency by more than 7% in 2 years

Madura Garments Exports, part of the Aditya Birla Group and one of India’s largest shirt manufacturers (capacity ~5 million pieces, ~US$50M turnover), faced rising complexity as it shifted focus to European and casual markets: shorter lead times, more styles and smaller orders, higher work content and value‑added processes that overwhelmed its manual planning systems.

They implemented Fast React planning to provide real‑time visibility, rapid re‑planning and cross‑department transparency (with SAP integration underway). Within two years delivery penalties fell from about $1.3M to under $67K, On‑Time & In‑Full rose from 35% to ~85% (Ship/Cut 97%), and shirts output grew 34.5% with only a 25.5% increase in machines/labour — a 7.1% improvement in operational efficiency.

Madura Garments

R. Swaminathan

Deputy COO