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The Textile Magazine
APRIL 2012
Lectra
cut order planning solves
Arvind’s technical problems
finishing
Arvind Ltd., the third largest producer of denim in
the world, also specializes in finished denim garments
for major international brands and its own local labels.
Manufacturing at multiple sites in Bangalore, Arvind
currently exports more than 600,000 units per month. Its
manual processes, however, have been counterproduc-
tive to the company’s growing success, causing delays,
production errors, and waste.
To improve operations, increase production capacity,
integrate process, save materials and enhance produc-
tivity, Arvind chose to implement Lectra’s Optiplan cut
order planning solution alongwith Lectra’s Diamino-
FashionExpertPro marker-making solution.
Arvind now enjoys all the benefits of automated proc-
esses as well as Lectra’s shared expertise. Lectra’s au-
tomated development and production solutions have
enabled the company to meet its challenges faster and
more effectively.
Arvind was facing significant challenges in cutting
room planning at its various sites. Excess fabrics and
fabric shortages were causing major inefficiencies in
production. Organization of cutting order was not opti-
mized, leading to wasted time and resources.
The company came to Lectra, seeking to improve
the operations level, increase efficiency, reduce mate-
rial consumption and enhance productivity in various
departments by using sophisticated technology, ideally
through creation of a centralized cutting facility.
The solution
Lectra’s business specialists carried out a process anal-
ysis of Arvind’s manufacturing processes. They studied
the existing methods used and detected production bot-
tlenecks. After a thorough evaluation, Lectra proposed
an integrated solution, including the DiaminoFashion-
ExpertPro marker-making software and Optiplan Expert
cutting room planning software, which would be a pow-
erful complement to a new centralized cutting facility.
“We are extremely happy with the support received and
the quality of the partnership developed with Lectra,”
says Mr. Ashish Kumar, Arvind’s CEO.
Uncentralized planning and inefficien-
cies
Before acquiring Lectra, Arvind was working with a
manual planning and marker-making system at its vari-
ous sites, with each production site handling its own
cut-order planning separately. With the arrival of each
customer order, individual operators would input pro-
duction order information into separate Microsoft Excel
files. The corresponding marker combinations would be
drawn up by the operator as well, often estimated from
similar markers used previously.
Meanwhile, Arvind’s fabric laboratories would esti-
mate the amount of fabric needed for each order based
on approximations of markers, and they would ship the
amount of fabric to the production site according to their
Mr. Ashish Kumar,
CEO