VSTAN Industries Pvt Ltd, Arani

Style-wise production planning lived across a stack of spreadsheets, one per style, reconciled by hand before every planning meeting. Allocating orders to the right lines and sizes took hours, and the plan was out of date the moment a style changed. Fabric was issued against a cut plan worked out by hand, so over-consumption only surfaced at month-end stock reconciliation, long after the margin on that order was already gone. No one could see, mid-run, whether a style was tracking to its planned fabric usage.

Fleek replaced the spreadsheet stack with style-wise work orders linked to the cut plan. Planning that took hours now takes minutes: orders are allocated to lines and sizes from one screen, and the plan updates live as production moves. Fabric is issued against the work order, and actual consumption is tracked per style in real time, with an over-consumption alert the moment a run drifts past its planned usage instead of at month-end.

• Production planning time cut by about 60%, from hours of spreadsheet reconciliation to a single live screen
• Fabric over-consumption flagged in real time per style, not discovered weeks later at stock reconciliation
• Style-wise allocation across lines and sizes managed from one dashboard instead of separate files
• Planning meetings shortened sharply, since the plan is already current before the meeting starts
• Go-live completed in 18 days with operators logging from their own Android phones