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Fast React Systems recognised the significant functionality gap between existing ERP solutions and
Spreadsheets and has developed a range of highly visual, easy-to-use and flexible solutions that allows
the planner the ability to visualise the plan and view all planning constraints (e.g. materials, critical path
constraints and available capacity options) graphically on screen, thus enabling a highly effective and
efficient planning process. Fastreact can work on a stand alone basis or linked to an existing ERP system
to leverage maximum benefit from existing data. It provides an essential management tool when trying
to offer the best customer service and to stay competitive in today’s highly aggressive fashion
marketplace.

Fast React Systems (FRS) is a Global supplier of Planning and Sourcing

solutions for the fashion industry supply chain. Our specialist software is
specifically designed for and used extensively by companies involved in
Garment/Apparel, Textiles, Footwear and associated industries.
The FastReact range of products offer highly visual, easy to use solutions, which focus on delivering
‘competitive advantage’ in difficult and volatile industry sectors, through improved visibility,
coordination and control.

Whether manufacturing or sourcing, FastReact provides a highly visual, easy to usesoftware tool for
management of the entire supply chain - planning and monitoring all new styles/orders from initial
concept to delivery.

FastReact offers a modular solution, which can be configured to meet the needs of each business and
which can operate either on a stand alone basis or integrated to other, existing systems.

FastReact solutions provide:

 Rapid implementation with minimal disruption
 Strong business benefits, delivered quickly
 A rapid return on investment and ongoing savings

Used well, FastReact software provides not just good solutions for planning, but a powerful management
tool to deliver significant performance improvements.

FastReact sits at the heart of a business and provides a control tower view of all styles/orders and a
central point of reference for information.

This approach promotes improved coordination between departments through 'one version of the
truth', whilst significantly reducing manual processes (spreadsheet and typed documents, emails,
telephone calls)

ABOVE ALL, FASTREACT OFFERS THE ABILITY TO ACHIEVE COMPETITIVE ADVANTAGE IN A

CHALLENGING MARKET!
Fast React are specialist providers of Planning, Sourcing and Critical Path Management
software specifically developed for the Apparel, Textiles and Footwear sectors where
tight margins and short lead-times are commonplace.Fast React are specialist providers
of Planning, Sourcing and Critical Path Management software

HOW TO CONTROL AND REDUCE WIP WITH FASTREACT

Seven steps to WIP Control:

1. Educate ....It is important to remember that supervisors and workers typically see high levels of WIP
as a good sign, as they see they have plenty of work, are productive and have a good opportunity to
produce bonus. 
Before starting a WIP reduction and control project it is essential to educate your production team about
the whole WIP issue. FastReact’s skilled team of implementers and project managers have the
knowledge and experience to guide your team through this project.
2. Measure ...the amount of WIP currently in the system and set up a daily report to identify the WIP
level by order/production department after each days production update.

As soon as a daily production update is made in FastReact the WIP figures are updated and can be
reported. FastReact’s report designer quickly allows flexible reporting of WIP by order, factory,
department, delivery date etc.

3. Target. For each production process/product type/factory a target should be agreed on for the
amount of WIP required. This can best be expressed in days (based on the current output target). This
should be sufficient to allow for smooth production flow allowing time for any issues to be resolved
before WIP shortages occur. If current levels are much higher than your target, a gradual reduction over
a period of months is better than a rapid one off reduction.

FastReact facilitates quick and easy configuration of WIP levels by process and factory. The WIP levels
are used to generate clear work schedules for each process.

Standard WIP levels can be overridden on a case by case (order) basis when more or less WIP is
required to address a specific problem.

4. Plan & Communicate to Achieve Targets. 

Clear schedules must be provided for each production process, these targets are worked backwards
(e.g. cut, embroider) or forward from the sewing schedule (e.g. wash, pack). They should reflect the
output requirements of the sewing plan but will be x days (depends on target WIP level) earlier or later.

Before the final plan is issued, capacity vs. load of all processes must be carefully checked to ensure that
the plan is achievable. For example in a cutting room the workload will increase dramatically if a high
proportion of the orders are striped or checked fabrics and require pattern matching.

FastReact’s integrated approach to planning means the planning of all processes, including scheduling
and capacity vs. load checks is done quickly leaving time for planners and managers to address any
issues faced and execute the plan successfully.

5. Monitor & Control  

Identify areas where there is too much or too little WIP and take action to correct. This is easy on a
department by department basis but should also be done on an order by order basis to identify orders
where WIP may not be sufficient to meet the plan and hence delivery schedule.

FastReact greatly simplifies the monitoring and control process by quickly identifying WIP shortages
(colouring orders on the plan with a red border). Drill down with a mouse click to get the exact size and
nature of the problem.

FastReact allows management time to be focused on problem solving instead of data analysis.

6. Improve
As with any KPI the goal should be to achieve the target consistently and then aim for continuous
improvement.

Achievement against target should be plotted overall and by process/factory in order to identify trends
and areas where further savings could potentially be made.

FastReact can process the data from daily production updates through our historic KPI analysis desktop
to provide a snapshot of WIP levels and trends.

Conclusion

In the current economic climate almost all businesses are asking themselves how to meet the demands
of the market in terms of price, flexibility and speed of response. Good control of work in progress is
ABSOLUTELY ESSENTIAL to running an efficient and cost competitive business. Reduced work in
progress allows you to free up capital for re-investment and use less floor space. Most importantly, good
management of work in progress also allows your stitching department to SPEND MORE TIME SEWING
and supporting departments to spend more time working on the priorities that the stitching department
needs. More productive time = higher production efficiency and significant cost savings.
 
During our travels Worldwide, many people have asked us recently, 'I can get the orders, but how do I
hit those price points'. Well, this is where it all starts! GET THE RIGHT TOOLS FOR THE JOB -
FASTREACT - The potential savings through good planning are HUGE, whether in efficiency
improvements (improved on time start, spending more time sewing), on time delivery performance
(reduced air freights and penalties), better management of WIP and raw materials (better workflow, plus
reduced working capital and floor space) - IT REALLY DOES WORK!