2005-04-07 : Fountain Set (Holdings) Limited to "Go Live" with Taylor Scheduling Software
by http://www.taylor.com
One of the world's largest knitted fabric manufacturers is about to "Go Live" with their first implementation of Taylor Scheduling Software in their Dongguan plant and is busy with a second implementation in a new plant west of Shanghai. The Dongguan plant implementation comes after 10 months of customization and integration.
Fountain Set (www.fshl.com) selected Taylor Scheduling Software after a lengthy "demo and proof of concept" phase of evaluation. The company had tried other scheduling products but all had failed at gaining the confidence of this world-class company with a history for producing quality products and a focus on using innovative technology.
Fountain Set (Holdings) Limited and its subsidiaries are renowned for their expertise and experience in the production and sales of knitted fabrics. Fountain Set is one of the world's largest circular knitted fabric manufacturers and has long been the driving force in the worldwide textile industry through their vertically integrated operations in spinning, knitting, dyeing, printing and finishing.
Headquartered in Hong Kong and listed on the Hong Kong Stock Exchange (SEHK: 420), Fountain Set has production facilities in the PRC, Sri Lanka and Indonesia. In addition Fountain Set has marketing offices in 7 countries and a global staff force of over 22,000.
The Dongguan Textiles Plant
Located in Dongguan City, Guangdong Province, China, this plant covers over 230 acres and total floor space of over 400,000 square meters. The plant has been in operation for almost 20 years, employs over 6,900 staff and has more than 1,600 sets of machines including yarn dyeing machines, yarn doubling machines, knitting machines, fabric dyeing machines and fabric finishing machines.
Business Case: The business drivers for Fountain Set were straightforward:
- Manage growing capacity.
- Integrate the production schedules of over 1,600 machines.
- Manage the wide variety of fabric types, dyes and manufacturing methods.
- Manage critical delivery dates for a large number of high-profile customers.
- Ensure quality control at critical steps during the manufacturing process.
The production of fabrics requires many steps and each stage must be completed before moving from one step to another. For example, with printed fabrics:
- Raw Yarns are tested for their physical and mechanical properties, and are graded for evenness, tenacity, elasticity, fiber maturity, contamination, twist level and hairyness.
- Raw Yarns are knitted into fabrics.
- Once knitted, fabrics undergo quality inspection to ensure that griege fabrics are the highest quality before going to the dye house.
- Presetting is done on fabrics that contain certain synthetic fiber content before going to the dye house.
- Fabrics are dyed using different methods depending upon the fabric type.
- After dyeing, excessive water is removed from the fabric.
- Any special finishings (e.g., anti-UV, water & oil repellent, stain release) are applied before heat setting.
- Heat setting then occurs.
- Fabrics are inspected once again for quality control before packaging.
- Further finishing and presetting occurs.
- Using a variety of printing methods and machines, fabric is printed.
- Some printing methods require that the fabric is baked, steamed, washed and then dried.
- Fabrics are then treated with a variety of finishes, then heat set or compacted.
- Final inspection is done before shipping.
Trying to manage a wide variety and large number of manufacturing issues without a good scheduling system is a common challenge faced by most manufacturers today. With the Taylor Scheduler™ implemented, Fountain Set is better equipped to handle capacity, critical delivery dates and their unique and complex manufacturing requirements. This was their first implementation and because of the efficiencies gained Fountain Set is now implementing the Taylor Scheduler in other plants.
Fountain Set products and services are trusted and used by high-profile brands and retailers including: adidas, Banana Republic, Calvin Klein, Carter's, Dillard's, DKNY, Eddie Bauer, Express, Fila, Gap, Gymboree, Itochu, Ito Yokada, J Crew, JC Penney, Jones, Kohl's, Lacoste, Lands' End, Lane Bryant, Laura Ashley, Levi's, Liz Claiborne, L.L. Bean, Marks & Spencer, May Co., Mitsubishi, Nautica, Next, Nike, Old Navy, RH Macy, Ralph Lauren Polo, Reebok, Sara Lee, Sears, Seiyu, Talbots, Target, Tesco, Tommy Hilfiger, Uniqlo, Victoria's Secret, Wal-Mart and more.
Fountain Set has received many awards and honours, including being selected by Forbes Global Magazine in 2002 as one of the "Best under a Billion" companies, showcasing 200 of the best small companies in the world.
The emphasis on quality reigns over every aspect of their business. As a technology leader in the field, they continuously strive to upgrade the quality of their products to satisfy the ever-changing needs and tastes of today's consumers.
About the products manufactured
Product range includes dyed yarns, sewing threads and garments.
Cotton Yarn
Fountain Set operates several cotton spinning factories in China and is one of the world's largest buyers of ring-spun cotton yarn. Their long standing reputation and credibility guarantees that they always enjoy a steady supply of the best quality cottons from global cotton suppliers.
Knitting, dyeing and printing
Fountain Set ensures stringent colour accuracy of their products and a consistent ability to meet the highest standards in the industry. Whatever the request, be it the manufacturing of solid, yarn-dyed or printed circular knitted fabrics, Fountain Set can quickly and efficiently provide these beautiful products, by skillfully monitored mass production
Sewing Threads
Goldlink is one of the best-loved brands in Asia and its client list encompasses hundreds of garment manufacturers.
As a major fabric supplier to factories all over the world, Fountain Set products are being cut and sewn into men's, women's, and children's garments, lingerie and sportswear, adding their "magic" to people's wardrobes all over the world.
For more information on Fountain Set, please visit their website: http://www.fshl.com