Case Study at Okamoto

Initial Situation

  • Production lead time hovers around forty days.
  • Excessive inventory stocks of semi-finished products and finished products exist.
  • Raw materials are not planned for in advance, wherefore no single-cost calculation can be made.

Advantages of Asprova

  • Asprova helps to quickly react to changes of delivery deadlines.
  • A standardized planning process enables for simple and effective operation.
  • Increased process efficiency and optimized inventory stock management are two of the many major improvements that come from effective planning.

Achievements with Asprova

  • Implementation has been completed in two months.
  • Throughput has been reduced from 40 days down to 21 days.
  • Communication between the planning department and the production department has become seamless and direct.
  • Precise raw material calculation allows for single-cost calculations and helps minimize inventory stocks.

Back in the nineties, knitwear producer Okamoto aims to shorten cycle times and improve production efficiency with the help of the Asprova production scheduling system. After celebrating great success, the manager of the Chinese factory introduces Asprova with hopes of achieving similar success.

Operating a very similar production line, the knowledge gained during the first implementation in Japan is used to make a swift implementation of only two months.

The result is astounding: Throughput times are halved, while improved flexibility allows managers to instantly respond to order changes.

Pre-emptively acquiring the most advanced scheduling software, Asprova, has led to optimal resource utilization, preventing bottleneck processes from emerging and thereby avoiding the problem of slow growth at the outset!

Okamoto Corporation

The Okamoto Corporation is a knitwear producer with headquarters and production in Japan. Another production facility is located in Zhangjiakou, about 100 km north-west of Shanghai.