Premier Bangladeshi garment manufacturer, Cotton Club (bd) Ltd., has reported a $250,000 annual profit increase following the successful implementation of Coats Digital’s GSDCost solution. Since adopting the method-time-cost optimisation tool in August 2021, the company has significantly improved costing accuracy, productivity, and supply chain efficiency.

The vertically integrated manufacturer, which includes Cotton Clout (BD) Ltd., Tropical Knitex Ltd., and Cotton Clothing (BD) Ltd., specialises in knitted fashion and underwear items for global brands such as Kiabi, Inditex, Primark, and Target USA. With a workforce of 15,000 and an annual turnover of $268 million, Cotton Club (bd) is targeting $300 million in revenue this fiscal year.

Prior to using GSDCost, the company relied on outdated spreadsheets and historical data, leading to inefficient costing, inaccurate capacity planning, and lost business opportunities. Without real-time visibility of standard-minute-values (SMVs), Cotton Club faced frequent workflow disruptions, missed delivery deadlines, and escalating overheads.

Cotton Club’s transformation exemplifies the power of data-driven manufacturing

Since adopting GSDCost, the company has reduced core style production time by 25.6%, improved productivity by 5%, and enhanced costing accuracy by 90%. Material waste has been reduced by 10%, while overtime costs have decreased by 8%. These gains have enabled Cotton Club to confidently take on more complex orders and improve on-time delivery performance (OTDP) by 7%.

Md. Zubayer Mondol, Director and Owner of Cotton Club (bd) Ltd. said: “Running a factory without accurate costing and capacity data is like flying blind. GSDCost has given us the visibility and precision we needed to optimise performance and grow our business sustainably.”

The company’s expansion in 2023 included a new 260,800 square foot seamless garment manufacturing facility in Gazipur. Equipped with advanced technology, the site upholds rigorous quality standards and is accredited with Leed (Gold), ISO 14001:2015, GOTS, and several other industry certifications.

GSDCost, developed by Coats Digital, is widely recognised as the international standard for garment manufacturing time and cost benchmarking. By implementing standard motion codes and predetermined times, the platform fosters collaboration and transparency between brands and manufacturers.

Golam Mahbub Sikder, Customer Success Manager at Coats Digital, commented: “Cotton Club’s transformation exemplifies the power of data-driven manufacturing. Their success proves the importance of digital tools in remaining agile and competitive in today’s fashion landscape.”

With improved communication, better bonus schemes for workers, and reliable, fact-based costing, Cotton Club (bd) Ltd. is now better positioned than ever to meet the evolving demands of global apparel manufacturing.

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