Case study · Garment manufacturing
“Where is order 3050?”
At Avyaan, answering that took three phone calls and about 40 minutes. The owner asked it more than 30 times a day. Here’s how they got it down to one screen.
- To find one order40 min
- Asked every day30+ times
The problem
Plenty of orders. No way to see them.
Avyaan makes kurta–jacket sets and sherwanis, around 450 orders a month, through 4 masters and outside embroidery units. Everything ran on WhatsApp, paper and memory.
Orders lost in WhatsApp
Orders, size changes and payment reminders all mixed in 41 groups.
1 in 12 orders had a size or colour mistake
One set, four masters
Kurta, jacket, pant and embroidery go to different people. The set waits for the slowest one.
Nearly 1 in 3 orders late in wedding season
Fabric on paper challans
Metres given to masters were written on paper. What came back was a guess.
₹2.8 lakh of fabric unaccounted in a quarter
Cost known too late
The real cost of a set was worked out after the month closed.
Two best-sellers were selling below cost
कौनसा डिज़ाइन किस मास्टर के पास है, ये सिर्फ़ मुझे पता था। मैं छुट्टी पे जाता तो फ़ैक्टरी रुक जाती।“Only I knew which design was with which master. If I took a day off, the factory stopped.”
What we did
We spent 9 days in the factory before we built anything.
We followed orders from the retailer’s message to the dispatch truck, then built the system around the way Avyaan already worked.
The life of one order
- Order on WhatsAppVoice notes, slip photos, size changes later in the chat
- Owner writes it downIn a notebook, from 41 different groups
- Split to 4 mastersKurta, jacket, pant, embroidery. Nobody tracks who has what
- Fabric on paperMetres guessed, leftovers rarely come back
- Dispatch and billingCost per piece known only at month-end
- Order entered onceRetailer gets a WhatsApp confirmation
- Jobs createdEach piece goes to a master with a due date
- Fabric issued exactlyMetres per job, stock updates live
- Masters update by phoneLate jobs flagged before the customer calls
- Dispatch and settleInvoice to Tally, LR to the retailer, commission calculated
What we built
A dashboard for the office. An app for the floor.
Masters use a simple phone app with design photos. Retailers don’t install anything. They get updates on WhatsApp.
The project
7 people. Live in 8 weeks.
- 7people on the team
- 9days in the factory
- 21days to the first working version
- 8weeks to go live
The team
- PLProject lead
- BABusiness analyst
- UXDesigner
- FS2 full-stack engineers
- MOMobile engineer
- QAQA engineer
Built with
- React
- Node.js
- PostgreSQL
- React Native
- AWS
- WhatsApp Business API
- Tally Prime
- GST e-way bill
The results
Six months later, nobody has to ask.
Finding an order
Before
40 minNow10 seconds
Delivery delays
Before
1 in 3 lateNow30% fewer
Time on follow-ups
Before
Every morningNow12–15 hrs saved / week
Fabric wastage
Before
UntrackedNow15% less
Paper job slips
Before
~180 / monthNowZero
Cost per piece
Before
Month-endNowBefore cutting
“Managing our raw material stock, production pipeline and dispatch used to involve three different tools. Faxtor built a custom solution that mirrors how we actually work, and reduced delays by almost 30%.”
Your factory next
Still asking “where is my order?”
A 30-minute call. We’ll show you Avyaan’s system and how it would work for your masters, fabric and agents.