Mars Fashion: Integration of MaxTex and RetailEdge

Connecting factory production with retail demand through AI-driven digital transformation

The Challenge

Manual processes, inconsistent inventory, and production inefficiencies

Mars Fashion retail store

Background

Mars Fashion manages both apparel manufacturing and a small chain of retail outlets. Before digitalisation, planning was manual at every stage:

Fabric markers prepared by hand
Dye-house sequencing based on experience
Branch stock levels guessed from weekly summaries
Fabric utilization: 82-85%

Re-dye cycles and unplanned overtime regularly delayed deliveries. Retail branches carried uneven inventories, with some styles oversupplied and others missing entirely, affecting margin and customer fulfilment.

Deployment Objective

In 2016 the company adopted MaxobizTex's AI suite to stabilise production performance and connect factory output with retail demand.

MaxTex

AI-driven cutting-plan generation, order sequencing, and waste-tracking dashboards for the production floor.

RetailEdge

SKU-level forecasting and automated purchase proposals for the retail network.

Up and Running

The rollout was coordinated and headed by Ahsan Sharif of MaxobizTex, who acted as the implementation lead. He oversaw data integration between the factory's ERP and the RetailEdge forecasting engine, configured QC and production inputs for the MaxTex modules, and trained floor supervisors, merchandisers, and retail planners in the daily use of dashboards and forecasting outputs.

The Solution

Integrated AI systems connecting production with retail

Digital integration process

Implementation Process

1
Phase 1: Baseline

3 months

Collected production and stock data, cleaned fabric and SKU codes, mapped ERP fields to MaxTex and RetailEdge APIs.

2
Phase 2: Pilot

3 months

Ran dual systems on one production line and two retail branches. Initial training focused on cutting-plan generation and interpreting waste metrics.

3
Phase 3: Full Rollout

6 months

Extended across all units; daily dashboards and weekly replenishment proposals became standard operating tools.

Operational Findings

(from internal logs and ERP reports)

Fabric Utilization

Average improved from 83% to 92% over 12 months

Fabric Waste

Down ≈ 25%, confirmed by cutting-room yield reports

On-Time Delivery

Increased by ~21% according to shipment registers

Re-dye Frequency

Decreased by ~20% based on QC batch records

Retail Stockouts

Reduced by ~30%, with branch gross margin improved ≈ 9%

Decision Process

Morning meetings now start with reviewing waste and demand dashboards

Integration and Data Flow

MaxTex outputs are automatically written to the ERP production module; the same data feed informs RetailEdge forecasts, closing the loop between manufacturing capacity and branch demand.

System Benefits
  • Reduced excess production of low-rotation styles
  • Shortened reorder cycles for high-turn items
  • Real-time alignment between production and demand

Data Flow Diagram

ERP System
MaxTex
RetailEdge
Production & Retail Dashboards

Closed-loop system connecting manufacturing with retail operations

Training session

Knowledge Transfer

Ahsan Sharif from MaxobizTex designed the training material in collaboration with Mars Fashion's production manager and supervised its delivery on site.

KPI Templates

Established for waste, efficiency, and replenishment accuracy

Team Empowerment

Factory supervisors now manage dashboards independently

Sustainable Implementation

The same parameters configured during deployment remain in use, ensuring consistency and reliability in ongoing operations.

The integration of MaxTex and RetailEdge created a verifiable link between production efficiency and retail performance.

Measurable Results

Reductions in waste, improved delivery reliability

Data-Driven Approach

Automated replenishment demonstrates quantifiable process improvement

Sustainable Model

Operational control now rests with Mars Fashion's internal team

Implementation leadership and system configuration were handled by Ahsan Sharif (MaxobizTex).

Mars Fashion is a premier textile manufacturer specializing in high-quality yarns, innovative fabrics, premium garments, and durable workwear. With 15+ years of industry expertise, we blend traditional craftsmanship with cutting-edge technology.

Sales Tax Reg No: 03-00-2946-548-17

NTN No: 2946548-6

Mars Fashion © All Rights Reserved.

Useful Link

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Divisions

Yarns Fabric Garments Workwear

Contact Us

218-C Said Pur Multan Road, Lahore 042-37497717 biz@marsfashion.co
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