ERP system for textile industries
With large operations and multiple departments, companies require an enterprise resource planning software to manage all resources and communicate systematically. You can have all the updated information about orders, stocks, clients at one glance instead of managing multiple sheets and documents.
Problem statement of client
Their textile manufacturing plant has more than 50 machines working with over 5000 threads of varied colours and materials. This huge mix of raw materials and orders became difficult to handle with increasing demand as there was no proper method for accountability. They could not use any normal off the shelf stock management software because of the variants associated with a textile industry.
They needed a custom ERP system that would improve their manufacturing process efficiency, manage data and stock centrally and organise the entire end-to-end operations. Our ERP developers used the below 3 step methodology to achieve their goals:
Our team visits their manufacturing plant to understand the entire workflow, raw materials and finished goods. This helped to understand the complexity of the project and think of ideas and solutions accordingly.
After understanding how all the departments and intra-departments function, our enterprise application development team were able to fixate on and create mock-ups of a few design layouts.
Development and Launch
A custom ERP system was designed and built which incorporated excellent features particularly needed in the textile industry. This software could be used for multiple functions including thread management, stock management, client database management, and sales management.
This resource planning system was developed after detailed study on the client’s requirements to improvise their manufacturing efficiency and reduce manual work. Here is a glimpse of the solutions we provided through this custom ERP solution:
A. Thread management system
Manufacturing a fabric involves tons of logic and calculations as how much thread or what kind of thread will be used. We integrated thread management with our ERP solution. This means that the designers can save a thread recipe, alter it or use it multiple times hassle free. Designers can also add photos for each fabric design for easier management.
B. Stock management system
From a single dashboard on the ERP system, users can check how much quantity of thread will be used per order, or how many resources are available to make one order. Everything related to stock is automatically calculated. It allows you to directly generate a purchase order if you see raw material is not in stock for a particular sales order. Moreover, they could now take orders instantly without having to make the customers wait till they manually checked if they had the stock to make an order. With all the data available at one place, they can analyse their demand and supply and take or place orders immediately. This analysis of stocks helped them track their most used materials, threads, designs etc., so they could calculate which threads to buy first and plan their purchase and sales in advance.
C. Orders and Accounts management system
Once the designers enter their design and thread recipe as per the sales order, a manufacturing order invoice is generated automatically which calculates the metres needed, it has the code, colour, width and all the details of the thread, so that the manufacturing floor workers know what to use and there is zero error.
Similarly, an accounting receipt is simultaneously generated to be sent to the client. This ensures an end-to-end automated workflow enhancing their efficiency with reduced manual work.
D. Delivery management system
The ERP system also allows them to schedule delivery or partial delivery so that all the employees are aware of the deadlines and dispatch dates. We also added a feature for material wastage. Every time designers see material wastage, there will be an automatic pop up to schedule delivery if there are any clients for the waste material.
Apart from seamless workflow through the ERP solution, their team benefits a lot from the reporting feature. Numerous reports can be generated at all levels throughout the manufacturing process helping them track the number of orders received daily, weekly, monthly or yearly, recent top customers, most and least used threads, last used dates for threads and much more. These reports on customers and threads can help their marketing and business strategies enormously.
- They were able to improve their manufacturing efficiency by 30%.
- They can now identify dead inventory, plan to get rid of it sooner to get rotational cash flow.
- They are able to view all business operations from a single dashboard, foresee sales orders and make strategic decisions without investing extra time and efforts.
- There were zero errors in manufacturing due to elaborate reporting and easier thread recipe and design methods in the ERP system.