Organizations engaged in the manufacturing of textiles face daunting challenges to address the diversities of this industry. There could be hundreds and thousands of variables in terms of size, color, patterns, design etc. which is requested by customers and these variables will have impact on cost, processes etc. and therefore would need to be efficiently managed, monitored and traced.
CANIAS ERP has proven that successful results could be accomplished even in such industry’s wherein intensive data gets accumulated and traceability of this data assumes greater significance. Efficiently managing the diversity of data in industry’s involving weaving (such as fabrics, carpets, towels etc.), and managing them through user friendly screens without compromising the overall efficiency requires a balanced combination of adeptness and flexibility in the system which is catered to in CANIAS ERP.
One of the challenges facing such organizations is that the exact design specifications might not be available at the initial sales offer stage and it wouldn’t be possible to define the exact material code with all the design attributes correctly mentioned. In most productions involving weaving operations, this difficulty leads to the delayed capturing of orders into the system, making it impossible to follow up and trace these orders through the system right from the beginning. With CANIAS ERP, such problems can be overcome through code request applications and variant structures which are fully integrated and the ensuing results could be communicated via e mails or text messages.
Companies that produce their own threads for weaving purpose should ensure that the thread production process is complimenting the weaving production process and both these production processes are been undertaken efficiently and promptly. It requires facilitating tight coordination between these two production streams especially in the stock management arena and the MRP infrastructure should function consistently in consideration of both these production streams. This brings about significant level of performance enhancement in the production arena as it offers true visibility on the current loom status and provides flexibility in decision making regarding capacity planning and determination of further operational needs in the work floor. Prompt delivery and loom management ensuring minimum installation time losses etc. are further gains which could be accomplished in CANIAS ERP by means of enhanced coordination between thread production and weaving production processes.
Main processes to be pursued in CANIAS ERP within the Textiles Industry are as follows:
Apart from the above processes, the following extremely useful adaptations form part of the system for efficiently managing textile industry operations.
Use of Variants:
Textile industry with lot of variety in attributes such as design, color, size etc. requires efficient means for managing these in the system. For instance a fabric having the same quality and pattern may have different finishes and colors. Creating separate material codes for each and every attribute will significantly slow down the order entries and the management of material codes becomes very difficult. CANIAS ERP caters to managing this multiple attributes requirement with its variant configuration utility, were in any number of attributes and its corresponding values could be attached to one material code and managed as distinct materials throughout the system. Thus the variant concept is inevitable for simplifying the order entries for sales staff and also facilitates to capture adequate information because of its ability to increase the variant options and its values. The same applies to branches such as carpets, towel etc. were in the same quality of materials could have hundreds of patterns, designs, color palettes and sizes. Another important aspect of the variant functionality in CANIAS is its ability to integrate with applications which are used specifically for creating patterns or designs.
Auto creation of product trees based on selection of variant options
Maintaining and managing the diversity in textile industry requires specific functions and processes to be adopted in the system. It is essential to ensure that the system utilizes all the attribute details been entered to the system during the core design process and it also should be ensured that only the defined design details are adopted by the system. To illustrate this point, for some material there could be certain variant options which could result in automatic formation of product trees and subsidiary material codes. CANIAS could not only manage this but in case if more than one option within the same variant is determining the structure of product tree, system could create the product tree by way of algorithms derived through the combination of these two variant options.
Production operations grouping ensuring production flexibility
CANIAS ERP manages the efficient undertaking of production orders by its facility to group the production orders as against the traditional concept of combined production orders. For combined production order concept, it is necessary to know in advance which operations will be combined when a production order is entered. However in industry’s like textiles where deadlines and monitoring are of great importance, it is necessary to relate operations with one another and thereby it is more appropriate to group them rather than combining them. In CANIAS, required options are been provided to opt for grouping some of the operations or all the operations within production orders. Production operations grouping also ensure that accurate information flow is maintained for vital aspects including actual cost by facilitating timely cost distribution in accordance with the determined factors.
Efficiency in order entries and authorizations
The abundance of diversity in this industry leads to customer orders running to several hundreds of products at the same time. This diverse nature of the orders and the fact that some of the products requested could be totally new could lead to slowing down of the order entries. However, with CANIAS special adaptations for this industry such as code request applications and fast order entry screens, the performance of employees entering sales orders could be substantially enhanced. It is also facilitated to automatically communicate the planning deadlines from the entered orders via e-mails and the necessary authorizations can be granted by clicking on the links in e-mails received in mobile devices while even on the move.
Flexible allocation and reservation functions
CANIAS provides convenient transactions for allocating a raw material or semi-finished product available in stock against production order and thereby making it exclusively available for that particular production order only. It is also possible to reserve a production operation against another uninitiated production order or an ongoing semi-finished product operation. These functions lead to better coordination of operations and prevent complications in the stock management and ensure successful results for the MRP functions.
Adaptation ensuring ease of use
System provides simple and easy to use authorization screens which enable the employees to perform their tasks efficiently and effectively. Transactions such as delivery issuance and packing list can be quickly performed by scanning barcodes with hand held terminals. It also provides quick information screens for ease of information retrieval. Such adaptations which are vital for user convenience and easiness plays significant role while transforming ERP systems into live operation.
Tackling deficiencies by more effective planning
Deficiencies in meeting the planned production volumes leads to delay in executing orders and thereby could incur considerable cost for all concerned parties. In CANIAS, production deficiencies could be minimized to the maximum possible extent due to more realistic production planning utilizing the previous available data. Thus, the previous available data is used for the calculation of mixture quantities required for thread productions or the quantities of threads required for carpet productions etc. This ensures that production shortages could be minimized and delays in deadlines could be avoided.
Batch monitoring capabilities ensuring forward and backward traceability
System allows batch monitoring at every stage right from order entry leading to its production and also the purchases made with respect to these orders. Thus corresponding relations are established between business operations executed in sequence either in the forward or backward direction. For instance of fiber purchased and goods been delivered to warehouse, it could be possible to track such information as, which is the purchase order issued for this purchase, from which purchase request document this purchase order was initiated, from which production order this purchase request document was initiated, on which weave the threads coming from this production operation will be used and ultimately to which sales order this textile been produced belong to. The same is the case for reverse tracking the above-mentioned transactions from sales order to its corresponding purchase orders. In case a fault is identified with certain batch of goods been sent to the customer, it could be analyzed from which dispatch document that batch was issued and the corresponding raw materials in the production of that batch of product could be traced. This also facilitates the identification of all ongoing operations were the same batch of raw material is in use and it could be replaced. Also, products which have been produced using the same batch of raw materials but not yet been delivered to customers could be identified and reproduced.
Authorization mechanism ensuring better controls
All documents produced in the system could be integrated with the authorization mechanism of the system. Users can view how many documents are pending for authorization, and they can either authorize or reject them by viewing their details on the screen. Moreover, an email could be send to users for authorization and the concerned person could either authorize or reject it by clicking on the e-mail link using their mobile device. User could mention additional remarks upon refusing the authorization and this is reverted back to those users who granted the authorization earlier and ultimately to the user who created the authorization request. Options are also provided for appointing substitutes for authorization, creation of separate authorization routes and departmental authorizations abased on quantity or value limits.