Main Benefits

• Precise and thorough control of all production processes to maximize volume and profits for each item - by department and by the whole enterprise
• Production tracking and exception reporting
• Reduction of production lead-times
• Quality improvement by better managing material usage and parameter settings for production
• Reduction of waste with accurate process standards and monitoring activities
• Accurate management of external processes, including in-transit shipping, sub contracted processes, and price lists for commissioned activities
  • Tracking the inventory
  • Tracking the external processing
  • Job costing
  • Invoicing
• Proactive communication between production and customer service so that potential delays and problems can be identified and corrected.

Routing and BOM (Bill of Material)

• Multiple types of BOM’s and routings are supported (per customer; with alternative materials and / or steps)
• BOM and routing for a specific production order / customer order
• Dynamic explosion of dye / print / finishing formulas based on production quantities

Production Entities

• Demand = customer orders, sales forecasts, sales projections, previously reserved work center capacity, and minimum inventory levels
• Bulk order = group or split of demands derived directly from customer orders or calculated automatically by MRP, containing one or more products
• Production demand = smallest entity to be tracked through production
• Production order = group of demands to be processed in one or more production steps
• Pre-created element = pallets, cartons, rolls... pre-defined to be entered from production demands or production orders

Capacity Balance

• Configurable to consider either infinite or finite capacity using a graphical tool to visualize or modify the calculated results
• Capacity analysis of demand plan based on a combination of: firm customer orders, sales forecasts, previously reserved work center capacity, and minimum inventory levels
• Bottleneck detection
• Dynamic calculation of required work center capacity per routing step, considering defined efficiencies, wastes, and standard batch sizes

Material Calculation

• Dynamic calculation of required materials per routing step, based on expected wastes (fixed and variable), for all upstream and downstream processes

Production Transactions

• Accurate tracks of all issues and receipts across all phases of production
• Support of inter-company transfers, to / from outside sub-contractors, with associated lead–times
• User-definable rules to allow / prohibit shipment of partial / over / remaining production order quantities
• Automatic back-flash management by production progress or end product stock entries. Quantity can be recalculated based on production quantity or as reserved

Dye-House Management

• Integrated module that guides the efficient scheduling of all dyeing, printing and finishing activities
• Calculation for both batch or continuous dyeing / printing / coating
• Support of dye / print / finishing formulas and recipes, allowing for dynamic adjustments
• Different items using the same recipe can be included in one dye lot
• Accurate definition of component usage by percentage of weight or by quantities per volume
• Ability to calculate based on bath volumes, liquor ratios, pickup percentages, residual volumes and standard losses
• Accurate tracks of actual dyeing and printing components consumptions
• Quality improvement with reports of variances for dye-house performance analysis and costing recalculations
• Direct connection to scales to manage and control weights

Shop-Floor Data Collection (CAMS) and Fabric Inspection & Optimization (CATS)

• CAMS: (Computer Aided Manufacturing System)
  
  • Records machine settings and monitors production ‘events’ in real-time
  • Meets regulatory reporting needs for many industries
  • Controls job progression status and job queues
  • Details productivity analysis and variance alerts

• CATS: (Computer Assisted Textile Supervisor)
  
  • Reporting and mapping of defects in fabric inspection activities
  • User-defined quality definitions / rules per customer and / or style
  • Cut optimization rules to maximize first quality rolls
  • Capability to tie inventory and production to fabric inspection activities

Production Progress, Tracking and Work in Process (WIP) Visibility

• Complete visibility across all areas of production, from issuing raw materials to putting away the finished product
• Support of both forward and backward scheduling, or a combination of both (priority to the ‘bottleneck’)
• Calculation of expected completion times based on order quantities, setup / change- over times, machine efficiency, average run lengths, waste, elongation / contraction, and reprocessing
• Negative availability analysis for each production step per defined period (day, week...)
• Work center load analysis
• Compatible with many popular monitoring and control systems (spinning, loom, knit, dye-house...)
• Fixed or rate-based outputs
• Operations: in parallel or in series
• Optional / mandatory shop-floor data collection
• User–defined technical data definable for each production step (standard operating procedures...)
• Multiple UM’s with automatic conversions
• Net, gross, or conditioned weights
• Partial step quantities can be progressed, allowing overlapping of operations
• Production steps can be stopped, taken off the machine, inventoried, and re-issued into production at a later time
• Allocation of completed job steps to next production step or to customer orders
• Supports internal, external, multi-item, multi-batch production
• Creation and handling of all required documentation: pick lists, piece tags, processing instructions...
• Exports to Excel for easy reporting
  

Quality Management

• The same product can be defined with multiple quality levels
• Inventory views are seen by these different quality levels
• Support of re-work to improve quality levels
• Configurable rules allow a ‘second’ quality measurement for one customer to be classified as ‘first quality’ for another customer

Waste Control

• Support of dynamic calculation of material issues based on expected wastes
• Accurate handling of fixed or variable wastes per production order
• Waste products to be re-processed
• Support of elongation / contraction and actual vs. expected wastes per production step

External Operations

• Visibility into outside sub-contractors with routing steps and warehouse transactions to / from
• Accurate calculation of surcharges and discounts, based on price lists
• Tracks of production by batch, piece, location...

Commission Work / Sub-Contracting for Others

• Management of price lists and invoicing directly from job lots
• Special inventory management rules for customer-owned materials
• Full price list capabilities based on processes, surcharges, and discounts
• Quantity price breaks and discounts
• Provisional and definitive invoices generated from production orders
• Printed reports and statistics