This copping with changes require solutions to effectively plan, execute and manage all the associated operations.
caniasERP ’s advanced parameterization and flexibility ensures efficient undertaking of all the planning, pricing, accounting, contract manufacturing monitoring and product monitoring functions in the garment manufacturing industry irrespective of whether the material is in-house manufactured, or directly purchased, or is manufactured on sub contract basis.
Garment manufacturing process could be initiated with raw thread purchases which could be used for producing fabric and subsequently producing garment using these fabrics. Alternatively fabric could be directly purchased and could undergo weaving or knitting operations to produce garments. The above scenario varies depending on the type and quality of the product to be produced. Therefore it is impossible to distinguish fabric manufacturing from garment manufacturing.
Supply of fabrics to the firms engaged in ready garment manufacturing is undertaken in 3 ways.
- Direct purchase,
- Contract manufacturing
- Internal manufacture
Those firms which do not possess fabric manufacturing facilities would source fabric either through direct purchase or by way of contract manufacturing, whereas those with fabric manufacturing facilities can either internally manufacture or procure through direct purchases or by way of contract manufacturing. These decisions are arrived mainly based on the capacity availability, the type of products to be manufactured and the ability of the machines to do the manufacturing.
Ready garment manufacturers having fabric manufacturing facilities keep raw threads and fabrics in their stocks. Required planning for these materials including maintaining of safety stock, minimum purchasing or minimum production levels etc. could be efficiently managed with the caniasERP MRP (Material Requirements Planning) module.
The core processes to be pursued in caniasERP with in the Ready Garment Industry are as follows:
- SAL - Offer, Order, Dispatch List and Invoice Management
- PUR - Purchasing
- WMS - Inventory and Warehouse Management
- PRD - Production and Planning
- CAP - Finite Capacity Planning
- DOC - Document Management
- EDI - Advanced Reporting
- BUD- Budget
- COS - Cost Analysis (Budget-Offer-Actual Comparison)
- HCM - Human Resources
Apart from the above core functions, the following industry specific adaptations helps to efficiently manage the production operations of this industry.
Material lot traceability and single lot production
Lot tracing is effectively used in this industry and this lot traceability is initiated from the purchase of raw threads and is extended to the corresponding fabrics which are been produced. Having the ability to identify the lot number of the threads been used in the fabric manufacture is extremely useful especially in cases where retrospective analysis needs to be undertaken after the production and delivery is undergone. Moreover, it is essential to produce the entire customer order quantity from one lot of fabric as this will avoid fabric color differences. Thus, lot traceability and single lot production are mandatory requirements for garment manufacturing industry and caniasERP “Single Lot Management” function provides great deal of convenience for this industry. Separate management tools can also be opted based on the material type.
Apart from the traceability and control aspects mentioned above, the following online production order management and customer order monitoring provisions utilizing hand held terminals and touch screen devices are been provided in canias ERP. In operations where manual labour is required, hand terminals could be deployed instead of online production management touch screens.
- Online monitoring of the production site
- Operational monitoring of customer orders and instantaneous response to the customer
- Performance monitoring (for labor) and machinery use ratios
- Efficiency analysis
- Measurement of standard operations time
- Efficient data collection for actual or estimated costs
- Online stock monitoring (product receipts and raw material consumptions along with production operation confirmations)
Use of Efficient Variant Configurator
caniasERP variant configurator helps companies in efficiently managing the multiple attributes of both finished garment and fabric and also maintains variant wise stock of fabrics. The advantage of variant functionality is that it enables users to manage both fabrics and garments with minimum stock codes, minimum product tree structure and minimum routing definitions (operational data). Though it is subject to change based on the actual requirements of companies, the generally identified variants for fabrics are width, weight in grams, irreversibility, color, pattern etc. Similarly color, size, quality etc. are the most prominent variants for ready garments.
With the use of variants, system is able to identify the fabric consumption (could be color wise if the color variant is chosen) and the required operations depending on the variant selection of the fabric. Here, consumption quantity and the routing operation to be performed are the variables which are dependent on the selected variants of the product. caniasERP variant configurator also ensures that the red thread and red dye could only be issued for consumption in red fabric production.
Customer order entries and production confirmation can be swiftly entered into the system in the form of matrix tables consisting of variant options. Online production management and online production order monitoring is also ensured in order to gain control, visibility and monitoring of production operations.
Variant feature of caniasERP also enables to produce various reports showing fabric used and the qualities, color and sizes of garments been produced etc.
Customer specific stock management based on orders placed
Customer specific stock management is very essential for this industry and all the stock item is managed in association with customer order number in order to ensure it is reserved against the same customer. Fabrics and accessories received in stock are entered into the system against their respective lot numbers provided by the supplier. Predefined rules which could be established in caniasERP ensure that such stocks material can only be used against the production of relevant customer orders. Thus on-line stock movements could be effectively involving one of the 3 following type of stock materials.
Raw material stocks which are not reserved for any customer. These are kept in the stock along with their supplier lot numbers. If lot numbers are not provided by supplier, they are assigned with lot numbers by the system when their receipts are performed thereby ensuring retrospective traceability.
Raw material stocks which are reserved for customers and are kept for consumption.
Ready garment products which are in stock pending delivery.
Reduction in byproducts and idle time through efficient Capacity Planning;
One of the commonly experienced constraints in the garment manufacturing industry is the band balancing and this is primarily due to lack of sufficient data which could be used in band balancing. In caniasERP, standard operation time can be determined through online production order confirmations and these can be used as data in band balancing. Decisions pertaining to band balancing are performed by caniasERP Capacity Planning Module.
In the process of executing garment production operations, the routing operations and the sequential order of these operations could vary a great deal. In such scenarios it is very essential to control the by- products and the idle time which could happen between the production operations. In order to accomplish such controls, the operations identified in the routes or the work centers could be revised based on capacity availability prior to the initiation of a production order. These revisions could include adding a new operation, or further splitting a current operation (internal production in parts + contract manufacturing, contract manufacturing + contract manufacturing + n etc.). Thus all operations revisions could be easily managed through production order revision functionality with caniasERP.
The most ideal plans could be established by caniasERP ’s capacity planning and advanced scheduling functions (machine or workers), taking into account the capacity constraints and other parameters such as looms or groups of looms, boilers, principles of priority, dynamic stocks etc. Moreover, such plans can also be revised whenever necessary and all revisions such as inserting operations in between, holding of operations, prioritizing of operations etc. can be graphically managed through a GANNT chart.
Planning to tackle deficiencies
Depending on the minimum deficiencies rule in case of household textiles, decisions pertaining to inclination in width and inclination in size could be determined by caniasERP MRP module and thus the fabric deficiencies during the cutting operation can be reduced to the maximum. In case of readymade garments, deficiencies should be entered into the system particularly along with the cutting operation and their stock records should be kept even if such records reflect only approximate figures. If the deficiencies in the product are pertaining to pipe cutting and stitching operations, then they can be utilized in that operation. Thus appropriate deficiency rates could be achieved. The sales involving deficiencies can also be managed directly through the system.
Operational quality control at every stage
As in the case of fabric, quality management is one of the important requirements for readymade garments. Quality control applications in caniasERP are conducted in the following two main areas.
The quality control processes are conducted in accordance with the established criteria in goods receipt and production operation arenas. The criteria and sample plans set by purchasing and manufacturing operations are made applicable in their respective areas and based on the quality checks, decisions regarding returns, re-works etc. are established.
Estimated and realized production cost monitoring
- Production costing is one among the most prominent end results expected from ERP systems and production costing has two varied dimensions in caniasERP.
- Standard cost (preliminary cost analysis prior to production)
- Actual cost (actual realized cost after production)
- In standard cost, the approximate cost prior to the execution of production is estimated based on product tree structure and production operations unit activity costs. Standard Cost is mostly used during the price offer preparation stage.
- On the other hand, actual cost is the realized cost established through real material consumption and other overheads.
- Comparison between standard cost and actual cost is reported by caniasERP by the end of
- Comparison between standard cost and actual cost can be produced from caniasERP, and the possible deviations can be identified. This constitutes a significant data source aiding the decision making pertaining to whether the products have to be produced in-house or procured from contract manufacturing sources.
Efficient means to undertake monitoring and control of contract manufacturing
Due to the intensity of contract manufacturing in the garments industry, monitoring and control of contract manufacturing is of prime importance. Contract manufacturing operations can be gathered under two headings. These are;
- Utilizing of contract manufacturing services (Purchase)
- Undertaking of contract manufacturing services (Sales)
Materials such as raw fabric, dyed fabric and accessories are in the lower most level of product tree hierarchy and therefore actual stock monitoring could be made possible by maintaining separate material codes, stock cards etc. However, creation of separate material records on the system for each intermediate level formed during the production process is not regarded as an advisable practice. Contract manufacturing management functions in caniasERP efficiently addresses this requirement without having to initiate stock codes for each intermediate level. Moreover, it is possible to monitor how many quantities of which type of materials each subcontractor is supplying against each customer order. Besides, subcontracting costs can be evaluated in more detail by correlating the subcontractor service invoices against their relevant customer sales orders.
In case of undertaking of contract manufacturing services (Sales), most of the operational processes can be effectively monitored by utilizing the standard sales, production, purchasing and stock functionalities in caniasERP. Unlike normal production, some of the product tree materials could be received from the customer free of cost and they have to be included in the production process as free of cost material only monitoring their quantities.
Detailed Sample Monitoring and Control
Sample production operations can be considered as a small replica of the normal production functionalities. While samples might turn out to be just models to be added to the firm’s collection, more often they could also be the basis for the orders received from customers. One of the important aspects to be controlled in sample production process is the version control functionality. A single model may have more than one version and it is imperative to control and report on these version differences.
The material main records in caniasERP also consist of different material files rather than only handling elementary details pertaining to material management such as unit, price, warehouse etc. These file, within each material main record contain the following details that will provide all additional information pertaining to its samples management.
- Sample versions
- Graphic designer
- Sample product receipt and route
- Variants to be used (color, size, etc.)
In addition to the above, all internal details pertaining to the sample such as cutting artist, sewing artist etc. could be maintained. Because of the enhanced reports and analysis tools made available in caniasERP, it is also possible to conduct evaluation of sample department employee’s performance.