TEXTREME’10

A Paper Presentation

On

“ERP IN TEXTILE INDUSTRY”

Presented By:-

A.R.NAGARAJ TEXTILE CHEMISTRY

SSM COLLEGE OF ENGINEERING,

KOMARAPALAYAM.

ABSTRACT

The textile industry is basically concerned

with the design or manufacture of clothing

as well as the distribution and use of textiles.

The textile industries have been changed

extremely in the last few years. Role of ERP

is very important in textile industries. ERP

stand for Enterprise Resource Planning

(business software). ERP is Software for

running a business; we can customize our

Enterprise Resource Planning software

according to our use. ERP for Textile

Industry has very important role. Enterprise

Resource Planning software was struck as

an extension of the concept of MRP

(manufacturing resource planning) software

and this erp software automated the process

of holding a manufacturing line supplied

with materials to meet incoming all

orders.ERP software is basically for the

following applications: Manufacturing,

financials, human resources (hr) and some

other modules. ERP software is the latest

high-end solution information technology

has lent to business application. Textile

Enterprise Management software for

organizing data and making internal

procedures more reliable.ERP refers to the

integration and extension of a business's

operational Information Technology

systems, with the end goals of making

information flow within a company more

immediate and dynamic. Now these days so

many companies in India have gone in for

implementation of ERP software.

INTRODUCTIONWhat is ERP?ERP ( Enterprise Resource Planning) is an

integrated system that allows information to

enter at a single point in the process (e.g. at

the material receiving process in

manufacturing of

apparels) and updates a single shared

database for all functions that directly or

indirectly depend on this information.This

integration should take place in real-time,

not through interfaces or programmes that

transfer information to one or more

modules, after it has already been processed

and updated in the module through which it

entered the system. Once placed into the

system, the information should be available

in all necessary forms thorough which it

may be accessed, throughout the system.

ERP could also be defined as an integrated

suit of application software modules,

providing operational, managerial and

strategic information for an enterprise in

order to improve productivity, quality and

competitiveness.ERP (Enterprise Resource

Planning) is the evolution of Manufacturing

Requirements Planning (MRP) II. From

business perspective, ERP has expanded

from coordination

of manufacturing processes to the

integration of enterprise-wide backend

processes. From technological aspect, ERP

has evolved from legacy implementation to

more flexible tiered clientserver

architecture.

NEED OF ERP IN INDUSTRY:

ERP covers the techniques and concepts

employed for the integrated management of

business as a whole with objectives of

effective use of management resources to

improve the efficiency of the organization.

This system designed to model and

automatic many of the basic process of the

company from the finance to the shop floor

with a goal of integrating information across

the company and eliminating complex

expensive links between computer systems.

It produces the

dramatic improvements when used to

connect parts of an organization and

integrate its various processes. Thus, it gives

a better products and better services at

affordable prices.

ERP Modules:

All ERP packages contain many modules.

The number and features of the modules

vary with the ERP packages. Here we will

see some of the most common modules

available in almost all packages.

Finance.

Manufacturing and Production

Planning.

Sales and Distribution.

Plant Maintenance.

Quality Management.

Materials Management, etc.

ENTERPRISE RESOURCE PLANNING FOR TEXTILES (ERP):

For maintaining higher efficiency and

productivity along with the quality of end

product, it would be necessary to think of a

solution which will help the industry right from

the purchase of raw material to the sell its final

product. Any such solution is known as ERP

solution. At present, many ERP solutions are

available in the market. Basically any ERP

solution should provide effective monitoring

and control, accurate planning and scheduling of

orders, better data predictions, quick response to

query and on-line detailed information of

orders.

Thus as seen from above figure, it is very

clear that any ERP solution should include

the manufacturing, marketing as well as

finance sectors of a Textile Industry. To

design such a module based system, one

requires to know certain parameters, which

are necessary for giving the necessary

outputs.

FABRIC MODULE:

This module should take care of various

operations of the weaving shed i.e. from the

yarn entering into the weaving department,

the preparation of the yarn for weaving, till

the actual manufacturing of the fabric. Also

various specifications of the fabric

manufactured, identification of the lot, etc.

has to be monitored and Recorded. This

module also like earlier ones should include

production, commercial as well as quality

details.

Production details may include

productions at Winding, Sizing,

Loom, and finishing stages.

Technical specification and quality

may include various specifications

such as Fabric specification,

Yarn count for warp and weft, Reed

count, Ends and picks per inch,

Process specification at winding,

Pre-beaming specification,

Size beam specification.

Process details and quality may

include various parameter like

Control of weight (spools & cops),

Number of knots, Sizing takeup,

fabric width, Ends and picks, Fabric

faults.

The steps in designing these

kinds of module are given as

below:

The system structure may be defined

through charts and values in over 100 tables.

Various master files for Articles, Customers,

Suppliers, Warehouse, Calendars, etc.

Should be created and maintained.The step

is to input incoming orders, check the

feasibility of requested dates for delivery,

suggest possible delivery dates. To manage

the entire order cycle from acceptance and

entry to packing list, shipping and invoicing.

To manage the pricelists and invoicing

directly from job lots. To allow orders to be

accepted via the Internet, on-line order

tracking booking of stocks and on-line

catalogue publishing. Article coding system

should be followed. Article types are

defined which are indications of the build up

of the end product. The code structure of

each article type may be named and defined

as per the software developer or the user and

the parameters required. For example, a

particular code name can be specific weave

of fabric or type of yarn.

Thus material into a material into a

production and materials out of production

can be distinguished. Also different sets of

technical data can be established for each

article type. Different units of measure can

be applied to different article type. Woven

cloth can have special weave technology

data attached to it, such as the warp plan and

filling plan details. Analysis of Production,

Sales and stocks can be conveniently

separated using article codes.

The next important step is planning i.e.

working from the given budget and

production plan, calculating material and

capacity requirements necessary for the

completion of the specified process.

Launching production orders and identifying

divergence of orders being processed from

planned production schedules.

Automatically assigning tasks to the most

suitable production facilities on-line with a

finite capacity.

Next is checking of the product

manufactured i.e. to allow planning,

launching and tracking of production

activities across the whole cycle. To handle

fault reporting and mapping, optimising

cutting of pieces at each inspection table,

recording and quality and rectification

details for each piece. Inventory &

purchasing is a very important task, which

should be taken care off.i.e. Managing and

evaluating raw materials and finished

products in terms of inventory levels,

Requisition and allocations.

Defining purchasing and stock policies by

specifying minimum inventory levels

reorder quantities and replenishment times.

Handling purchasing upto the issuing of the

order and checking of purchase invoices.

Mapping of physical warehouse locations

and indicates the most suitable for incoming

goods.

The major benefits of any such systems may

be summarized as below:

Aid in optimal use of manufacturing

resources

Monitoring of contribution margins.

Quick response

Improved customer service

Higher quality and less waste.

Reduction of work in progress and

inventory.

MARKETING WING:

This module deals with the Store section

and requires various parameters such as the

stock, MRP, etc.

FINANCE WING:

As the name suggests, it deals with H.R.

Cell and includes various parameters such as

Database on HR, Performance Rating, HR

Allocation, Selection & Recruitment,

Training to all and also Absenteeism.

QUALITY ASSURANCE WING:

In this module, SQC, IE Cell is included.

The various parameters are Databank,

Control Charts, Sampling Plan, Cost, Waste

Realization, and Maintenance Schedule.

The following figure shows one of such

integrated systems in textiles:

 

Evolution Of ERP

ERP (Enterprise Resource Planning) is the

evolution of Manufacturing Requirements

Planning (MRP) II. From business

perspective, ERP has expanded from

coordination of manufacturing processes to

the integration of enterprise-wide backend

processes. From technological aspect, ERP

has evolved from legacy implementation to

more flexible tiered client-server

architecture

The Evolution of ERP from 1960s To 1990s

Timeline - 1960s

System - Inventory Management & Control

Description-Inventory Management and

control is the combination of information

technology and business processes of

maintaining the appropriate level of stock in

a warehouse. The activities of inventory

management include identifying inventory

requirements, setting targets, providing

replenishment techniques and options,

monitoring item usages, reconciling the

inventory balances, and reporting inventory

status.

Timeline - 1970s

System - Material Requirement Planning

(MRP)

Description-Materials Requirement

Planning (MRP) utilizes software

applications for scheduling production

processes. MRP generates schedules for the

operations and raw material purchases based

on the production requirements of finished

goods, the structure of the production

system

Timeline -1980s

System - Manufacturing Requirements

Planning (MRP II)

Description- Manufacturing Requirements

Planning or MRP utilizes software

applications for Planning or MRP utilizes

software applications for coordinating

manufacturing processes, from product

planning, parts purchasing, inventory

control to product distribution.

Timeline –2000s

System - . Enterprise Resource Planning

(ERP)

Description-Enterprise Resource Planning or

ERP uses multi-module application software

for improving the performance of the

internal business processes. ERP systems

often integrates business activities across

functional departments, from product

planning, parts purchasing, inventory

control, product distribution, fulfillment, to

order tracking. ERP software systems may

include application modules for supporting

marketing, finance, accounting and human

resource.

ERP Software used in Textile

Industries

1. Datatex Software

2. AREL Software

3. Abas Business Software

1. Datatex Software

Datatex has been designing, developing, and

implementing solutions exclusively for the

textile and apparel industry since 1987.

Dedication is the key to the Datatex

development strategy. Specialization is the

foundation of service to its customers.

Datatexs technological know-how and

application skills have resulted in the

worldwide success of TIM Textile

Integrated Manufacturing - an ERP

(Enterprise Resource Planning) solution

designed for textile manufacturers of all

sizes, whether vertically integrated, or

specializing in just one stage of the

manufacturing chain. Datatex is an

international company with offices in Italy,

Israel, the USA, Germany, and Switzerland.

The Datatex structure has been designed to

cater to:

The customers needs

The customers practices and

procedures

The customers competencies.

Datatex:

Has the expertise required presenting

a detailed and realistic offering to

the textile and appareling industry.

Has the product and skills to

implement the required functions

of our solution while respecting

the cost and time budgets (On

time and within budget).

Guarantee its customers that TIM

will be supported for years to

come.

Figure 1.2 TIM - Textile Integrated

Manufacturing

TIM is an integrated solution; therefore the

enterprise information is available to

everyone, not just to the few. Data is

entered once and to be used across all

company functions. A TIM implementation

can cover all the manufacturing and

logistical requirements, or only some of

them. The TIM functions will be

highlighted with reference to the following

application areas: Sales, Planning,

Inventory and Purchasing,

Manufacturing, Costing and company

Database.

 MTO / Make-To-Order Highlights

Capacity and/or materials feasibility

checking

Multi-level product views

Suggested dates or availability if

original request is not feasible

The ability to consider forecasted

orders from the master Gantt chart

without having to create firm

production orders

Manual overrides of blocking as

required

Scheduling and allocating of scarce (critical)

resources.

Fabric Inspection and Cut

Optimization System

CATS (Computer Aided Textile

Supervision) is a PC based module that

integrates the production and inventory

systems with greige and finished inspection.

It provides methods to identify, map, and

place inspected fabric defects either directly

into the TIM database, or into an integrated

PC network, so as to both archive the data,

and to make it immediately available for use

in allocation and production confirmation.

CATS utilize an encoder to measure the

cloth and a PC screen at each inspection

table.

Business Intelligence and Analysis:

BOARD-Management Intelligence is a

unique and outstanding business intelligence

product in the market place, with innovative

design and advanced technology. Through

standard interfaces data is extracted from

TIM and is made available in a BOARD

database, where navigating through the data,

generating reports and graphs, and building

simulation models is the simple matter of a

few clicks of the mouse.

2. AREL Software

AREL is a leading solution provider with

specialized expertise in textile

manufacturing worldwide & across-industry

logistics & distribution solutions. We

provide both hardware and software based

solutions for manufacturing and distribution.

In addition to this our consulting team has

years of experience in helping our customers

to improve and gain a competitive edge.

Arel Control is a leader in Automatisation

Solutions for the Textile Wet Processing

Industry, which includes:

Batch Dyeing Controllers

Continuous Process Controllers

Dispensing Systems & Solutions

Supervision Process Management

Systems

1. Dye House Control Center

AREL offers complete line of software

modules for dye house control center; from

basic central monitoring and dye program

editing, to a comprehensive system that

combines all the operations of the dye

house. The central control hardware is based

on a single PC or a PC network. The

communication with the machine controllers

is carried via dual ported R.A.M micro

processor-based, communication board, that

ensures fast and reliable communication, or

through Ethernet network. The number of

connected controllers is practically

unlimited.

Standard Software Modules

Control Room" Basic module,

including dye programs

management and reporting.

Dye Lots Creation and Maintenance

On-line Production Scheduling

Look Ahead, showing expected

MANUAL interventions.

Recipe Management

All Costing Analysis (Energy, Dyes

and Chemicals, Operation).

Guided Weighing Stations

Integration with Liquids and

Powders Dispensers

Smart Dye Program/Recipe

Optimization

Smart Scheduling Optimization

The AREL Control Center fully supports

integration with other systems. Beside the

built In connectivity to leading dye-house

peripherals like powder dispensing, color

matching or E.R.P systems, any other

system can easily integrate with the AREL

system, using data base link methods.

Integration with AREL Liquids Dispenser is

immediate, since the dispenser's controller is

the same controller, which controls the

dyeing, machines.

2. Dispensing for Batch Dyeing

O.T.D. - On Time Volumetric Dispenser

  AREL Volumetric On Time Dispenser is a

high precision, high capacity dosing system

for liquid products. The dispenser measures

programmed quantities of the liquid and

forward it to a selected destination.   

 

The system combines a high capacity

variable speed-dosing pump and high

precision flow measuring device, controlled

by a PC based industrial controller. The

delivery valves are installed on a common

battery.  Carefully sized distribution

pipeline, with air actuated three way valves,

is normally used to connect the dispenser to

the destinations, ensuring an efficient and

very simple layout. Very small quantities of

water are required to flush the line. A unique

algorithm controls the variable speed dosing

pump, enabling high capacity and high

accuracy/resolution, for large, as well as, for

small dispensing quantities

Two Operation Modes are available:

1. Operator Menu-Driven Mode:

The operator keys the requested chemical or

recipe and the destination. When the start

key is pressed, a dispense cycle starts. When

completed, the controller will prompt the

operator to key in the next dispense.

2. Supervisory PC Computer Integrated

Mode:

The dispenser is part of the integrated dye

house control. Based on the preparation step

in the currently processed batch, the central

computer sends the required chemicals and

quantities to the dispenser controller. The

central computer maintains a queue of the

dispenses required by the machines at any

given time. When the dispenser controller

confirms that dispense to a specific machine

is completed, the next required dispense will

be sent from the central computer.

Figure 1.6 O.T.D. Main Components

3. Abas Business Software

The brand name abas Business Software

include the products abas ERP, abas Trade

and abas eB. Thus, a complete solution,

which provides a broad spectrum of

functions, is available to medium-sized

industrial, trade and service companies:

from purchasing and sales through to

materials management, production planning

and production through to accounting and

eBusiness.

BENEFITS OF ERP IN TEXTILE

INDUSTRY

Help reduce operating costs

• Facilitate Day-to-Day Management

• Support Strategic Planning

• Integration among different functional

areas to ensure proper communication,

productivity and

efficiency

• Design engineering (how to best make the

product)

• Order tracking, from acceptance through

fulfillment

• The revenue cycle, from invoice through

cash receipt

• Managing inter-dependencies of complex

processes bill of materials

• Tracking the three-way match between

purchase orders (what was ordered),

inventory receipts

(what arrived), and costing (what the vendor

invoiced)

• The accounting for all of these tasks:

tracking the revenue, cost and profit at a

granular level.

Conclusion:

Textile Companies are looking for ERP

solutions to fit their specific needs. Both

generic and textile specific packages have to

be utilized in the industry. The barriers to

implementation in textile seem similar to

those in the industries. Electronic commerce

in the form of traditional EDI, but no

electronic marketplaces, which have lot of

changes, is used by the textile industry.

Textile companies are looking to integrate

their ERP systems with supply chain

management and business intelligence

systems. The latest ERP software programs

have overcome this menace. They offer

need-based applications. The firms need not

be worried even if these Software Programs

were not available. They were given the

liberty to purchase and install Software

Programs pertaining to that particular

function. This advantage has helped to

increase the scope of ERP not only among

large firms but also small and medium

business as well. The world class

competition, modern business environment

and the availability of the Internet are the

premises which stress the need for ERP. The

evolution of ERP is presented briefly

starting with Pay roll and Bill of Materials

in the 1960s to Web enabled ERP in the

2000s. The salient features of ERP II which

makes it different from ERP are presented in

addition to presenting some of the disruptive

technologies which help reengineer ERP

systems fast. The results of an international

survey pertaining to the embedding of

intelligence in the modern day ERP are also

presented.

REFERENCES:-

Enterprise Resource Planning by

ALEXIS LEON published by TATA

McGraw HILL, 1999 Edition

E.R.P by PARAGDIWAN and

SUNILSHARMA published by

PENTAGON PRESS, 2000 Edition

E.R.P A Managerial Perspective by

SADAGOPAN published by TATA

McGraw HILL, 1999 Edition

www.erpinform.com

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