ERP for Knitting & Dyeing Industry

The textile business has specific business requirements of catering to seasonal demands, precise order completion dates, processing capacity management, and process variability due to several operating parameters (heat, moisture, material quality).

There is also a shift smart manufacturing where IT has led the automation of designs and exact process planning.

Whether you are into the knitting, knit dyeing , finishing or processing segment or all of it, Lighthouse ERP can help in running operations smoothly.

Lighthouse ERP for Knitting & Dyeing Industry is designed to handle complete needs in most efficient, effective & accurate way. Lighthouse ERP has continuously evolved since 1987 and Lighthouse is committed to provide a industry- specific ERP module, comprehensive and robust solution for the Textile Industry. Lighthouse technical expertise and mapping of key requirements is the key behind its success.

Efficient Supply Chain

Conversion of Bulk Raw Material consignment to rolls (thru bar coding).

Fabric procurement –Storing the Fabric Raw Material details: Weight, quality etc. at Plant Inward.

Issuing Rolls on Roll no., Batching of Rolls Inventory.

Capture Final Production with Roll No. & Box no. (Export Packing).

All inward and outward movement is tracked at Security Gate, Weighbridge, Quality lab and store/ yard locations

Plant movement: various scenarios including Inward, Outward, Stores Related, Purchase or Sales Return, Rake Inward, Inter-Yard Transfers, Waste or Scrap movement etc.

Traceability throughout the manufacturing process: Track lots by order, color/shade, labdip no.

Effective Production Planning & Control

Production planning: Monthly Production Schedule, Stage wise Bill of Material management  at each stage (Raw Material to Semi Finished; SM to Finished Goods )

Production Scheduling: Order wise planning having Machine, batch/date plan, Process Routing, and Supervisor allocation details.

Process wise production: Conversion of Bulk Raw Material consignment to rolls (thru bar coding).

Process wise production management: Greige fabric inspection; Batching; Fabric turning;  Pre-treatment (Scouring & Bleaching); Dyeing; Dewatering; Drying; Compacting; Final inspection ; Re-process Control by taking in-process material to reject stage, and then allocating to another batch/ order.

Time and Action Analysis: dashboard to keep track of all order wise start and end point of each stage.

Complete Financial Control

Manage Division wise & consolidated finance books Costing/ efficiency , Ledgers & Profitability. Inter division Sales & Purchase on a real-time basis.

Expenditure analysis for subcontracting, production etc.

Accounts approval and bill passing for Purchase, Services (jobwork/ contractors) or Freight scenarios.

Material costs, Overhead costs and Process wise costs; detailed product costing and variance analysis to control product costs.

Various Stock MIS with 10 level drill down: Group->Entity->Division->Plant->Dept->CostCenter->Equipment->Item Group->Item->Issue Slip.

Quality Control

Pre-Production: Capturing color %, composition of dye colors (raw material proportion for consumption)  Based on lab reading

Shade Checking during Dyeing production Process: linking bar code after each process.

Sophisticated and  accurate MIS on Production Costing / Plant Performance PLC & DCS  Integration with ERP.

Item Enquiry based on feasibility of items

Linking fabric, attributes as ISO standard parameters to items

Capturing fabric and color/ shade details in order

Linking of customer wise specific labdip details 

Product Catalogue Management

  Item Code Management.

Code Generation for Raw Material (R.M.), Semi-finished material (S.M.) and Finished Goods (F.G.).

Attributes linking to each item (fabric): Generation Item name and code based on attributes.

Auto Bill OF material generation: BOM of Input Material to produce item.

B.O.M. Variant: multiple count wise linking.

Export Management

Pre-shipment

Post-shipment

L.C. management

Sample Management

Approval by Client

Labdip sample details: shade wise no of options

Final labdip shade Approval and manufacturing clearance 

Re request of labdip color post clearance and manufacturing clearance

Production planning

Stage wise Bill of Material management

Raw material BOM for making S.M.

S.M. BOM for making F.G.

Production Order: In-house Vs Job-work management

Quality control

Capturing color %, composition of dye colors (raw material proportion for consumption)  Based on lab reading

Production Quality batch wise parameters to be attained after each process (thru bar code linking)

Production Scheduling

order wise planning:

Machine, batch/date plan, Process Routing, and Supervisor allocation 

Job card management

Creation of batches for rolls issue

Production Management

Conversion of Bulk Raw Material consignment to rolls (thru bar coding)

Process wise production management: Greige fabric inspection; Batching; Fabric turning;  Pre-treatment (Scouring & Bleaching); Dyeing; Dewatering; Drying; Compacting; Final inspection .

Re-process Control by taking in-process material to reject stage, and then allocating to another batch/ order.

Time and Action Analysis: dashboard to keep track of all order wise start and end point of each stage Shade Checking during Dyeing production Process: linking bar code after each process.

Sales & Dispatch

Consignment Sale transactions: Stock transfer invoice for consignment agent and subsequently invoices as per actual sales.

Enquiry & Quotation followed by three level order cycle: Sales Contract, Sales Order and Delivery Orders.

Sales e-invoicing generated instantly, by linking to Weighslips and Delivery Orders.

Flexible pricing methods- cash discounts, quantity discounts, fixed period sales contracts, credit control etc.

Finished Goods Management

Order wise Packing of finished goods with bar code tagging of each roll

Export Box Packing

Sales & Dispatch Management

Finished Good Rolls to be captured in Packing list.

Linking Packing List to Invoice