TEXTREME10

A Paper Presentation On ERP IN TEXTILE INDUSTRY

Presented By:-

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

A.R.NAGARAJ
TEXTILE CHEMISTRY

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 resource of MRP

(manufacturing

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

SSM COLLEGE OF ENGINEERING, KOMARAPALAYAM.

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.

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, an enterprise providing in order quality operational, to improve and (Enterprise managerial and strategic information for productivity, competitiveness.ERP

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

INTRODUCTION
What 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

model and automatic many of the basic process of the company from the finance to the shop floor with a goal of integrating links information across the company and eliminating 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. For maintaining higher efficiency and complex expensive between computer systems. It produces

ENTERPRISE RESOURCE PLANNING FOR TEXTILES (ERP):

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.

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 and Production are available in the market.

Finance. Manufacturing Planning.

Basically any ERP solution should provide effective monitoring and control, accurate planning and scheduling of orders, better data predictions, quick response to query and online detailed information of orders.

Sales and Distribution. Plant Maintenance. Quality Management. Materials Management, etc.

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 quality

specification may include such as

and various Fabric

specifications specification, 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.

Yarn count for warp and weft, Reed count, Ends and picks per inch, Process specification at

winding, specification,

Pre-beaming

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.

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

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,

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

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

Production, Sales and stocks can be conveniently 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 separated using article

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

identifying divergence of orders being processed schedules. Automatically assigning tasks to the most suitable production facilities on-line with a finite capacity. from planned production

Next

is

checking

of

the

product

Monitoring margins.

of

contribution

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

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.

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

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.

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:

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. use of The following figure shows one of such integrated systems in textiles:

Aid

in

optimal

manufacturing resources

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 identifying

management inventory

include requirements,

setting targets, providing replenishment techniques and options, monitoring item

Evolution Of ERP
ERP (Enterprise Resource Planning) is the evolution of Manufacturing

usages,

reconciling

the

inventory

balances, and reporting inventory status.

Timeline - 1970s System -

Material Requirement Planning

Requirements Planning (MRP) II. From business perspective, ERP has expanded from coordination of manufacturing

(MRP)
Description

-Materials
(MRP)

Requirement utilizes software

Planning

processes to the integration of enterprisewide backend processes. From

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

technological aspect, ERP has evolved from legacy implementation to more flexible tiered client-server architecture

ERP Software used in Textile

Timeline -1980s System -

Industries

Manufacturing Requirements
1. Datatex Software 2. AREL Software 3. Abas Business Software

Planning (MRP II)

Description-

Manufacturing Requirements MRP utilizes software

Planning

or

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 -

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

. 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.

Switzerland. The Datatex structure has been designed to cater to:

The customers needs The customers practices

and procedures

The

customers TIM is an integrated solution; therefore

competencies.

Datatex:

the enterprise information is available to everyone, not just to the few. Data is Has the expertise required a detailed and entered once and to be used across all company functions. can A cover all TIM the

presenting

realistic offering to the textile and appareling industry.

implementation manufacturing

and

logistical

Has the product and skills implement the required

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.

to

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

MTO Highlights

Make-To-Order

Capacity and/or materials

feasibility checking

Multi-level product views

Suggested

dates

or

measure the cloth and a PC screen at each inspection table.

availability if original request is not feasible

The ability to consider orders from the

Business Analysis:

Intelligence

and

forecasted master

Gantt

chart

without

having to create firm production orders

BOARD-Management Intelligence is a unique and outstanding business

Manual

overrides

of

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

blocking as required Scheduling and allocating of scarce (critical) resources.

Fabric Inspection and Cut Optimization System

CATS (Computer Aided Textile

reports

and

graphs,

and

building

simulation models is the simple matter of a few clicks of the mouse.

Supervision) is a PC based module that integrates the production and inventory systems inspection. with It greige provides and finished to

2. AREL Software
AREL is a leading solution provider with specialized manufacturing expertise worldwide in & textile across-

methods

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

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

confirmation. CATS utilize an encoder to

gain a competitive edge. Arel Control is a leader in Automatisation Solutions for the Textile Wet Processing Industry, which includes:

connected unlimited.

controllers

is

practically

Batch Dyeing Controllers Continuous Process

Standard Software Modules

Controllers

Control

Room"

Basic

Dispensing

Systems

&

module, including dye programs management and reporting.

Solutions

Supervision

Process

Dye Lots Creation and

Management Systems

Maintenance

On-line

Production

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

Scheduling

Look

Ahead,

showing MANUAL

expected interventions.

Recipe Management All Costing Analysis

(Energy, Dyes and Chemicals, Operation).

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

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 dyehouse peripherals like powder

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

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.

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

2. Dispensing for Batch Dyeing

O.T.D. 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. On Time Volumetric

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.

The system combines a high capacity variable speed-dosing pump and high

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

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 production to materials planning and management, production

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

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 3. Abas Business Software 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.

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.

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

REFERENCES:-

Enterprise Resource Planning by ALEXIS LEON published by TATA Edition McGraw HILL, 1999

programs have overcome this menace. They offer need-based applications. The firms need not be worried even if these Software Programs were not available.

E.R.P by PARAGDIWAN and SUNILSHARMA published by PENTAGON Edition PRESS, 2000

E.R.P A Managerial Perspective by SADAGOPAN published by TATA Edition McGraw HILL, 1999

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