The textile industry has a high level of diversity and variety. Each order can be considered as a customized product. Hence, there should be a mechanism to manage this variety and diversity. The high level of variety needs to be monitored within the system by methods such as variant and assortment. When the variety is further enriched by features like assortment, color, size and pattern, much effective systems are needed for management. Monitoring the status on Critical Path (CP) through summaries also has key importance in the sector when carrying out detailed planning operations where relationships are closely monitored. In a market where customers do not compromise on quality, we need strict control mechanisms to meet the expectations. While doing so, we shall not compromise on backward traceability, either. Backward traceability, critical path (CP) and quality control phases can be listed among the distinctive features of the industry. Work processes have a rather diverse structure in this industry: Compared to other industries, textile industry needs a distinctive system particularly in a quotation, order, and production phases. The system to build to meet these needs should be highly flexible and able to generate solutions in a fast way.
We need to discuss this issue under two headings: Garment and fabric. Basic processes of garment can be summarized as product information sheet, assortment management, accessory management, critical path, and cloth spreading planning. As for fabric, color management, pattern management, composition management and mix & match processes need to be set within the system. Sub-production management is highly needed in both of these processes.
Depending on customer demands, textile companies have a rich variety and a high level of diversity in their products. Therefore, the key element companies expect from a corporate resource planning system is that, it should offer an integrated solution to this product variety and the high velocity of product diversity. Each order contains several details in this industry. The data obtained during an order have a significant effect on both planning and production. Location, assortment matrix, line details, accessory details, color, and pattern change in each order. All these details should be brought together in the ERP system. Specific solutions are needed to integrate all the data into the system in an effective and efficient manner. The company will lag behind if it utilizes the standard ERP system. Hence, it is significant to respond to purchase order as soon as possible. So, rather than standard versions, companies need to have a system that could be set depending on product structures. Adoption of a flexible and an integrated ERP system that generates solutions in a fast way, is the key to achieve that. Systems not offering freedom of movement, will not bring success smoothly in textile industry, indeed.
Owing to the flexible structure of our corporate resource planning product, caniasERP and canias4.0 technologies, we gather a mixture of several modules under a single body to build a system where users can manage their work orders in a simpler and faster manner. With caniasERP, we offer two specific solutions to the textile industry: Garment and fabric. Both of these solutions are developed with the guidance of the experiences we have gained through our cooperation with several textile companies. We observe the needs of textile companies. Compared to others, we offer solutions that are built based on the best methods identified. Among these applications, we use basic structures like product tree, path, work order management, material card and product configuration that are within the standards of caniasERP. Yet, facilitated user interfaces (UI) have been designed to help users execute these industrial solutions in a simpler and faster manner. There are several modules and applications in caniasERP to facilitate the job of companies engaged in textile industry. Our Industrial Solution brings critical planning operations together with MRP - Material Requirement Planning and CAP- Capacity planning modules in order to facilitate calculations in global standards. During these calculations, it automatically ensures the connection of special fabrics/accessories in the supply chain for a customer order. Hence, the supply-demand equilibrium is achieved in a clearer and traceable manner with a Customer Special Order concept. In caniasERP MRP module, traceability of purchase orders is taken to the top level with customized burst modes and since its relationship with the order is clearly set, any fabric or accessory needed to be supplied for the customer's order, can be traced as well.. In addition, the product information we have developed works in integration with the standard cost module to enable users to calculate their costs directly. It is possible to directly create an offer by just entering some specific information into the system, without the need to open a product card or create a product tree. This brings the advantage of high speed to companies. We offer several other effective applications for fabrics, as well. For example, when a company starts producing an order concerning fabrics, not all the demands related with such product are identified initially. All the preparations needed in the process can be easily planned to use this system. Our sub-production management application allows for traceability of materials and orders at sub-producers and smooth management of the traceability of the jobs completed. The operations of an item and the percentage of the completion of the project can be observed. In addition, persons can enter their data on suppliers' data portal and check out data on the system. Color management is also one of the important issues for fabric operations. Color Laboratory applications are built on the product tree module to create color prescriptions and to carry out lot-based tracking. We manage that through the product trees module of caniasERP and some specific applications. In this way, color prescription can be formed and tracked based on product lot. Dye house management processes can also be monitored on the system. The color prescriptions created can be directly forwarded to machines owing to the applications we have developed for this process. We have further developed applications for the capacity planning module and built a system that takes sequential painting of colors and related boiler washings into consideration based on the capacity of painting boilers. We have allowed for integrations with the dye house automation systems to minimize user mistakes and maximize precision. In brief, we can say that caniasERP offers a flexible, fast and an integrated system needed by textile companies.
As we have already mentioned, the textile industry has several unique necessities and we have developed the most effective solutions for our customers, using our experiences. When applying these industrial solutions, our principle has been to ensure that the systems use the highly functional modules in a much more effective and fast manner depending on the dynamics of the industry. We offer end-to-end solutions in garment and fabric productions. As for garments, the designing process starting with product information sheets and tracking of product information on the system is followed by structures that are customized for order management, planning management, production management and shipping management. Sub-details include detailed tracking of several structures like PP, Size set, Fit and Sample for an order. All these items are brought together in the project infrastructure by CP - Critical Path and monitored to offer a holistic perspective to customers. For instance, the entering process is executed in a faster and more effective manner thanks to the assortment matrix and different sets of assortments are included in a single order with the purpose to facilitate the user experience. As for cloth spreading planning, we enter user information such as cloth layers and lots to offer a system that enables users to keep track of the number of layers of clothes spread, the lots of cloth used, and the semi-products produced based on these data. With this system, companies are able to see which item of a garment has been produced. The assortment matrix in the system facilitates the approval and planning operations. Although each line and each space in the assortment matrix correspond to separate registries, all these registries are collectively managed with ease. Critical path is also an important issue in this industry. Critical path covers the entire process from the start of production to delivery to customer, allowing the monitoring of all process including supplying, cutting, sewing, packaging, and delivering the materials, together with date information. We do this using the project management module infrastructure available in caniasERP. To manage product variety, we benefit from the variant structure of caniasERP. In this way, the changes in size, color and length etc. can be easily resolved within the variant. In textile industry, time study is one of the key elements particularly for the companies serving in the field of garment. The duration of the production process of a product can be identified along with all its sub-details and monitored through the applications we have developed for time study.
IIoT is quite effectively used in textile industry. Dye house integrations, quality control testing process, production outcomes and tracking, scale integrations and RFID barcode integrations are successfully set in IIoT system. Thanks to the IoT solution we offer with canias4.0, we can directly communicate with the machines. The systems interact with each other without the touch of human hands and the prescriptions collected are impeccably transferred to caniasERP system. We particularly utilize IoT technologies during the fabric rolling and quality control processes of the fabrics produced. Meter, kilogram, and other similar data is collected from the device and directly transferred to the system. Upon completion of production and during the quality control of the final product, we are able to extract from the system all the criteria defining product features. In addition to all these, IIoT solutions allow real-time tracking of machines on the system. For example, a user can display, in real-time, the washing phase of a machine in the dye house. In many cases like this one, machines directly interact with the ERP system to minimize the margin of error and to gain speed and efficiency.
Industry 4.0 technologies are said to be more widely used for fabrics. Yet, they are not much common for garments at this moment. There is a big gap in the industry regarding this. The textile industry requires complicated work processes and customized solutions. Therefore, companies should cooperate with software firms that will understand their needs and expectations to adapt to their work processes and produce fast solutions. Unfortunately, there is a lack of software solutions in the market to meet this dynamism. We have gained experience from our cooperation with the customers serving in the textile industry and integrated this experience into our software solutions. In this regard, we lead the industry with canias4.0 technologies... We gather several applications and modules required in the textile industry together in a single system to offer them in an integrated way. The IoT solution we offer with canias4.0 allows for feeding data from devices and big data solutions for the management and reporting of the data collected from a wide variety of products. We provide companies with a holistic, fast, integrated, and flexible software service via caniasERP that runs in full integration with other solutions and offers end-to-end solutions.