In the Spinning Industry, from sourcing the Raw Material and
till the yarn is sold, IT plays a crucial role. Like other verticals, textile
spinning Industry also has to the core processes that differentiate it from
others and make it unique in many ways. Most of the Spinning Industry do the
computerization or go for the ERP for Financial, Sales, Inventory Management
and General Purchase which is more of a common one with other Industries
function also. But the area of Technical part where the ERP have to play a
significant role is left unattended or simple computerization is done.
Why ERP Technical Modules part are important?
There is an increased emphasis on improving quality of the
product to transcend in the cutthroat competitive global market. The function
of the Spinning mill in the Textile Industry is complex due to the following
To overcome the above inscrutable conditions, textile
Spinning Industry specific ERP Technical modules are required to perform in a
systematic and scientific manner.
The following Technical modules are important to do the day
to day operations, increase Productivity and Quality levels
What should we expect from Technical ERP system?
Production Planning module is of high substance to any ERP
environment. It should have a direct link from the Sales Plan. When a Sales
plan is drawn the Machinery requirement in each Departments, allocation of Ring
Frames according to priority and it should mark up to Raw material requirement.
If the Raw Material stock is not there, the system should automatically look
for nearest quality lot and it should inform the Raw material which is in the
purchase pipe line. It should have a seam less integration with the Raw
material Purchase and Sales ERP system
It should have an automatic data collection system with all
the Production Machineries. If manual entry of Production is in place means
then it belongs to first generation of ERP system. Considerable day to reports
like Count wise, Machine wise production reports should be integral part of ERP
system. Other added features like Operator wise, Shift Officer wise production
to have a control over the man power and to increase their efficiency.
Important productivity factors given by Research Organizations like HOK and OHS
should be available shift or day wise for continual improvement purpose.
Spinning Industry specific operations like Cone rejections, Idle spindles and
Idle Drums should form a part of the Production module.
The obligatory requirement for any Quality Management ERP
should be automatic and instant data transfer from all latest Offline Lab
Instruments. Nowadays, most of the Lab Instruments have the facility to port
the data to ERP system. The system should indicate whenever there is a
deviation in the Quality value as soon as the material is tested. Porting On
line Quality data from Production machineries is not far away. For the Lab Quality
parameters the report should be available in a user friendly way for analysis
like Count wise, machine wise and Trend reports.
Other day to day Quality Assurance Department functions like
Process study, Customer complaints registration & Analysis, Trials with
statistical comparison provision, Quality plan and Quality Certificate to
buyers should form part and parcel of Quality Management module.
Maintenance & Electrical Management:
The first step to ensure Quality is to carry out the
Preventive and Routine Maintenance schedules properly and in time. To ensure
the Maintenance activities are done properly and automatic generated schedule
is required for any period of time so that man power planning can be done and
the work also shall be carried out properly. The system should inform the
deviation in the Maintenance schedule, so that the Maintenance official can act
on it immediately.
Spinning Industry centric features should be available like
Criteria based maintenance and Count based Maintenance. For example if a Card
wire need to be changed after reaching the 800 tones of Production, the system
should automatically intimate the period of change. It should not refer only
the Production criteria. The system should automatically look for the Quality
criteria also. Say if the Neps per gram is only 60, the system should inform
the user that the activity of Card wire change can be postponed as the Quality
out the Card wire is still good.
Machine History, Breakdown History, Component and Spare
parts consumption History, UKG power calculation, Power study and Power
transmission loss should be available in the Maintenance and Electrical
The function of Bale Management is very much unique to the
Spinning Industry. The module should have a function in such a way that the
system should automatically generate the issues for Mix or a Count, where all
the Lay down or Issues should have a consistent quality parameter both in terms
of average and SD. The system should be capable of generating the Issues or Lay
down as per the User requirements like:
As the Technical operations in the Spinning Industry are
unique, the technical ERP modules should be diligently designed. Generic
Technical modules and simple computerization of the Technical activities will
result in twinge to the technicians rather than facilitating them.
Premier texpert ERP system has incorporated all the above
said features and it has added unique features like SMS and email notification
system. As hundreds of Production, Process and Quality parameters are
available; the Premier texpert ERP system presents the data in a convenient way
for analysis. It highlights the exceptions so that the technician can attend
the problem immediately and ensure the Quality. Premier texpert ERP system has
been astutely designed for Spinning Industry and it presents a new dimension to
the Spinning Industry for Technical modules of ERP.
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