Textile Manufacturing
Textile production requires planning based on several parameters (e.g. colour, thickness, thread type, length, design). A strong planning and scheduling engine is crucial to optimize materials used for different products and minimize wastage.
Alfazance’s engagement with the client began over a decade ago. With the recent upgrade to Microsoft Dynamics 365, the client enhanced digitization in their production process and improved operational efficiency, leading to cost savings of ~$300K+ annually. The journey over the years involved reimplementation of the earlier ERP system (Dynamics AX), several customizations and integrations, development of automations, and upgrade to a modern, cloud-based ERP system—Microsoft Dynamics 365 Finance & Supply Chain.
Improved quality due to visibility to live data on raw material and finished goods
Improved decision making about the products to be manufactured based on better forecasting and visibility to inventory
Improved quality due to visibility to live data on raw material and finished goods
Improved data quality and reporting capabilities has eased access to relevant data to the right people to make the right decisions at the right time
The client wanted to integrate the PLC system (Programmable Logic Controller) to control the inventory flow, reduce wastage and minimise quality issues. With a custom-built internal requisition screen, production team was able to see current stock levels, 6-months consumption, etc. to plan production quantity. Accordingly, they could now provide instructions to transfer raw materials (roll) to the machine for cutting. The queuing system validates the priority of the rolls in queue and where & how much to be cut. The quality system then handles errors based on any deviation to ERP instructions prior to cutting before sending the rolls to the PLC system for cutting. The ‘cut’ information is then fed back to the D365 system for order processing.
Carpet manufacturing involves a highly complex process—colouring and extruding of the yarn, twisting-cabling and heat-set facilities, pattern making, tufting lines and finishing. With design aesthetics, customers need quality and durability in each product. Vertical integration, with control over the entire process, enables the company to offer flexible, creative and customized solutions to its clients. Ensuring complete quality control at every level and deliver premium products consistently is critical. Have a robust system like Dynamics 365 with the right integrations, automations and controls has helped the client reduce quality issues significantly. Client reduced quality claims ratio from ~12 containers to 0, saving an estimated $120K annually.
The client’s relentless focus on innovation and drive to exceeding customer demand has helped them build their market in 60+ countries across 6 continents. With 1,000+ products, the client is always looking for ways to innovate and improve. Alfazance is currently engaged in developing a complex algorithm to aid in the production planning and scheduling process. With 9 different parameters, optimizing the product process is an extremely challenging ask and once deployed can not only improve efficiency, but also help achieve their sustainability goals to reduce environmental impact.
