ERP at Fabric Manufacturing ( Weaving & Knitting ) – Surat

Weaving is the oldest method of making yarn into fabric.

It is a process of producing fabric by the interweaving of warp and weft yarn. It is mainly used to make woven fabrics. All Trousers are produced by the process of weaving.

There are two methods used for weaving the yarn:

• Lengthwise Weaving
   – In this method of weaving, the yarn is weaved up and down or lengthwise or longitudinal in the body of clothing. It is also called as the warp.

• Crosswise Weaving
   – In this method of weaving, the yarn is weaved across the body of clothing. It is also called as the weft or filling of yarns.

Types of Weaving

There are three basic types of weaving:

• Plain Weave
  – In this type of weaving, the yarn is weaved one above the other. This method of weaving is strong, durable and easy to sew. It is the most basic type of weaving used for fashion and furnishing fabrics.

• Twill Weave
  – In this type of weaving, the yarn is passed or glides over one or more yarns in the same direction.
  It is a type of diagonal parallel ribs. This method of weaving is durable, more attractive and wrinkle-free.

• Satin Weave
  – It is produced by the interweaving of warp and weft yarn. This type of weaving is characterized by four or more fill to give a smooth, shiny and droppable fabrics.

Knitting is a method of constructing fabric by using a series of needles to interlock loops of yarn

It is a process of producing fabric by the joining or interlinking of loops of one set of yarn. Different fabrics including the T-shirts, Sweaters, coats, shawls are all produced by the process of Knitting.

Knitted fabrics are very popular and can be very easily produced either from the yarn or any other fibres including cotton, nylon, woollen and the polyester.

There are different types of knitting techniques and are produced both by computerized and machine-based knitting.

The process of knitting is given below :

The yarn package is placed in the creel.

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Yarn feeding

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Set the design

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Knitting

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The rolled fabric is withdrawn and weighed

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Mark the roll

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Inspect

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Number

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Dispatch

Key Challenges Faced by Fabric Manufacturers :

Shortage in supply of raw material:

• Shutting down some units in China and Europe due to pollution issues has resulted in an unprecedented rise in prices of basic raw materials in international markets.

Increase in cost of raw material:

• Prices have seen an upward increase after many units in China were shut down due to pollution norms. The rise in prices of imported raw materials has increased the prices of dyes.

Pressure to meet stringent social and environmental norms:

• Environmental compliance often isn’t at the top of textile and garment importers’ concerns.
• Failing to comply with environmental regulations can put supply chain in jeopardy, as pressure mounts for the apparel industry to improve environmental compliance efforts.

Infrastructure bottlenecks:

• The low quality of India’s infrastructure, continues to lag behind that of many other Asian countries.

Uneven regional development:

• The country’s Fabric industry is concentrated in a few pockets of Gujarat and Maharashtra in the west and Tamil Nadu and Karnataka in the south.
• A large proportion of workers employed by these units comes from Bihar, Uttar Pradesh, and West Bengal.

Lack of efficiency due to manual work:

• Unlike in developed countries, textile factories in India are not fully automated and remain labour-intensive.

Unorganized weaving sector:

• Approximately 95% of the weaving sector in India is unorganized in nature.
• The decentralized power loom and hosiery sector contributes 85% of total fabric production.
• In terms of technology adoption in the weaving sector, India has only 2% share in global shuttle-less looms installed capacity. 

Why ERP Software needed in the Fabric Manufacturing 

The fabric industry has undergone tremendous changes in the last few years. This industry is highly concerned with the manufacturing and design of clothing and also the use of textiles. Flexibility and quick response have become essential for any effective textile business. Companies must re-examine their business processes and deliver high-quality products at very low costs to maintain a competitive advantage. Most companies now outsource manufacturing for less labour. Globalization has increased competition and quality awareness. So integrating with information technology has become very important for the textile industry to survive.

ERP (Enterprise Resource Planning) is an integrated system. ERP integrates all departments and functions of a business into a single system and meets each department’s specific needs. ERP provides an outline to textile industries to organize business and manufacturing expertise.

Countless businesses worldwide are providing top-notch services with their exceptional products but are not profitable enough.

The main reasons they lag behind their competitors in solving day-to-day challenges, streamlining processes, reducing costs, and improving productivity. In such cases, ERP comes to the rescue by solving the followings :

• Difficulties gathering information
• Eliminate miscommunication and data aggregation
• Accessing data
• Time-consuming inventory management
• Unorganized team organization
• Removal of inconsistencies
• Automate repetitive tasks
• Elimination requirements of physical presence
• Customer tracking
• Cash-flow disorders

ERP has been in the knitting and Weaving industry for quite some time. The need for ERP came when the industry required a more innovative way of working and reducing data redundancy.

ERP has automation and business intellect which help the Fabric industry to achieve perceptions and reports. It enables the companies in planned decision-making. ERP software also has numerous modules for knitting and Weaving to communicate.