Magnitude of Erp Technical Modules For Spinning Industry

MAGNITUDE OF ERP TECHNICAL MODULES FOR SPINNING INDUSTRY
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 parts 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 reasons.
1. More variation in Raw Material

2. More no. of Production points
3. Lack of availability of skilled Technicians and Labours
4. Susceptible to ambient Conditions etc.
5. Abrupt Market conditions and
6. Stringent Quality requirements
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
 Production Planning
 Production Management
 Quality Management
 Maintenance & Electrical Management
 Bale Management
Production Planning:
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.
Production Management:
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.
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. It should not refer only the Production criteria. For example if a Card wire need to be changed
after reaching the 800 tons 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. The system should automatically look for the
Quality criteria also.
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
Management module.
Bale Management:
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:
Standard Distribution - The average Quality of all Parameters are same from the first issue to the final issue.
Normal Distribution - The Issue should contain the required average for the selected Quality parameters and
it should follow the theory of normal distribution.
Moving point distribution - If the user prefers to have a very narrow working range for the selected Quality
parameter, the system should generate the issue and according to the availability the shift in the parameter
should happen gradually till all the bales are exhausted in the Lot. For example if the User would like to have
the Micronaire working range of 4.2 to 4.6. After exhausting the bales in 4.6 Micronaire, the system should
automatically shift to 4.1 to 4.5. After exhausting 4.5, the system should go for 4.0 to 4.4.

Magnitude of Erp Technical Modules For Spinning Industry

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MAGNITUDE OF ERP TECHNICAL MODULES FOR SPINNING INDUSTRY

Why ERP Technical Modules parts are important?

1. More variation in Raw Material

Maintenance & Electrical Management:

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