Textiles ERP System
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The Odacc textile factory system, developed by David Lipschitz, is an open-source software solution designed to enhance various textile processes, including stock control, warehouse management, and sales order processing. It addresses significant challenges in production and efficiency, providing tools for improved materials management, real-time reporting, and reduced lead times. The system also emphasizes user training and knowledge transfer, ensuring ease of maintenance and adaptability for textile companies.
Textiles ERP System
- 1. ODAcc Textile Factory System By: My Power Station Presentation by: David Lipschitz 21st April 2017 The ODACC system is open sourced, and is designed and mostly written by David Lipschitz.
- 2. Objectives of Presentation • Open Source • Help you with your programming • Start a discussion • Help get an understanding of the complexities of Textile & Factory Software
- 3. Textile Processes Computerised • Stock Control • Stock Tracking, Lot # Tracking • Warehouse Management (Bar-coded) • Sales Order Processing • Planning • Multi-Currency Invoicing • Reporting and Analysis
- 4. Overall Requirements • To provide instant information on the status of all stocks • to increase sales • reduce lead-times to the customer • reduce all stocks and work in progress • provide order requirements information for each process • improve materials management • historical knowledge
- 5. Critical Success Factors • No writing as an objective of the system • user acceptance • accurate recording
- 6. Essential Factory Functions • Materials Management • Operations Management • Planning
- 7. Experience Gained • To reduce errors, each process needs its own unique program • because of this, a background OLAP (on- line analytical processing) transaction file system is required to facilitate an increase in the speed of reporting
- 8. Major Problems Solved (1) • Work in progress management • Work Breakdown Structures or Bill of Materials • “fixed weight” pallets (eg 25 bags of 30kgs each) • consumption reporting • ‘onwards in process or return to warehouse’ • materials taken out of the process (factory) and sent to the dye-house, etc
- 9. Major Problems Solved (2) • efficiency calculations • OLAP reporting and reasons • refinishing • returns • lot number tracking • ordering and receiving different quantities • sales orders and despatching different quantities
- 10. Major Problems Solved (3) • measuring what happened, eg to a warp • demand planning based on orders, stock on hand, estimated despatch date • planning using a pull system (orders create activity) • planning without using MRP • heuristic planning • multiple warps or wefts per piece
- 11. Major Problems Solved (4) • multiple products per warp • multiple finishes per warp • cutting a fabric into pieces & tracking • bar code printing using serial communications(different printers programmed) • scanning using keyboard wedge devices and Psion Workabouts(remote scanning).
- 12. Performance Improvements (1) • If end of month stock take is required, it takes one day with scanners and is 100% accurate due to systems and processes used • stock take reporting – before production management system: spreadsheets were used: took 2 weeks (~70% accuracy) – after system, took 3 days – after OLAP, takes 3 hours (100% accuracy)
- 13. Performance Improvements (2) • accurate consumption reports • exact stock: 2 central problems solved – if the system says the stock is in the warehouse, it is! – if the system says we haven’t got the stock, we haven’t got it! • fast picking(housekeeping means we know where the stock is) • limited writing leads to recording, accuracy and speed improvements
- 14. Performance Improvements (3) • From order to despatch time took between 2 and 6 weeks on average before the ODAcc system. Although stock was kept, it was difficult to track and in many cases products were only made when an order was received • after implementation of the ODAcc system, 80% of despatches are done the same day as the order or on the estimated despatch date given to the customer when the order is received.
- 15. Performance Improvements (4) • soon after going live with the picking program, we received a very large order at 10am and despatched it the same day • orders leave the warehouse on estimated despatch dates • many differing kinds of reports can now be produced which couldn’t be done before, eg average sales per month, suggested minimum stock requirements
- 16. Performance Improvements (5) • planning took 2 to 3 days and was done manually once per week. Any orders received would have to wait until the next plan was done • planning now takes 2 to 3 hours and can be done as often as required. Mixes can be changed quickly and differing scenarios can be looked at.
- 17. “Factory Dictionary” • As part of the training of users and the development of the system, a dictionary of terms showing the jargon of the factory was created. This “factory dictionary” or nomenclature facilitates a common ground in order to accommodate clear and precise communication between users, management and developers.
- 18. Factory Dictionary Examples • Delivery: of goods from supplier • Despatch: of goods to customer • Receipt: of SKU from factory to warehouse or to computer system if WIP • Issue: of SKU from warehouse to factory • Fibre Classification: Flock, Carded, Drawn, Blended • Weaving (required to weave), Woven, Finished, Piece, Slit
- 19. Textile Factory Material Flow
- 20. Bar Code System Fabric (1)
- 21. Bar Code System Fabric (2)
- 22. Bar Code System Fabric (3)
- 23. Bar Code System Fabric (4)
- 24. Bar Code System Fabric (5)
- 25. Bar Code System Raw Materials
- 26. Systems Written • Spinning factory • weaving factory incl. sales order processing, picking, palletising, despatching • multi-currency (export) invoicing • loom loading planning • spinning planning • administration & audit system incl. pricing • user privilege manager
- 27. System Menus • The following nine screens show the system menus:
- 28. Spinning Menus’ Slide Show
- 29. Weaving Menus’ Slide Show
- 33. Administration & Audit System
- 35. Computerised Processes (1) • Deliveries: – order goods – receive goods – bar-code and warehouse (put-away) goods – manage returns to suppliers – manage issues and receipts from sub- contractors (e.g. dye houses)
- 36. Computerised Processes (2) • Deliveries (continued): – manage discrepancies between ordered and received quantities – allow multiple deliveries for an order – manage breakdown of totals • total delivery • pallet totals • box / carton / bale totals
- 37. Computerised Processes (3) • Warehouse To/From Spinning Factory: – issue to factory (to any stage of production!) – receive from factory (at any stage of production!) – create fibre lot numbers – create yarn lot numbers – issue raw materials and yarn to factory – receive raw materials, processed raw materials and yarn from factory
- 38. Computerised Processes (4) • Warehouse To/From Spinning Factory (cont.): – issue yarn to be processed, eg into fancy yarn or warps – bill of materials and consumption management – WIP Management – waste management – issue and receive yarn for assembly, twisting, warping preparation, warping, beaming
- 39. Computerised Processes (5) • Spinning Factory To Customer Despatches: – yarn despatches • Spinning to Weaving Factory Despatches: – yarn despatches for weft yarn – warp yarn despatches for warp yarn • At Weaving Factory: – deliveries of weft yarn – deliveries of warps (incl warp lot numbers and warp statistics)
- 40. Computerised Processes (6) • Weaving Production: – weaving (fabric planned to weave) – woven (entered per greige (unfinished) per day) – finished (multiple per greige) – cut / slit (multiple per finish)
- 41. Computerised Processes (7) • Despatching: – sales order processing – picking – palletising – despatching – invoicing – multi-currency invoicing
- 42. Computerised Processes (8) • Loom Loading Planning – planning per loom – drag and drop planning – planning based on order dates, stocks, minimum stock requirements – automatic checking that warps run on correct looms and reeds – automatic checking that weft jobs run on correct warp jobs – report on warp and weft yarn required
- 43. Computerised Processes (9) • Spinning Planning – planning per group of spinning machines – automatic checking that correct jobs run on correct machine groups – report on fibre and other bill of materials requirements
- 44. Textile System Costs • all the systems are available excluding or including source code • separate module quotes available on request • implementation assistance is available • programming is available • maintenance contracts can be arranged
- 45. Consultancy • David Lipschitz is available on a consultancy basis to help with: – implementation – problem solving – stock control, tracking and accuracy projects – reporting, OLAP & data mining – other textile factory and stock control computer problems
- 46. Knowledge Transfer • In all our projects we will: – 1) transfer knowledge from ourselves to you (our clients); – 2) create processes and systems that allow you to work without us; – 3) when writing software, write it so that it is: maintainable, expandable, understandable; – 4) when training you, ensure that each individual has a foundation in place so that you can "work without getting stuck”.
- 47. Technical Section • Entity Relationship Diagrams (ERD’s) • Database Structure (DDL) • Forms • Reports • Source Code
- 48. Database ERD’s • Raw materials, purchasing and spinning factory ERD (Entity Relationship Diagram) • weaving factory system ERD • despatch ERD • planning ERD • These will be published
- 49. Database Structure (DDL) • DDL (database definition language) including tables, triggers, stored procedures, exceptions, primary keys, foreign keys, views, generators and any other database components: will be published
- 51. System Forms • Approximately 197 forms in the applications will be published free of charge
- 52. List of Reports • There are ~ 308 ReportSmith® reports in the applications • the list of reports will be published • report source code will be published
- 53. Source Code • The source code is available and will be found on GitHub
- 54. Demonstrations • System demonstrations can be provided and online demonstrations will be created • If you wish us to do a presentation at your site, the following terms apply: – payment of disbursements, eg travel, accommodation – payment of a daily rate
- 55. System Development Steps • Analyse requirements • choose hardware, operating system, network infrastructure, database, programming tools • design processes • write system • implement system • maintain system
- 56. Maintenance Requirements • “The system must have a zero maintenance requirement on a monthly basis as there will be no technical computer people on hand. This means that the chosen system must manage itself, that the software must be bug free and at the same time easy to maintain.” - David Lipschitz, 1995
- 57. System Implementation (1) – System implementation deals with getting the system going • overall parameters: factory name; invoicing companies • currencies • users • week numbers • working hours
- 58. System Implementation (2) • product categories • units of measurement and units of receipt of goods • terms • agents • departments • suppliers • customers
- 59. System Implementation (3) • raw material products • OLAP system work in progress control accounts and reporting groups • prices: stock; standard; various sales types
- 60. System Implementation (4) • Yarn Maintenance – efficiency groups – yarn kind (eg: basic, colour, fancy, etc) – yarn structure (tex / count, twist) – yarn colour – yarn type (kind + structure + twist + colour = type) – yarn bill of materials
- 61. System Implementation (5) • Loom Maintenance – loom type (incl: tappet, dobby, jaquard) – loom specification (specification for each loom) – warp type (incl: reed, length, ends, yarn types) – warp colour (colours for each warp type)
- 62. System Implementation (6) • Fabric Maintenance – fabric width – fabric structure (incl warp type, greige & finished lengths) – structure on type (looms each fabric runs on) – finish types – stock minima (incl automatic calc or manual override) – quality types
- 63. System Implementation (7) • enter all orders • enter all raw materials received from suppliers • enter all materials received from factory • enter all yarns • enter all warp and weaving work in progress • enter all fabrics
- 64. David Lipschitz BSc (Honours), MBA, Textile Certificate, Reiki Master, Tai Chi Instructor, NABCEP PV Associate • analysed & designed all aspects of the textile system from purchasing through bar-coded warehouse management, production management, sales order processing, picking and despatching • Programmed a substantial part of the system relying on contractors for components and the visual loom loading system
- 65. My Power Station and ODAcc • Distinctive competency (strengths that set the organisation apart from its competitors): – ODAcc designed specifically for textile companies – we understand textiles inside out from both user and development points of view – we own the whole system, and it is open source – ideal: system should be available 100% of the time; downtime only required for planned maintenance or hardware failure
- 66. Separate (Live) Databases • Spinning • Weaving • Planning
- 67. ODACC Textile Factory System My Power Station was formerly called Orbital Decisions